Building Expertise: Flyability and Holcim's North America Drone Days
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Holcim has been a pioneer in adopting Elios drones for inspections, leveraging this innovative technology to advance its Plants of Tomorrow initiative—aimed at integrating Industry 4.0 solutions across its operations. This strategic move not only enhances efficiency but also strengthens safety and sustainability at their facilities.
The partnership between Flyability and Holcim began back in 2016 at the Holcim Eclepens site, 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 the world. This collaboration supports Holcim’s vision of leading in innovation and operational excellence while allowing Flyability to fulfill its mission of sending drones into hazardous environments instead of human inspectors, keeping workers safe.
One of the key advantages of using Elios 3 drones in the cement industry is their ability to safely access hard-to-reach areas like clinkers and silos. These drones collect both visual and LiDAR data, even in dusty conditions, ensuring accurate and timely information. By using drones, Holcim reduces risks to employees and improves asset management, making it a safer, faster, and more cost-effective solution. This reliability has led to the expansion of their drone program, with trust in Elios growing across all locations.
The North American Holcim Drone Days took place at Midlothian Plant in Texas.
In June 2024, Flyability and Holcim organized the third edition of the Holcim Drone Days, marking the second event in North America. A total of 17 pilots from 9 different sites across the region attended, along with members of the Flyability 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, sparking new ideas and project collaborations.
Expert Talks on Drone Inspections in Cement
The Drone Days provided a platform for knowledge exchange between Holcim and Flyability. Flyability presented updates on future developments for the Elios drones, highlighting how the technology can evolve beyond basic inspections to become an essential part of reporting and communication. They also invited James Comeau from Glencore Kidd Operations to share insights on how his team has transitioned from early adopters in mining to full-time drone operators with well-established use cases.
Internal Holcim pilots also shared their experiences, offering valuable perspectives on how drones are being used across various plants. These discussions helped quantify the benefits of drone usage and inspired pilots to explore new applications. With participants ranging from beginners to seasoned professionals, the event was a great opportunity to strengthen the overall drone program and encourage continuous improvement.
Customized Training for Holcim Drone Inspections
This year's Drone Days were held at the Midlothian Plant in Texas, providing an ideal setting for practical training. The environment allowed pilots to practice in real assets, giving them an immersive experience to refine their skills. Given that many cement facilities have challenging conditions like dust and confined spaces, Flyability designed a tailored training program focusing on flying in such environments, adapting techniques, and navigating with limited visibility.
Pilots also had the chance to simulate unpredictable scenarios and learn how to manage the fear of losing a drone during an inspection. They tested features like the Elios 3’s Return-to-Signal function and explored the limits of the drone in a controlled and safe manner. Additionally, the group experimented with new payloads, including ultrasonic thickness measurement and surveying tools, expanding the range of applications for the drones.
Team photo! The North American pilots from Holcim with the Flyability team.
The training also highlighted the versatility of the Elios 3, showing that its applications go beyond visual inspections. Pilots learned about best practices for data processing, digitalization, and how to integrate Scan to BIM technologies, which aligns with Holcim’s long-term vision for smart, connected plants.
An Example of Fostering Innovation Through Drones
The North American Drone Days showcased the spirit of innovation within Holcim’s pilot teams. Led by David Hull, Manufacturing Support Coordinator at Midlothian Plant, the U.S. drone program is already evolving through collaboration. Pilots meet biweekly to discuss their experiences, but the event gave them the chance to connect in person and see how others operate. This kind of interaction is vital for driving progress and sharing best practices.
The sessions not only built stronger relationships among pilots but also inspired new ideas and skill development. Less experienced pilots gained insights from their more seasoned colleagues, while veterans got a glimpse of what’s coming next from Flyability. The open discussions allowed both parties to learn from each other and explore new ways to support one another.
Back at HQ in Switzerland, the Drone Days team described the event as a huge success, bringing together passionate individuals dedicated to improving safety and efficiency through drone technology. They thanked David Hull and Aaron Toles for their coordination efforts, as well as the plant manager in Texas for providing the venue and support needed for the event to take place.
This was just the first Drone Days event of 2024, but its positive impact shows that more events are planned for the future. Both Flyability and Holcim are committed to building a revolutionary drone program that positions Holcim as a leader in innovation and operational excellence.
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