What KIMA Process Control does

KIMA Process Control GmbH is a privately held German industrial technology company founded in 1996 in Jülich, Germany, originally as KIMA Echtzeitsysteme. The company develops, produces, and markets measurement and regulation technologies for industrial process optimization, with a product portfolio centered on SMARTFILL (structure-borne sound sensors for high-precision fill-level measurement in ball mills), MILLPILOT (an AI/Advanced Process Control system that operates grinding mills fully autonomously), and SMARTCONTROL (a modular OPC-connected control platform combining fuzzy logic, predictive control, neural nets, and rule-based expert systems). Supporting products include KILNCOOLER (infrared-guided kiln-shell cooling), GASTEMP (acoustic gas temperature/flow measurement), and V-SENS (vibration monitoring sensors).

The company's technology is built around proprietary sensor designs mounted directly on mill shells and a layered AI/APC software stack that turns sensor inputs into autonomous closed-loop control. Products integrate into existing plant PLCs via OPC and 4-20mA interfaces, and are deployed across cement, minerals, and energy industries, with extensions into discrete manufacturing. Documented outcomes include 9-11% power-consumption reductions, approximately 10% production increases, ROI typically under one year, and 5.6 million tons of CO2 saved cumulatively by 2022 across 1,500+ installations in over 50 countries.

KIMA makes money by selling proprietary hardware (sensors and control units), software systems (MILLPILOT and SMARTCONTROL), and process optimization services to large industrial plant operators, primarily through direct enterprise field sales supported by ROI-based proposals and technical case studies. The go-to-market relies on international trade fairs, technical publications in industry magazines, video demonstrations, and direct developer-to-customer engagement, with no self-service e-commerce. The company is founder-managed, led by Dr. Peter Kalkert and Matthias Kalkert in General Management, holds ISO 9001:2015 certification, and appears to operate without external venture capital or institutional investors based on available information.

Name

KIMA Process Control

Legal name

KIMA Process Control GmbH

Website

https://kima-process.de

Company type

Private

Founded year

1996

Operating status

Operating

Headcount range

11–50 employees

Short description

KIMA Process Control GmbH, founded 1996 in Jülich, Germany, develops proprietary AI-driven measurement and process control systems (SMARTFILL, MILLPILOT, SMARTCONTROL) for cement, minerals, energy, and industrial manufacturers, with 1,500+ installations across 50+ countries.

Ownership category

akta.pro rank

Product category

Industrial Process Control Systems

NAICS

Instruments and Related Products Manufacturing for Measuring, Displaying, and Controlling Industrial Process Variables (334513), Relay and Industrial Control Manufacturing (335314), Other Measuring and Controlling Device Manufacturing (334519), Navigational, Measuring, Electromedical, and Control Instruments Manufacturing (3345)

SIC

Industrial Instruments For Measurement, Display, And Control (3823), Measuring & Controlling Devices, Nec (3829), Electrical Industrial Apparatus (3620)

akta.pro primary industry

Industrial Controllers & Control Systems (PLCs, PACs, CNC Controllers) (IMAHAHAH)

akta.pro secondary industries

Process Automation Instrumentation & Control (DCS, Valves, Actuators, Analyzers) (IMAHAHAM), Process & Batch Control Software (Recipe Management, ISA-88) (IMAGABAH), Industrial Control Panels & Enclosures (Panel Building, MCCs, Integration) (IMAGABAJ)

Keywords

• Industrial process control
• Fill level measurement
• Advanced process control
• Vibration monitoring sensors
• Grinding circuit automation

Headquarters

HQ city

Jülich

HQ country

Germany

HQ region

Europe

Offices1 record

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Technology or R&D, Personnel, Operations, Marketing or Sales, Infrastructure

Revenue model

1. Process Control Systems and Sensors: KIMA Process Control generates revenue through the sale of proprietary measurement and control systems including SMARTFILL, MILLPILOT, KILNCOOLER, SMARTCONTROL, GASTEMP, and V-SENS products. The company provides both hardware (sensors, control units) and software (expert systems, control algorithms) for industrial process optimization. Revenue is generated from equipment sales, installation, and ongoing technical support services.
2. Software and Control Systems: Advanced Process Control and AI-based software solutions including MILLPILOT and SMARTCONTROL are sold as software systems that integrate with existing PLC infrastructure via OPC protocol. These modular systems provide building blocks for process optimization.
3. Process Optimization Services: The company provides process optimization consulting and commissioning services. Projects are approved based on ROI calculations with focus on energy savings and carbon footprint improvement. Return on investment is a key consideration for customers.

Go-to-market motion2 records

Distribution channels1 record

Marketing channels5 records

Core offering

KIMA Process Control develops, produces, and markets industrial measurement and regulation technologies for cement, minerals, and energy plants. Its core offering combines proprietary sensors (SMARTFILL, GASTEMP, V-SENS) with AI-driven advanced process control systems (MILLPILOT, SMARTCONTROL, KILNCOOLER) that automate and optimize grinding mills, kilns, and combustion processes, integrating into existing PLCs via OPC/4-20mA interfaces.

