Customer Background
Holcim operates one of the UK’s largest cement production facilities, where finished cement is transferred through high-pressure pipelines to storage silos prior to dispatch. Over time, pipe wear and joint degradation can occur within these pressurised systems, making minor leaks difficult to detect before they develop into larger operational issues. In some cases, this can result in the loss of several tonnes of finished cement, along with costly clean-up and production disruption. To minimise this risk, Holcim sought a reliable solution capable of detecting developing leaks at the earliest opportunity.
Why CODEL
Holcim selected CODEL for our proven expertise in industrial dust monitoring and our reputation for delivering robust, low-maintenance instrumentation in demanding process environments. Building on our long-standing relationship with the site, we supplied a reliable, fit-for-purpose solution designed to provide continuous particulate monitoring, enabling early leak detection, reducing material loss and supporting more proactive maintenance.
The Solution
CODEL supplied and installed the EnergyTech 501 Ambient Dust Monitor, positioning units along key points of the transfer line where deterioration was most likely to occur.
The EnergyTech 501 provided a marked improvement over the legacy system, offering stable sensitivity, real-time alarm visibility and continuous operation with minimal operator attention.
Results and Impact
Since installation, the EnergyTech 501 has enabled Holcim to:
• Detect dust leaks at an early stage
• Prevent minor issues from escalating into significant product-loss events
• Reduce unplanned downtime and clean-up effort
• Improve confidence in high-pressure transfer operations
• Strengthen overall process reliability and material protection
Efficency and Savings
With early leak detection provided by the EnergyTech 501, avoiding even a single major dust-loss incident can offset the cost of the instrument.
Estimated annual savings from reduced product loss, lower resource consumption and reduced downtime provide a clear return on investment.
This project demonstrates how effective continuous monitoring can protect both operational efficiency and material value in demanding industrial environments.
The EnergyTech 501 Ambient Dust Monitor provides reliable, real-time ambient dust monitoring for industrial applications including coal handling, processing and storage. Designed for harsh environments, it delivers continuous visibility monitoring to support containment control, improve safety and provide early warning of developing dust emissions.
