Cementing Cybersecurity

The global cement industry is undergoing a period of profound change, driven by multiple operational and strategic challenges. A severe shortage of skilled labour has increased the need for automated and remotely managed systems to ensure uninterrupted operations, as downtime poses significant financial risks. At the same time, the industry faces increasing pressure to meet sustainability targets, especially on energy consumption and carbon emissions, while incorporating alternative energy concepts into existing processes. These demands are amplified by the need to innovate within a landscape of established facilities in a competitive, price-sensitive market.

Digitalisation offers viable solutions to these challenges: advanced process automation, real-time operational monitoring, and predictive maintenance can help optimise resource utilisation and minimise operational disruptions. At the heart of these digital initiatives is the role of data – its integration, accessibility, and integrity. Reliable and accurate data and seamless communication between systems provide the foundation for advanced analytics and machine learning tools that further drive operational efficiency. Without robust data management, efforts to digitise processes risk being undermined by inconsistent or siloed information.

In addition, digital tools facilitate the integration of alternative fuels or energy concepts by using real-time data to dynamically adjust production parameters to ensure stability of clinker quality and emissions levels. They also support energy efficiency measures by accurately tracking energy flows and optimising power consumption across processes. With comprehensive data systems in place, companies can more effectively demonstrate compliance with environmental standards and build resilience, balancing the industry's economic constraints with the pressing need for sustainability.

No digitalisation without cybersecurity!

Based alone on the few advantages mentioned, it is obvious that the cement industry needs to transform from an automated industry to a digitised one. However, the associated exponential growth in data communication poses significant cybersecurity challenges. As connectivity increases, so does the risk of cybercrime, with attackers targeting vulnerabilities in both information technology (IT) and operational technology (OT) systems.

This is of particular concern in the cement industry, where older systems – many of which are no longer supported or maintained by their manufacturers – present serious security risks. Of course, also modern systems need to be kept up to date with an integrated approach that requires regular updates to remain secure. However, routine maintenance (and unplanned but security-related patches) cause downtime and should be avoided.

“With industrial companies transforming into digital enterprises, the importance of cybersecurity has grown tremendously in the last years.” – Michael Metzler, Head of Horizontal Management Cybersecurity for Digital Industries.

To address these risks, companies are now investing in digitalisation strategies and implementing stringent requirements for IT infrastructure. Unfortunately, OT infrastructure often receives less attention, despite its critical role in plant operations. A holistic approach to cybersecurity must include both IT and OT and be aligned with the maturity level of each facility. Frameworks such as the NIST cybersecurity framework and the controls of the Center for Internet Security Controls (CIS 18) provide structured ways for organisations to assess and improve their security posture.

As a result, every facility needs a cybersecurity strategy that is not only holistic in design and implementation, but also based on its current cybersecurity maturity level. The following three phases should be viewed as a circular process: identify, protect, and monitor. Holistic approaches require more, but this is a simplified model. It provides a solid foundation for securing cement plant operations in a connected world.

Identify: a comprehensive status analysis

The first step in establishing cybersecurity in cement plants, particularly in the OT environment, is to understand the plant's current security status.

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Read the article online at: https://www.worldcement.com/special-reports/28022025/cementing-cybersecurity/