Holcim launches world's first cement plant digital twin

  • Real-time 3D virtual model of cement plant to optimize its operations
  • Sensors, data analytics, and machine learning for faster, more efficient and reliable manufacturing
  • Part of Holcim’s Plants of Tomorrow Industry 4.0 technologies rollout


Holcim launches the world’s first cement plant digital twin, a real-time 3D virtual model accurately replicating one of its sites in Switzerland. The digital twin integrates Holcim’s enterprise software and performance prediction algorithms with the 3D model, enabling faster, more efficient and more reliable operations at minimal cost. With sensors, data analytics and machine learning capabilities, the digital twin prevents costly downtimes and enables predictive maintenance. The project is part of Holcim’s Plants of Tomorrow program, deploying Industry 4.0 technologies across its sites for enhanced efficiency, safety and sustainability. Building on this launch, Holcim will scale this digital twin technology across its operations, starting in Europe.

Rozemarijn Wesby, Global Head of Plants of Tomorrow: “Our digital twin in Switzerland is a breakthrough for the entire industry. By leveraging digital technologies like this, we are generating massive amounts of data, allowing smarter decision-making to take our operational efficiency to the next level.”

The digital twin platform was developed in partnership with artificial intelligence startup HyBird. It uses data from Holcim's enterprise software and predictive maintenance system to keep the 3D model continuously updated with the real-time status of manufacturing equipment.

Launched in 2019, Holcim’s Plants of Tomorrow program is one of the largest roll-outs of Industry 4.0 in the building materials industry. To date, it has deployed more than 1,600 applications across 140 sites, delivering annual savings of more than CHF 70 million and reducing CO2 emissions by over 400,000 tonnes.

About Holcim

Holcim is a global leader in innovative and sustainable building solutions. Driven by its purpose to build progress for people and the planet, its 60,000 employees are on a mission to decarbonize building, while improving living standards for all. The company empowers its customers across all regions to build better with less, with its broad range of low-carbon and circular solutions, from ECOPact to ECOPlanet. With its innovative systems, from Elevate’s roofing to PRB’s insulation, Holcim makes buildings more sustainable in use, driving energy efficiency and green retrofitting. With sustainability at the core of its strategy, Holcim is becoming a net-zero company with 1.5°C targets validated by the Science Based Targets initiative (SBTi).

Learn more about Holcim on www.holcim.com, and by following us on LinkedIn.

Sign up for Holcim's Building Progress newsletter here and follow our journey to a net-zero future.

Important disclaimer – forward-looking statements:

This document contains forward-looking statements. Such forward-looking statements do not constitute forecasts regarding results or any other performance indicator, but rather trends or targets, as the case may be, including with respect to plans, initiatives, events, products, solutions and services, their development and potential. Although Holcim believes that the expectations reflected in such forward-looking statements are based on reasonable assumptions as at the time of publishing this document, investors are cautioned that these statements are not guarantees of future performance. Actual results may differ materially from the forward-looking statements as a result of a number of risks and uncertainties, many of which are difficult to predict and generally beyond the control of Holcim, including but not limited to the risks described in the Holcim's annual report available on its website (www.holcim.com) and uncertainties related to the market conditions and the implementation of our plans. Accordingly, we caution you against relying on forward-looking statements. Holcim does not undertake to provide updates of these forward-looking statements.

Contact Media Relations

Phone: ​+41 (0) 58 858 87 10

Email: media@holcim.com