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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, leveraging this technology to drive innovation as part of their "Plants of Tomorrow" initiative—a bold effort to integrate Industry 4.0 solutions across their facilities. This partnership with Flyability began in 2016 at Holcim Eclepens, where they tested early prototypes. Fast forward to 2024, and Holcim now operates a global fleet of 42 Elios drones, supported by over 100 trained pilots spread across the world. This collaboration not only enhances Holcim’s leadership in innovation, efficiency, and safety but also aligns with Flyability’s mission to send drones into hazardous environments instead of humans, keeping people safe.
In the cement industry, Holcim has seen significant advantages from using Elios 3 drones. These drones provide safer access to hard-to-reach areas like clinkers and silos, while capturing both visual and LiDAR data. Their ability to operate effectively in dusty conditions makes them ideal for industrial settings. By using drones, Holcim reduces risks to workers, gathers accurate and timely data, and improves asset management—making it a faster, safer, and more cost-effective solution. This is why Holcim continues to trust and expand its use of Elios drones.
In June 2024, Flyability and Holcim hosted the third edition of Holcim Drone Days, marking the second event in North America. Pilots from 9 different sites across the region joined the event at the Midlothian Plant in Texas, along with Flyability’s team. Building on the success of the 2023 event in Lausanne, this session featured expert talks, custom training, and opportunities for pilots to exchange experiences and inspire each other to explore new drone applications.
During the event, Flyability shared insights into future developments for the Elios drones, including how to move beyond basic inspections toward more integrated reporting and communication tools. James Comeau from Glencore Kidd Operations also spoke about how his company evolved from early adopters in mining to having full-time pilots with established drone use cases.
Holcim pilots presented their own experiences, offering valuable perspectives on what’s possible with the drones and how new applications can be safely implemented. The diversity of experience among attendees made it a great opportunity for learning and growth, helping to strengthen the overall drone program.
The training sessions were tailored to Holcim’s specific needs, especially given the challenging environments found in cement plants. Pilots practiced flying in dusty and confined spaces, learning best practices for visibility and navigation. They also explored how to handle unexpected situations and even tested the Elios 3’s Return-to-Signal feature, pushing the drones to their limits in a safe environment.
Additionally, pilots had the chance to test new payloads, such as ultrasonic thickness measurement and surveying tools, which expand the drone’s capabilities beyond simple visual inspections. Discussions on data processing and digitalization helped improve their skills and autonomy in conducting inspections and surveys.
The event also highlighted the growing interest in Scan to BIM, an area that could further support Holcim’s “Plants of Tomorrow†initiative. Through these hands-on experiences, pilots gained deeper insight into how drones can be used for more advanced applications.
The North American Drone Days showcased the collaborative spirit and innovation within Holcim’s pilot teams. Led by David Hull, the U.S. drone program is already focused on continuous improvement. Pilots meet regularly to discuss their work, but the event provided a rare opportunity to connect in person and learn from one another.
A video captured during the event highlights the energy and enthusiasm of the participants, showcasing real-world applications of drone technology in industrial settings.
The event was not just about training—it was about building relationships. Experienced pilots shared knowledge with newcomers, while veterans got a glimpse of what’s coming next from Flyability. The roundtable discussions allowed both companies to exchange ideas and explore ways to better support each other moving forward.
Back in Switzerland, Holcim’s team praised the event, thanking David Hull and Aaron Toles for their coordination efforts. The plant manager in Texas also played a key role in making the event possible by providing the necessary space for training and collaboration.
This first Drone Days event of 2024 was a huge success, and both Flyability and Holcim are excited to plan more events in the future. Together, they are committed to developing a cutting-edge drone program that positions Holcim as a leader in innovation and a pioneer in the use of drone technology for safer, smarter inspections.
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