Continuous / process
ERP for Cement Manufacturers
Continuous process, silo-wise quality and a strength result that arrives days after the bag has shipped. Quality here is statistical, not pass-fail.
- Stages mapped
- 6
- Quality checks
- 3
- Wastage rules
- 3
- Compliance items
- 3
Your process
The stages, already mapped.
Crushing to packing with silo-wise quality. These are the stages the template ships with — machines and checks included. Yours will differ in detail; that is configuration, not development.
- 1
Crushing
Crush limestone to raw-mill feed size
- Machines
- Crusher
- Checked
- Feed size analysis
- 2
Raw mill
Grind and blend raw meal to LSF targets
- Machines
- VRM raw mill
- Checked
- LSF/SM/AM (XRF)
- 3
Kiln
Pyroprocess to clinker with free-lime control
- Machines
- Rotary kiln 3000 TPD
- Checked
- Free lime, litre weight
- 4
Clinker cooling
Cool and store clinker
- Machines
- Grate cooler
- Checked
- Cooler efficiency
- 5
Cement mill
Grind clinker + gypsum/fly ash to fineness
- Machines
- Ball mill + separator
- Checked
- Blaine, residue
- 6
Packing plant
Rotary packer bagging with weight audit
- Machines
- Packer 120 TPH
- Checked
- Bag weight ±200 g
What goes in
Limestone, gypsum, fly ash
What comes out
OPC / PPC bags & bulk
OPC 43/53 · PPC · Bulk cement
Who is it for
Not all cement manufacturers work the same way.
The template is the same; what it has to answer for is not. Find the one that sounds like you — if none of them do, say so on the call and we will tell you honestly whether this is the right fit.
Integrated cement plants
Clinker and grinding stages costed separately.
Grinding units
Bought clinker, additive ratios and bag-wise dispatch.
RMC and block manufacturers
Mix designs, cube tests and site-wise delivery.
MANUPRIME AI
Ask it about this floor, in your own words.
The AI reads the same records this template creates — so on a cement manufacturer floor the questions it can actually answer are the ones you already ask at the morning meeting.
Questions it answers here
- “Why has clinker factor moved this week?” — currently 0.68 in the demo data
- “Why has power kwh/t moved this week?” — currently 72 in the demo data
- “Why has kiln run factor moved this week?” — currently 92% in the demo data
- “Where is my wastage going?” — dust (recycled), costed back to the batch that caused it
- “What am I short of in the next 14 days?” — with the covering purchase order drafted for approval
And what it is not allowed to do
It shows its working, or it does not answer
It drafts. A person releases
It sees only what the person asking can see
Quality
What quality control looks like here.
Checks that hold a dispatch, at the frequency this trade actually inspects.
| Parameter | Method | Frequency |
|---|---|---|
| Free lime (clinker) | Lab titration | Hourly |
| Blaine fineness | Air permeability | Per mill hour |
| Compressive strength | Mortar cubes 3/7/28 d | Per silo lot |
Wastage and recovery
The part generic ERPs get wrong.
Most systems can only write material off. In this trade that is the difference between a costing you believe and one you argue with.
Rules that ship with this template
- Dust from bag filters recycled to process
- Spillage cement reprocessed
- Torn bags reconciled at packer
What drives your cost per unit
- Fuel (coal/AFR) per clinker tonne
- Power kWh/T cement
- Clinker factor (PPC blending)
In short:Dust (recycled).
Compliance
What this trade has to prove.
Configured, not bolted on afterwards — the records come out of the same transactions your floor is already entering.
On the dashboard
The numbers this plant is judged on.
Sample figures from the demo, so you can see the shape of what you would be looking at every morning.
- Clinker factor
- 0.68
- Power kWh/T
- 72
- Kiln run factor
- 92%
Illustrative values from the demo dataset, not a customer's figures.
Questions
Questions we get asked first.
Is quality tracked silo-wise?
Yes. Fineness, setting time and strength are recorded against the silo and the production window, so a dispatched lot resolves to the quality data behind it.
How are 7-day and 28-day strengths handled?
As scheduled inspections that land after dispatch, held against the original production lot, so the record completes without re-opening the transaction.
Can it handle bulk and bag dispatch together?
Yes, with weighbridge capture for bulk and bag counts for packed, both reducing the same silo stock.
See it running with Cement Manufacturing data.
The demo opens with this trade's materials, machines, checks and reports already in place. No signup, nothing to install.