- The advanced process control solution has been used across seven finish mills over one year and across a kiln operation for five years
- Expert Optimizer deployment at Nanyo Plant has improved productivity and reduced power consumption
- Tokuyama says it has exceeded a 90 percent automatic operation rate to stabilize operations and improve efficiency
Tokuyama’s Nanyo Plant, one of the largest factories in Japan1, has reported a range of results from the proven use of ABB advanced process control (APC) technologies in its cement operations. ABB Ability™ Expert Optimizer has enabled the control, stabilization and optimization of processes, including an automatic operation rate exceeding 90 percent in its finish mills.
Since initial test deployment on one finish mill in 2024, the solution has been delivered and commissioned on another six; four cement ball mills and two vertical mills (pre-grinding and slag). Tokuyama had already seen successful results from the kiln optimization in 2022, including a three percent reduction in specific heat consumption and a 70 percent reduction in manual operator actions on the cement kiln.
ABB Ability™ Expert Optimizer has also helped establish an efficient production framework by improving grinding throughput by three percent and reducing specific power consumption by three percent, while maintaining stable operations.
Results from the use of ABB Ability Expert Optimizer include reductions in heat consumption and fewer manual interventions. Image ABB 
Tokuyama Nanyo Plant where ABB Ability™ Expert Optimizer was deployed. Image Tokuyama Corporation
“When we first introduced ABB Ability™ Expert Optimizer for test purposes, results were clear and the project completed smoothly,” said Mr. Junya Doi, Engineering Section, Cement Manufacturing Department, Tokuyama. “We decided to extend the use of the solution to the entire cement mill process. ABB has been a reliable partner, collaborating effectively to fit the operating schedules. We believe ABB Ability™ Expert Optimizer has delivered exactly the results we expected.”
“ABB Ability™ Expert Optimizer has delivered a level of control at Nanyo plant that can not only emulate operator actions but enable process stabilization and optimization at the same time,” said Hiromichi Yoda, Local Division Manager for Japan, ABB’s Process Industries division. “The continued implementation of advanced digital solutions for Japanese industries supports a desirable pathway to autonomous operations.”
By enabling finish mills to achieve a high automatic operation rate, ABB’s APC solution has also reduced operator workload, standardized operating practices and minimized manual intervention, providing a strong foundation for future operational improvements.
ABB Ability™ Expert Optimizer’s model predictive control (MPC) and AI continuously predict process behavior and automatically adjust operating parameters such as feed rate and mill power. By maintaining optimal mill load and throughput, the system supports stable, efficient operations. As part of ABB’s wider digital portfolio, it helps cement producers use real-time data to optimize processes, maintenance and production performance.
1. Cement Business | Cement Business Division | Tokuyama
ABB’s Automation business automates, electrifies and digitalizes industrial operations that address a wide range of essential needs – from supplying energy, water and materials, to producing goods and transporting them to market. With its ~26,000 employees, leading technology and service expertise, Automation helps process, hybrid and maritime industries outrun – leaner and cleaner. go.abb/automation
ABB is a global technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. By connecting its engineering and digitalization expertise, ABB helps industries run at high performance, while becoming more efficient, productive and sustainable so they outperform. At ABB, we call this ‘Engineered to Outrun’. The company has over 140 years of history and around 110,000 employees worldwide. ABB’s shares are listed on the SIX Swiss Exchange (ABBN) and Nasdaq Stockholm (ABB). www.abb.com
