Maximise kiln uptime, prevent costly refractory failures, and ensure regulatory compliance with intelligent maintenance management designed for energy-intensive cement manufacturing across the United Kingdom.
24/7 clinker production maintenance platform
Refractory & shell tracking
Operating hours scheduling
Shift-based management
Production insights
Complete maintenance management tools for rotary kilns, cyclone preheaters, vertical roller mills, ball mills, grate coolers, and cement processing equipment operating in high-temperature, dusty environments
Customisable checklists for rotary kilns, preheater cyclones, VRM gearboxes, ball mills, grate coolers, and bag filters with offline capability for dusty plant floors.
Schedule maintenance based on kiln operating hours, mill grinding cycles, or tonnes produced—not arbitrary calendar intervals that waste resources.
Create, assign, and track work orders with structured handover notes across three shifts for continuous 24/7 clinker production.
Maintain compliance with HSE COSHH silica dust regulations (WEL 0.1 mg/m³), Environment Agency requirements, ISO 45001, and ISO 50001 energy management.
Monitor OEE, MTBF, MTTR, and equipment reliability metrics in real-time across kiln lines, grinding departments, and packing plants.
Empower maintenance teams with mobile access designed for dusty, high-temperature cement plant environments with offline sync capability.
MOBILE SOLUTION
Equip your operators and maintenance crews with a mobile inspection app built for dusty, high-temperature cement manufacturing environments:
For Cement Plant Maintenance Teams
Work in dusty areas with limited connectivity
Refractory logs & failure records
Log vibration, temperature & readings
QR/barcode for rapid identification
Make data-driven decisions with comprehensive cement manufacturing performance analytics:
Clinker Production & Equipment Insights
Kilns, mills, crushers & coolers
MTBF, MTTR & availability tracking
Kiln stops & mill trip tracking
ISO 50001 aligned tracking
Deep asset management supporting plant-to-component tracking across all cement manufacturing stages—from quarry to dispatch:
Complete Asset Management
Kilns, preheaters, precalciners, coolers
VRM, ball mills, roller presses, separators
Crushers, stackers, reclaimers, conveyors
ID fans, bag filters, ESPs, coal mills
Pre-configured inspection templates ensure compliance with cement industry safety, environmental, and energy regulations:
Audit-Ready Documentation
Crystalline silica dust control
Emissions & permit compliance
Energy management systems
Kiln entry & confined space procedures
Predictive maintenance reduces unplanned kiln shutdowns by up to 70%. With kiln downtime costing up to £80,000 per hour, early detection of refractory issues and bearing failures saves millions annually.
Stay compliant with HSE COSHH silica dust standards (WEL 0.1 mg/m³), Environment Agency requirements, and confined space regulations while protecting workers in high-temperature, dusty environments.
With energy making up 30% of cement production costs, proper maintenance of mills and kilns can reduce electrical energy costs by up to 25% through ISO 50001 aligned practices.
A 5,000 TPD cement plant with two kiln lines reduced unplanned kiln shutdowns by 70% and improved overall kiln availability from 85% to 94% after implementing Oxmaint's maintenance system, avoiding over £2.3 million in annual production losses.
Up from 85% with Oxmaint implementation
Annual avoided production losses
Early VRM gearbox bearing detection
"Oxmaint helped us detect a VRM gearbox bearing issue four months before it would have failed. The early warning saved us an estimated £220,000 in emergency repairs and avoided 56+ hours of unplanned grinding downtime during peak production."
Maintenance Manager
Cement Plant - 2 kiln lines, 5,000 TPD capacity based in the East Midlands
"The runtime-based scheduling transformed how we plan refractory inspections and mill overhauls. We now trigger work based on operating hours rather than arbitrary calendars, extending refractory life from 6 months to 12 months in our kiln head zone."
Plant Reliability Engineer
Cement Plant - 3,500 TPD with VRM and ball mill grinding based in South Wales
Oxmaint supports the complete cement manufacturing process including rotary kilns with refractory zone tracking (burning zone, transition zone, preheating zone), cyclone preheaters (4-6 stage) and precalciners, vertical roller mills (VRM), ball mills, roller presses, grate coolers, raw mills, coal mills, cement mills, crushers, conveyors, bucket elevators, bag filters, and electrostatic precipitators (ESPs). Our asset hierarchy supports tracking from plant level down to individual components like gearboxes, bearings, and refractory linings.
Unlike calendar-based maintenance, Oxmaint triggers maintenance tasks based on actual operational metrics. For kilns, this means scheduling refractory inspections based on operating hours or thermal cycles. For VRM gearboxes, which typically require complete overhaul every 48,000 operating hours, Oxmaint tracks runtime automatically and generates work orders at the right time. This approach avoids both premature maintenance (wasting resources) and unexpected failures (costly downtime).
Yes, Oxmaint's mobile app features offline-first functionality designed for cement plant conditions. Technicians can complete inspections, log work orders, and capture data even in dusty areas near kilns, mills, or crushers with limited or no connectivity. Data syncs automatically when connection is restored. The app supports ruggedised devices commonly used in high-dust, high-temperature industrial environments.
Oxmaint provides templates and tracking for HSE COSHH respirable crystalline silica standards (WEL 0.1 mg/m³ workplace exposure limit), Environment Agency environmental permit requirements for cement plant emissions, ISO 45001 occupational health and safety management, and ISO 50001 energy management systems (critical since energy makes up 30% of cement production costs). Our permit-to-work and isolation features ensure safety protocols are followed for kiln entry and confined space work.
Yes, Oxmaint provides API-based integration with SCADA systems, kiln shell infrared scanners, vibration monitoring systems (for VRM and ball mill bearings), ERP platforms like SAP, and condition monitoring solutions. This enables real-time data flow from equipment sensors to trigger maintenance alerts—such as kiln shell hot spots indicating refractory damage, or elevated vibration levels on mill gearboxes signalling bearing problems.
Join leading UK cement manufacturers who trust Oxmaint to maximise kiln uptime, reduce energy costs, and ensure regulatory compliance in demanding 24/7 clinker production environments.