Building Expertise: Flyability and Holcim's North America Drone Days
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Holcim was one of the first companies to embrace Elios drones for inspections, using this innovative technology to support their Plants of Tomorrow initiative—a bold effort to bring Industry 4.0 solutions to their operations worldwide. By integrating drones into their processes, Holcim is not only improving efficiency but also setting a new standard for safety and innovation in the cement industry.
The collaboration between Flyability and Holcim started back in 2016 at the Eclepens plant, where they tested early prototypes. Fast forward to 2024, and Holcim now operates a global fleet of 42 Elios drones, with over 100 trained pilots spread across multiple countries. This partnership has helped Holcim stay ahead of the curve, pushing the boundaries of what's possible in industrial inspection while keeping workers safe. For Flyability, it's about sending drones into tough environments instead of people—ensuring safety without compromising on data quality or operational efficiency.
One of the biggest advantages Holcim has seen from using Elios 3 drones is the ability to access hard-to-reach areas within silos and clinker systems. The drones are able to gather both visual and LiDAR data, even in dusty conditions, which is a huge win for the company. This means Holcim can collect accurate, timely information without putting employees at risk, making asset management safer, faster, and more cost-effective. It's no surprise that they've built such a large and trusted drone program around this technology.
The North American Holcim Drone Days took place at Midlothian Plant in Texas.Â
In June 2024, Flyability and Holcim co-hosted the third edition of the Holcim Drone Days, marking the second event in North America. A total of 17 pilots from nine different sites across the region joined, along with Flyability’s team. Building on the success of the 2023 event in Lausanne, this session featured expert talks, hands-on training, and opportunities for pilots to share experiences and learn from each other. It was a great chance to inspire new ideas and strengthen the drone program across the company.
Expert Talks on Drone Inspections in Cement
The Drone Days provided a platform for knowledge exchange between Holcim and Flyability. Flyability shared updates on future developments for the Elios drones, showing how they’re evolving from simple inspection tools into essential parts of reporting and communication. They also invited James Comeau from Glencore Kidd Operations to speak about how his team transitioned from early adopters in mining to full-time drone operators with well-established use cases.
Inside Holcim, several pilots presented how they're using drones in their own plants. These presentations were incredibly valuable, as they allowed attendees to explore new possibilities and discuss how to safely implement new drone applications. With pilots of all experience levels, the event was a great opportunity to build a stronger, more cohesive drone program across the organization.
Customized Training for Holcim Drone Inspections
This year’s Drone Days were held at the Midlothian Plant in Texas, offering an ideal setting for hands-on training. Pilots had the chance to practice in real-world environments, including dusty and confined spaces—common challenges in cement production. Flyability designed a custom training program focusing on flying in difficult conditions, adapting techniques, and maintaining confidence with limited visibility.
Additionally, the group discussed how to handle unexpected situations, including the fear of losing a drone during an inspection. They tested the Elios 3’s Return-to-Signal feature and pushed the limits of the drones in a controlled, safe environment. The training also introduced new payloads like the ultrasonic thickness measurement and surveying tools, expanding the drone’s capabilities beyond visual inspections.
Team photo! The North American pilots from Holcim with the Flyability teamÂ
The sessions also highlighted how Elios 3 can be used for more than just visual inspections. Pilots tested new payloads and learned how to process and manage data efficiently. Topics like stockpile volumetry, plant mapping, and digitalization were covered, helping pilots become more autonomous in their work. Discussions on Scan to BIM also sparked interest, aligning with Holcim’s broader vision for the Plants of Tomorrow.
An Example of Fostering Innovation Through Drones
The North American Drone Days showcased the collaborative spirit of Holcim’s pilot teams. Led by David Hull, the Manufacturing Support Coordinator at Midlothian Plant, the U.S. drone program is already focused on continuous improvement. While pilots meet biweekly to discuss their experiences, the event offered a rare opportunity to connect in person and see how others operate.
The event strengthened relationships among pilots, giving everyone new ideas and skills. Less experienced pilots gained insights from seasoned ones, while veterans got a glimpse of what's coming next from Flyability. The roundtable discussions allowed both sides to learn from each other, creating new opportunities for collaboration and growth.
Back in Switzerland, the Drone Days team called the event a huge success, highlighting the passion and dedication of the people involved. They thanked David Hull and Aaron Toles for their support in organizing the event, as well as the plant manager in Texas for providing the space and resources needed. It was a powerful reminder of how partnerships can drive innovation and make a real difference in the industry.
This was just the first Drone Days event of 2024, but its success sets the stage for more events in the future. Both Flyability and Holcim are committed to building a cutting-edge drone program that positions Holcim as a leader in innovation and safety. With each event, they're moving closer to their vision of smarter, safer, and more efficient industrial operations.
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