CIMPOR’s private 5G blueprint boosts efficiency, cuts CO2

Cement producer CIMPOR has completed deployment of private 5G networks across its three main Portuguese plants and is preparing to extend the model to other operations worldwide.

The company has activated a Mobile Private Network at its Souselas facility, following earlier deployments at Alhandra and Loulé. All three now run on Ericsson Private 5G technology under a programme delivered with Vodafone Portugal.

The networks replace or supplement legacy wireless systems with dedicated cellular infrastructure across each plant. The deployment targets large industrial sites with heavy equipment, dust, vibrations and extensive metal structures.

CIMPOR’s private 5G networks provide site-wide coverage with latency below 10 milliseconds, according to the companies. The infrastructure carries traffic from a mix of internet-of-things sensors, autonomous vehicles and other connected equipment.

This structure separates connectivity from public mobile networks and from traditional Wi-Fi. It also centralises control of industrial traffic on CIMPOR’s own infrastructure at each location.

Vodafone Portugal led installation, parameter setting, configuration and deployment of all radio equipment. The operator defined core network parameters with CIMPOR and managed integration of the industrial applications that run over the network. It also carried out service validation work for both the private network and the associated use cases.

CIMPOR is already using the networks to support new digital tools and automation at the plants. These tools cover inspection, maintenance, safety and workforce support.

Drones now carry out inspections in areas that are difficult to reach. The company said this approach improves safety and speeds up checks.

Smart glasses support remote maintenance assistance and training. VR glasses support simulation and training using virtual reality. Tablets in the hands of workers replace paper processes and speed up data collection and access.

Sensors gather data for predictive maintenance. Video cameras support safety monitoring. The company also applies artificial intelligence across several technology use cases that run over the private networks.

CIMPOR has used experience from the first site rollout to shorten deployment times at the other plants. It plans to use the same framework as it considers expansion to further locations in its global portfolio.

The cement group expects the network-backed shift toward predictive maintenance to reduce unplanned failures and production stoppages. Internal assessments at CIMPOR indicate that improved inventory and maintenance planning could deliver up to USD $1 million in annual savings per plant.

The company reports that the early phase of the programme has already improved efficiency. It cites an approximate one per cent increase in overall efficiency across connected production systems at the three sites.

CIMPOR estimates that this gain equates to an annual economic effect of USD $10 million to USD $15 million, including direct and indirect impacts. The same efficiency improvement is linked to a reduction of about 140,000 tonnes of CO2 emissions.

The company said the figures underline the role of digitalisation in industrial decarbonisation strategies, as well as in cost savings.

CIMPOR is part of Taiwan Cement Corporation and operates across 14 countries on four continents. It has stated ambitions around Industry 4.0, 5G connectivity and predictive monitoring as part of its path towards carbon neutrality by 2050.

The new Portuguese networks are expected to act as a template for other CIMPOR facilities. This template includes a common technology platform, a standard process for deployment and integration, and a set of repeatable industrial applications.

The blueprint also envisages gradual integration of additional technologies. These include further IoT systems, automation projects, digital twins and expanded use of autonomous vehicles on industrial sites.

Berkan Fidan, Global Chief Technology Officer at CIMPOR, said the three-site programme marks an inflection point in the firm’s digital plans.

“This implementation of private 5G networks across our production units marks a decisive step in strengthening the resilience, efficiency and safety of our industrial operations. This technology lays the foundation for a new generation of digital applications and enables us to operate with greater precision and responsiveness. This is only the beginning of a wider journey,” said Fidan.

Henrique Fonseca, Executive Board Member, Enterprise Business Unit at Vodafone Portugal, linked the project with the broader role of private networks in manufacturing.

“The implementation of private 5G networks in these three CIMPOR factories not only demonstrates the company’s determined commitment to its sustainable future but also reinforces the role these networks play in enhancing economic competitiveness, particularly in industrial activities. With immediate communications and large-scale sensing, data can be interpreted quickly, and a wide range of remote activities becomes possible - expanding the reach of these factories well beyond their physical locations,” said Fonseca.

Manish Tiwari, Head of Enterprise 5G at Ericsson, said the deployment highlights how industrial groups are standardising around repeatable private network models.

“CIMPOR’s multi-site deployment illustrates how Ericsson Private 5G networks can transform industrial operations at scale. As enterprises move toward more automated and real-time processes, demand for reliable private cellular networks continues to grow. By establishing a replicable approach across three sites, CIMPOR now has a strong blueprint it can apply across its wider global footprint,” said Tiwari.

CIMPOR plans to extend the approach developed in Portugal across additional plants as it advances its modernisation and decarbonisation strategy.