Product overview

KIMA Process Control offers a portfolio of measurement and control products for industrial grinding and pyro-processing optimization. The core offering combines SMARTFILL™ (high-precision fill-level measurement via structure-borne sound sensors) with MILLPILOT (AI-powered autonomous grinding control) and SMARTCONTROL (flexible APC platform). Supporting products include KILNCOOLER (infrared-controlled kiln shell cooling), GASTEMP™ (acoustic temperature/flow measurement), and V-SENS (vibration monitoring). SMARTFILL™ (Coal) extends the flagship fill-level sensor for coal mill applications. The products integrate into existing plant PLCs via OPC/4-20mA and are deployed across cement, minerals, and energy industries in over 50 countries.

Differentiator

Problem solved

Functional benefit

Products and services

• SMARTFILL Fail-safe, high-precision fill-level and temperature measurement system for ball mills. Uses structure-borne sound sensors positioned directly on the mill shell to measure the fill level of each chamber, shell and material temperature, wear of mill internals, and the impact point of balls. Designed for cement and minerals plants.
• SMARTFILL (Coal) 360-degree impact sound analysis system for ball mills used in coal grinding applications. Delivers precise fill-level measurement optimized for combustion stability and reduced unburnt carbon at coal-fired power plants and energy facilities.
• MILLPILOT Advanced Process Control and AI system for predictive control of grinding facilities. Enables fully automated closed grinding circuit control with auto-adaptive fill-level adjustment, controlling up to four mills simultaneously. Targeted at cement, minerals, and energy plants.
• SMARTCONTROL Flexible, modular high-end control system providing building blocks including digital filters, predictors, closed loop controllers, and fuzzy-expert systems. Connects to plant PLCs via OPC protocol and serves as the platform layer for APC and AI control applications.
• KILNCOOLER Water-based kiln shell cooling system using infrared temperature sensors and fuzzy-controlled nozzle activation. Available in Stationary (covering 10+ meters) and Mobile (covering 2.5 meters) configurations to target hot spots on rotary kiln circumferences in cement plants.
• GASTEMP Acoustic gas temperature and flow measurement system. Measures speed of sound through a duct to determine gas temperature with under 3 degrees Celsius accuracy and under 1 second response time, operating in a 0-900 degrees Celsius range using ceramic sensing elements.
• V-SENS Compact industrial vibration velocity sensor with 4-20mA output for direct PLC connection. Monitors engines, pumps, sifters, cyclones, mills, and kilns at 10-1000 Hz frequencies with IP67 protection, used for condition-based monitoring of rotating equipment.

Quantifiable outcome

• Power consumption reduced by 9-11%
• +7 more outcomes

Named customers5 records

Segments4 records

Ideal customer profiles4 records

Technology focussed Yes

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

AI capability5 records

Feature6 records

Scale indicators11 records

Recent moves6 records

Expansion highlights3 records

Broad incumbents

• Siemens: Siemens (Process Industries & Drives / Digital Industries) supplies SIMATIC PCS 7 and MindSphere-connected industrial automation to cement, mining and power customers. It is a broad incumbent that competes with KIMA on integrated plant automation and APC.
• Metso: Metso (Metso Outotec) supplies equipment, services and process optimization solutions to mining, aggregates and minerals processing. It overlaps with KIMA in grinding circuit optimization, SAG/ball mill process control and minerals industry digital solutions.
• Emerson Automation Solutions: Emerson (DeltaV, Ovation) provides process automation, control software and APC modules across power, mining and heavy industry. It competes with KIMA's SMARTCONTROL/MILLPILOT as part of broader plant automation suites sold to heavy industrial operators.
• Honeywell Process Solutions: Honeywell (Experion, Forge) provides DCS and APC software to power, cement and minerals operators. It competes with KIMA's APC/AI offerings as part of full-plant automation deployments, though it does not specialize in grinding fill-level sensing.
• ABB: ABB provides industrial automation, DCS/PLC systems and process control software across cement, mining and power generation. It competes with KIMA through its broader 800xA platform and embedded APC capabilities, but does not specialize in grinding fill-level sensing.

Direct peers

• VEGA Grieshaber: VEGA specializes in level and pressure measurement sensors for industrial processes including cement, mining and power. It competes with KIMA in fill-level and process measurement, particularly as a supplier of bulk-solids level instrumentation.
• Schenck Process: Schenck Process supplies weighing, feeding, screening and measurement solutions to cement, minerals and power industries. Its industrial measurement and process-optimization portfolio competes directly with KIMA's sensor and control offerings for grinding and bulk solids handling.
• KHD Humboldt Wedag: KHD is a long-established cement plant equipment and process technology supplier with a strong position in grinding and pyro-processing. Its overlap with KIMA in grinding circuit optimization and kiln process know-how makes it a closely comparable niche peer.
• FLSmidth: FLSmidth supplies equipment, digital/APC solutions and aftermarket services to the global cement and minerals industries. It directly overlaps with KIMA in cement grinding optimization, kiln process control, and plant digitalization, making it the most directly comparable peer.
• Endress+Hauser: Endress+Hauser is a leading supplier of industrial process measurement instrumentation (level, flow, temperature, pressure). Its level and analytical instrumentation products directly overlap with KIMA's SMARTFILL, GASTEMP and V-SENS sensor lines in cement and minerals.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks6 records

Key highlights7 records

Customer concentration

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Compliance1 record

Revenue estimate

Valuation estimate

Number of profiles

Profiles2 records

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about KIMA Process Control