Driving Automation and Sustainability in the Cement Industry: A Conversation with Christopher Ashworth

In an era where digital transformation is redefining even the most traditional sectors, the cement industry is at a pivotal moment in its evolution. Responsible for roughly 7% of global CO₂ emissions, the industry faces a critical need to evolve not only to remain competitive but also to align with urgent sustainability goals. Automation and digitalisation present powerful tools in this transformation, promising to revolutionise efficiency, reduce environmental impact, and prepare cement plants for the future of industrial operations.

With this in mind, we turned to Chris Ashworth, President of FLSmidth Cement, to gain insight into how digital advancements are reshaping the industry. Chris brings decades of experience in industrial automation, guiding companies through digital change and exploring sustainable innovations. His vision for FLSmidth Cement, a company that has led in cement technology for over a century, offers a unique perspective on the industry’s challenges and the path forward. In our conversation, he shares how digital tools, AI, and automation are making it possible to enhance production, drive sustainability, and ultimately reshape the future of cement.

Can you share your personal journey in the automation industry and what inspired you to focus on solutions for the cement sector?

My career in automation began over several decades, with roles across leading industrial companies. Starting with Ingersoll Rand, I moved through different regions in Europe, eventually working with companies like Wonderware (now AVEVA) and Schneider Electric, where I was focused on digital solutions at multiple levels, from machine control to enterprise systems. What inspired my move to the cement sector with FLSmidth was the opportunity to drive a transformational shift in an industry known for both its tradition and the pressing need for modernisation, especially around sustainability. Cement manufacturing is challenging, with unique environmental pressures and complex technical requirements, making it a perfect fit for automation and digitalisation.

What are the most significant changes you’ve seen in the cement industry due to the adoption of automation and digitalisation?

Automation and digitalisation have significantly reshaped the cement industry. We’re now able to gather extensive process and quality data, which we leverage for real-time monitoring and optimisation. This has improved efficiency, productivity, and safety by enabling predictive maintenance and online condition monitoring. Notably, automation has played a role in sustainability efforts, helping reduce the CO₂ footprint of cement, which is critical since cement production contributes about 7% of global CO₂ emissions. These technologies allow plants to operate with lower energy and raw material use, optimising inputs to meet both productivity and sustainability goals.

How does your company differentiate itself in providing automation solutions specifically for the cement industry?

FLSmidth Cement’s history gives us a unique depth of expertise. We’re one of the few companies that have over a century of experience not only in cement plant manufacturing but also in automation, with software solutions dating back to the 1960s. Our solutions are tailored to cement’s unique requirements, rather than adapting general-purpose technology. Additionally, our hardware-agnostic approach enables us to integrate seamlessly with various systems, providing flexibility for cement plants worldwide. This expertise ensures that our automation solutions deliver reliable performance under real-world conditions specific to cement production.

What leadership qualities do you believe are essential in driving digital transformation within traditional industries like cement manufacturing?

Digital transformation requires leaders to be visionary yet pragmatic, willing to embrace calculated risks while maintaining a clear understanding of industry challenges. Collaboration and stakeholder alignment are crucial, as digital solutions only succeed if they are embraced at every level. Leaders must encourage a culture of curiosity and innovation, facilitating cross-functional teamwork and breaking down silos to foster collaboration. Ultimately, it’s about creating a shared vision that balances technological innovation with operational reliability.

How have automation solutions impacted operational efficiency and sustainability in cement production, and what results have you witnessed firsthand?

Automation has driven significant improvements in operational efficiency and sustainability across cement plants. Our ECS/ProcessExpert (PXP) system, for instance, optimises the pyro process, stabilising operations to increase production, reduce emissions, improve fuel efficiency and utilize alternative fuels effectively. These efficiency gains lead to reduced energy consumption and lower CO₂ and NOₓ emissions, directly contributing to sustainability. We’re also actively involved in R&D, like our work with the DETOCs program, which helps optimise blends in real-time for reduced clinker content, advancing our decarbonisation goals.

What role do you think data analytics and AI will play in the future of cement manufacturing, and how is your company preparing for this?

AI and data analytics are transforming the industry by enabling predictive modelling, which helps manufacturers understand and optimise every aspect of production. Our collaboration with Carbon Re, for instance, integrates AI into our PXP system for advanced process control. This allows us to analyse real-time data and forecast potential inefficiencies, reducing costs and emissions while enhancing operational insight. We see AI as a key enabler, accelerating innovations and providing cement manufacturers with the tools to adapt dynamically to market and regulatory demands.

How is the rise of AI affecting the role of humans in cement plants and businesses? Is there a risk that human experience and intuition could be lost as AI takes over a greater number of roles? How can management mitigate these risks?

While AI offers powerful insights and automation capabilities, it is designed to augment, not replace, human expertise. We believe AI will enable more informed decision-making by providing a comprehensive view of operations, but human experience and intuition remain invaluable in understanding the nuances of cement production. Management can mitigate risks by fostering continuous learning and upskilling, ensuring teams are equipped to work alongside these advanced technologies. By combining AI with human expertise, we achieve a balanced approach that maximises both efficiency and operational insight.

How does your leadership style influence the innovation and implementation of digital solutions within your company?

I prioritise breaking down silos and fostering a collaborative environment, which is critical to driving innovation. By encouraging cross-functional teamwork, we can integrate our product and process expertise to deliver holistic solutions. My focus is on removing friction within the organisation to enable people to work more effectively together, fostering a culture that values curiosity, cross-discipline collaboration, and a service-centric mindset. Recognising and celebrating successful collaborations is also part of my approach, as it motivates the team to stay aligned with our transformation goals.

What challenges do you foresee in further automating the cement industry, and how is your company addressing these obstacles?

Some challenges include legacy system integration, cybersecurity risks, and a skills gap as the industry requires non-traditional technical skills. Furthermore, there’s a high implementation cost, and the industry competes with tech-savvy sectors for skilled talent. At FLSmidth Cement, we’re addressing these challenges through initiatives like our PlantLine™ service agreements, which provide continuous support and 24/7 access to expertise, helping bridge the skills gap. Our hardware-agnostic solutions also allow us to integrate with legacy systems, and we’ve incorporated cybersecurity modules into our offerings.

How do you think AI will shape the broader business strategies of cement companies in the long term?

AI will be an accelerator, enhancing existing strategies rather than replacing them. For example, the industry is focused on reducing its carbon footprint, and AI will streamline this by helping optimise SCM (supplementary cementitious material) usage and clinker substitutes, driving both cost and sustainability improvements. Cement companies will continue pursuing core strategies like efficiency and sustainability, but AI will make these pursuits more achievable, positioning the industry to meet evolving regulatory and market demands.

Conclusion

Our discussion with Chris Ashworth made it clear that automation and digitalisation are more than just trends—they’re essential strategies for cement companies in a rapidly changing world. From advanced process control systems that improve efficiency and reduce emissions to AI-powered tools that guide decision-making, the digital transformation of cement manufacturing is just beginning. Beyond technology, it’s leadership and a forward-looking mindset that will empower this transformation, a point that Chris emphasises with passion.

As we look ahead, the role of automation in the cement industry will continue to evolve, becoming a cornerstone of both operational resilience and sustainability. FLSmidth Cement’s approach, driven by industry expertise and a commitment to innovation, underscores the importance of experience and adaptability in making this shift successful. By embracing these advancements, the cement industry can not only meet today’s challenges but also build a more sustainable and efficient future.

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 Alex Catana on: alex.catana@beaumontbailey.com