Ighnatios Maatouk

Senior Industrial Performance and Digital Transformation Leader with 19+ years of experience in cement manufacturing, energy systems, and advanced process optimization. PMP-certified with deep expertise in Advanced Process Control (APC), industrial AI, and large-scale operational excellence programs. Proven track record of delivering measurable business impact across multi-site and international environments, including double-digit OPEX reduction, production throughput improvement, energy efficiency gains, and CO₂ intensity reduction.

Experienced in transitioning from plant and regional performance leadership to corporate and enterprise digital roles, supporting executive teams in governance, standardization, and sustainable value creation.

TIS Expert at AMRIZE (2026-01 – Present)

Corporate owner and subject matter expert for Technical Information Systems (TIS) supporting cement and industrial operations.

• Accountable for system governance, data integrity, and cross-system integration (production, laboratory/LIMS, and enterprise platforms).
• Acts as corporate interface between operations, IT, and vendors to standardize performance reporting, improve data reliability, and enable executive decision-making.
• Contributes to group-level digital performance strategy aligned with operational excellence, reliability, and business objectives.

Senior Consultant at YASH TECHNOLOGIES (2025-07 – 2025-12)

Supported selected industrial clients in the deployment and integration of digital performance systems and operational data solutions.

• Advised on system architecture, performance governance, and integration between production, laboratory, and enterprise systems.
• Leveraged 15+ years of cement and process expertise to bridge operations, digital platforms, and management requirements.

Senior Project Manager at ES PROCESSING (2020-10 – 2025-03)

Led the AI-APC projects (Artificial Intelligence & Advanced Process Control) for the cement industry, optimizing plant operations through machine learning and predictive analytics. Directed high-impact performance optimization programs across multi-site international cement operations.

• Dangote Group (Senegal, Cameroon, Ethiopia) – €2.2M+ APC portfolio delivering +7–10% throughput increase and up to $9M annual profit per site
• Saman Cement (Iraq) – €450k CMO projects generating ~$4M annual profit
• Ciment de Sibline (SECIL Group) – Kiln AI Autopilot improving production and reducing specific energy consumption
• Accountable for production uplift (up to +20%), energy efficiency improvement, and CO₂ reduction across multiple sites.
• Senior technical interface with plant management and executive stakeholders; contributor to technical-commercial activities and negotiations.

Process & Environment Manager at HOLCIM (2013-05 – 2020-10)

Directed the process performance optimization of 2 cement plants and major initiatives.

• Directed major initiatives including Kiln Master, Mill Master, FAME (+8% clinker production), Energy Reference Value (-8 kWh/tcem, -100 MJ/tcli), and SO₂ reduction projects.
• Led major CAPEX industrial projects reducing OPEX and energy consumption while improving plant throughput including Hot Gas Generator Project (+30% throughput in wet seasons), Kiln Hot Gases Project (-80% fuel consumption for drying materials)
• Led regional performance audits including Process Efficiency Audit (2019) at Lafarge Bazian (Iraq) and Energy Process Audit (2018) at Lafarge Sokhna (Egypt)
• Steered the CRO Technical Training (2016 – 2018) at Holcim Chekka (Lebanon) to train and certify the control room operators

Safety & Environment Officer at HOLCIM (2010-01 – 2013-05)

Implemented and managed comprehensive safety and environmental management systems in full compliance with OHSAS 18001 and ISO 14001, reducing incidents and environmental impact.

• Led a hazard identification and risk mitigation project developing a proactive safety culture and enhancing employee training programs
• Designed and enforced an environmental monitoring plan reducing dust emissions and improving air quality around the cement plant
• Conducted emergency response drills and crisis management simulations preparing teams for potential industrial accidents
• Developed and executed an industrial waste management strategy optimizing resource utilization and reducing landfill dependency

Production Engineer at FOLDA (2008-04 – 2010-01)

Managed process improvement and lean manufacturing initiatives for steel accessories production.

• Managed a process improvement project for steel accessories production, reducing manufacturing defects by 12% through advanced quality control techniques
• Implemented a lean manufacturing initiative, eliminating production bottlenecks and reducing cycle times by 15%
• Coordinated the procurement and installation of new production equipment, enhancing operational capacity and reducing downtime
• Led a cost reduction program, identifying inefficiencies in raw material consumption and optimizing resource allocation
• Contributed in the ISO 9001 quality management system implementation, internal audit and re-certification process

Power Engineer - Site Engineer at Joseph Tehini & fils. (2005-10 – 2008-04)

Oversaw the execution of a $10M power plant project, including the installation and commissioning of an 18,900 kW MAN B&W Genset.

• Led electrical and mechanical system optimization efforts, improving plant reliability and reducing maintenance costs
• Coordinated on-site construction and engineering teams, ensuring compliance with technical specifications and safety regulations
• Conducted performance testing and commissioning of power generation systems, ensuring optimal efficiency and output
• Supervised preventive and corrective maintenance programs, extending equipment lifespan and reducing unplanned outages

Executive Master in Business Administration in EMBA – University of Balamand (2026-08)

Master in Mechanical Engineering – Lebanese University (2000-10 – 2005-07)