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Building Expertise: Flyability and Holcim's North America Drone Days
Holcim has been a pioneer in adopting Elios drones for inspections, embracing this technology to drive forward their "Plants of Tomorrow" initiative—a bold step towards integrating Industry 4.0 technologies into their operations. Their collaboration with Flyability began back in 2016 at the Holcim Eclepens site, where they tested early prototypes. Fast forward to 2024, and Holcim now boasts a global fleet of 42 Elios drones, supported by over 100 trained pilots scattered worldwide. This partnership empowers Holcim’s vision to lead the industry in innovation, efficiency, and safety, while Flyability continues its mission to send drones into hazardous environments instead of risking human inspectors.
The advantages Holcim has reaped from using Elios 3 drones in the cement industry are immense. These drones offer safer access to the insides of clinkers and silos, capturing both visual and LiDAR data effectively, even in dusty conditions. The drones’ ability to maintain clarity and precision in data collection despite challenging environments has been particularly impressive. For Holcim, this translates to reduced employee risks, faster data acquisition, and cost-effective asset management. These benefits have made Elios drones a trusted and essential tool for the company.
In June 2024, Flyability and Holcim co-hosted the third edition of the Holcim Drone Days in North America, following the success of the previous year's event in Lausanne. Seventeen Holcim pilots from nine sites across North America joined forces with Flyability’s team for this three-day extravaganza held at the Midlothian Plant in Texas. The agenda included expert talks, specialized training, and opportunities for pilots to share their experiences and explore innovative uses for drones within their facilities.
Flyability delivered insightful presentations on the future of Elios drones, highlighting upcoming developments and strategies to transition from basic inspections to comprehensive reporting tools. James Comeau from Glencore Kidd Operations shared his team's journey, from early adopters in the mining sector to establishing full-time drone operators with set use cases. Holcim pilots also showcased their creative approaches to drone utilization, fostering a collaborative atmosphere that encouraged experimentation and growth.
The Midlothian Plant provided an ideal setting for hands-on training, allowing pilots to practice in realistic environments. Flyability designed a custom curriculum focusing on flying in dusty conditions, navigation tips, and handling unexpected scenarios—such as losing a drone mid-inspection. Participants thoroughly tested the Elios 3’s Return-to-Signal feature, gaining confidence in pushing the boundaries of drone capabilities safely.
Beyond inspections, the pilots experimented with advanced payloads like the ultrasonic thickness measurement tool and surveying equipment. These tools enhanced their ability to conduct stockpile volumetry, create plant maps, and digitize operations. The team also explored the potential of Scan to BIM, aligning with Holcim’s broader innovation goals.
Led by David Hull, the Midlothian Plant’s Manufacturing Support Coordinator, the drone program in the U.S. exemplifies collaborative progress. Regular meetings have already fostered teamwork, but the Drone Days enabled face-to-face interactions that deepened understanding and inspired fresh ideas. The event built camaraderie among participants, bridging gaps between newcomers and seasoned professionals.
The sessions also sparked excitement about Flyability’s future innovations. Back at headquarters in Switzerland, the organizing team expressed gratitude to David Hull and Aaron Toles, who played pivotal roles in facilitating the event. The Texas plant manager also deserves recognition for enabling this unique gathering.
This inaugural Drone Days event of 2024 was a resounding success, leaving everyone eager for future iterations. Both Flyability and Holcim remain committed to advancing this transformative program, positioning Holcim as a trailblazer in the industry.