ABB’s Expert Optimizer was first installed at Votorantim Cimentos’s Itau de Minas (Fig. 1) and Salto de Pirapora plants (Fig. 2) in 1995. Ageing hardware needed to be replaced (Fig. 3) and at the same time the opportunity to upgrade the optimization solution was taken. The challenges were to upgrade to the latest version without losing any of the existing plant specific features, and to bring the alternative fuels used in the plants into the strategy and therefore to bring them under better control. The upgrades were completed in 2009.