Data: The Digital Currency of Decarbonisation

The Net Zero Issue in Cement and Concrete

The cement and concrete industry is entering a decisive phase in its transition toward net zero. The scale of the challenge is well understood, but so too is the reality that there is no single solution that will deliver it.

Much of the focus to date has centred on breakthrough technologies such as carbon capture, plant modernisation, alternative fuel usage and many more. These remain essential. However, they are often capital intensive, long term in nature, and complex to deploy across existing operations.

There is however an emerging hero within low capital net-zero transition, one that already exists within every plant, every process and every production cycle, but perhaps is not fully utilised.

Data.

Across cement and concrete operations, vast amounts of data are generated daily. Historically, much of this data has been underutilised, fragmented or inaccessible. Today, advances in machine learning and predictive analytics are enabling producers to extract value from that data in real time, and in doing so, they are improving efficiency, stabilising production and reducing emissions without the need for additional capex investment.

To explore how this shift is playing out in practice, I sat down with Alejandro Espejel Garcia (Head of SaaS) and David Alós Shepherd (Head of Business Development) of alcemy to discuss the role of data in decarbonisation. Our conversation focused on how better use of existing data is already unlocking measurable reductions in emissions and why this approach is becoming one of the fastest, most scalable routes to impact in the sector.

About Alcemy

At its core, alcemy is a data and machine learning platform built specifically for cement and concrete production. The company uses predictive analytics to forecast key quality parameters such as compressive strength in real time, enabling producers to move from reactive, lab based control toward proactive, data driven optimisation. By using existing plant data, alcemy allows operators to stabilise production, reduce variability and make more precise adjustments to their processes without requiring additional hardware or major capital investment.

This approach is already being deployed at scale. Alcemy is currently active across 40 cement plants and more than 120 concrete plants globally. In Germany alone, alcemy’s sofware is used in half  of the integrated cement plants, supporting a broader industry shift toward lower clinker factors. At an individual plant level, producers using alcemy’s technology are typically able to achieve clinker factor reductions of 1.5 to 3 percentage points within the first year of implementation, delivering measurable emissions reductions alongside improved process stability.

Decarbonisation at Scale

The cement industry’s emissions profile is often framed as a technical challenge, driven by the chemistry of clinker production. Alejandro points out that scale is just as important.

“The main challenge is that the release of CO₂ is part of the inherent process… but it’s also the sheer volume of cement required globally that drives emissions.”

Concrete is the second most consumed material after water on earth. Even small improvements, when applied at global scale, can deliver significant impact.

There is growing attention and investment in high impact technologies such as carbon capture, but many point to the large upfront cost and payback period, and lack of infrastructure to deploy in global markets.

“Carbon capture will be very important,” Alejandro explains, “but it’s not going to be the silver bullet.”

Producers are therefore working across multiple levers, including alternative fuels, new materials and process optimisation. Data is increasingly part of that mix. As data is already produced, in the cement plant or at the construction site, this solution is tapping to a preexisting network of value, and looking at low impact ways to optimise and improve efficiencies.

The Untapped Value of Data

Alcemy’s approach is grounded in this simple observation. Cement and concrete producers generate vast amounts of data, much of which is not used effectively.

“Most producers have a lot of unsorted and unused data… and that data is very valuable to optimise the process, but it’s not being utilized,” David explains.

The opportunity lies in turning that data into insights. Using machine learning, alcemy enables producers to predict product performance during production, rather than relying solely on lab testing after the fact.

“It’s really about using the data to improve operational efficiency without the need for additional hardware.”

This approach allows producers to optimise processes in real time, using infrastructure that is already in place.

Reactive to Predictive

Traditional quality control in cement and concrete is largely reactive. Lab testing provides reliable results, but with a delay that limits how quickly operators can respond. Alcemy introduces a predictive layer.

“We use historic and live lab data to predict what the compressive strength is going to be while the cement is still being produced,” David says.

On the concrete side, visibility extends beyond the plant.

“Most ready mix producers have a blind spot… they don’t really know what happens from the moment the product leaves the plant until it reaches the site,” Alejandro notes.

By monitoring and predicting changes during transport, producers can maintain tighter control over quality and consistency.

Reducing Clinker with Confidence

Reducing clinker content remains one of the most effective ways to lower emissions in cement. In practice, this introduces variability that increases risk. Lower clinker mixes are more sensitive to changes in raw materials and water content. This leads producers to build in safety margins, which limits how far they can reduce clinker. Data changes this dynamic.

“Better use of the data allows our clients to go closer to the boundary than they normally would,” David explains.

“It reduces the safety factor and gives the certainty that you can still deliver the required performance.”

With improved confidence, producers can reduce clinker content further without increasing operational risk.

“Typically, customers can achieve 1.5 to 2 percentage points of clinker factor reduction within the first six months,” Alejandro says.

At scale, these incremental gains translate into meaningful emissions reductions.

Unlocking Value from Existing Data

One of the less visible challenges in cement and concrete production is not the absence of data, but the lack of effective utilisation. Plants generate large volumes of operational and quality data every day, yet much of it remains fragmented, unstructured or underused.

As David explains:

“There’s a lack of understanding of how to work with big data. A big part of our work is cleaning and structuring data before we can even use it.”

In many cases, data sits across disconnected systems, with limited accessibility and inconsistent formatting. Before any predictive modelling can take place, it must first be organised, validated and made usable. This foundational step is often overlooked, but it is critical to unlocking value.

At the same time, the urgency around decarbonisation is shifting priorities. Producers are increasingly looking for solutions that can deliver measurable impact in shorter timeframes.

“There’s a push for quick wins in decarbonisation, and using existing data is one of the fastest ways to achieve that,” David adds.

Compared to more capital intensive technologies, data driven optimisation offers a more immediate route to improvement. It allows producers to act on insights already available within their operations, improving efficiency and reducing emissions without waiting for new infrastructure or long investment cycles.

A New Lens on Decarbonisation

The conversation around decarbonisation in cement and concrete is evolving. Large scale technologies will remain essential, but there is increasing recognition of the role that operational efficiency can play.

Data provides a practical route to improvement. It enables better decisions, reduces variability and increases confidence in production processes. These gains can be realised quickly and without major capital investment.

In that context, data is becoming a central part of how the industry approaches net zero. It enables producers to act earlier, optimise continuously and build the foundation for broader transformation.

If you would like to discuss any of the topics raised in this piece, or if you need support with your leadership resourcing strategy, please get in touch with Cobi Busst on: cobi.busst@beaumontbailey.com.