LafargeHolcim Unveils ‘Plants of Tomorrow’: A Global 4.0 Initiative to Boost Efficiency by 20%

LafargeHolcim has announced the launch of its ambitious “Plants of Tomorrow” program, a four‑year Industry 4.0 rollout aimed at modernising more than 270 integrated cement plants and grinding stations across 50+ countries. The initiative will embed automation, robotics, artificial intelligence, predictive maintenance and digital‑twin technology throughout the production chain, positioning the company as a leader in the building‑materials sector.

Certified “Plants of Tomorrow” sites are projected to achieve 15‑20% higher operational efficiency compared to conventional plants. To date, LafargeHolcim is running over 30 pilot projects worldwide, with the Siggenthal, Switzerland plant serving as the global showcase for integrated module testing.

“Transforming how we produce cement is a core pillar of our digital strategy,” says Solomon Baumgartner Aviles, Global Head of Cement Manufacturing. “The ‘Plants of Tomorrow’ initiative will bring Industry 4.0 to life, making cement production safer, more efficient and environmentally responsible while supporting profitable growth under Strategy 2022 – ‘Building for Growth.’”

Key technology components include predictive operations that flag anomalies in real time, reducing maintenance costs by more than 10% and cutting energy consumption. Digital twins will optimise training and plant design, while autonomous robotics will handle high‑exposure tasks. In partnership with Swiss start‑up Flyability, drones enable frequent, cost‑effective inspections of confined spaces, a capability now expanding across the U.S., U.K., Switzerland, France, Germany, Canada, India and Russia.

LH MAQER, LafargeHolcim’s new platform for technology selection, is fostering partnerships with manufacturing and software innovators. Philipp Leutiger, Chief Digital Officer, notes, “Our global cement expertise is unmatched. LH MAQER unlocks the ingenuity of the world’s leading digital talent, and we’re already seeing tangible benefits across operations.”

Since 2006, the company’s technical information system—now connected to over 80% of its plants—has delivered more than $80 million in savings and 3 million additional tons of cement sold through reduced downtime. The platform provides real‑time data transparency from plant to global level, enabling proactive decision‑making.

For further details, visit www.lafargeholcim.com.