ENERGY STAR Plant Profile

Theodore Cement Plant
3051 Hamilton Blvd.
Theodore, AL 36582
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The Holcim (US) plant in Theodore, AL was originally commissioned in 1981. It replaced a wet process plant in Mobile that had operated since 1947.

The manufacturing facility consists of one single kiln with an indirect firing system and two preheater strings with a single swirl calciner and mixing chamber. There are two finish mill circuits. Nearly all raw materials arrive at this plant site by water. The dock at the plant is 2,350 feet in length. There are two gantry cranes on the dock that service the full length of the unloading dock. The rated annual capacity is 1.5 million tons of Portland cement.

Virtually the entire manufacturing process is controlled from one centralized control room. A computerized system provides the production supervisor data graphics displays and data entry capabilities.

The Theodore plant received the Portland Cement Association (PCA) Environmental Community Outreach Award for 2006, honoring activities that enhance community, employee, and government relations.  

The plant has received other major national environmental awards, including:

?         PCA Energy & Environmental Award in the category of "Environmental   
 Performance" in 2008 and 2005.

?         Environmental Pratection Agency (EPA) Gulf Guardian Award in 2007.

The Theodore plant was first awarded the ENERGY STAR for plants in 2008. Several programs were initiated in conjunction with an Electrical Energy Assessment. The program has resulted in a savings of 63,920 mMBTu in 2008.