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“The challenge is to move cement from the warehouse to the consumer?s site”

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Rohit Vohra Head Logistics, Reliance Cement

The total cost of logistics considering inbound and outbound movement can come up to 20 to 25 per cent of cement production cost. This is for companies having good infrastructure such as rail sidings, etc., and who transport 40 to 60 per cent product by rail. For companies that do not have such facilities, the cost can go as high as 30 per cent of the cement cost. Rohit Vohra highlights the challenges faced by cement companies in last mile deliveries. Excerpt from the interview.

How much is the cost contribution of logistical expenses to cement cost?
The cost of transporting cement via road comes to about Rs 1 to 3 /tonne/km. The wide range is due to the variation in lead distance, which can range from anywhere between 50-300 km. Longer the distance, lower is the cost of transport. Railway on other hand costs Rs 1.3 to 1.4/tonne/km. However, railway has additional fixed costs related to loading and unloading.

The handling cost is high for railways. So for a distance below 200 km rail is not viable. We generally outsource the unloading process to the C&F agents.

What are the losses experienced in cement transport via rail wagons?
Railways charge a fixed fare based on the number of wagons employed. If the wagon is not loaded completely, the company will still end-up paying for the entire wagon. One area where cement is lost is due to spillage from torn or damaged bags. Many a times the floor of the wagon is in bad constitution and may have sharp edges that damage the cement bags during transit. To minimise such loss we are using specialised packing material for our cement bags. These bags are not lifted using metal hooks. Instead the workers put a sort of wire loop around it and pick it up. Although the cost of loading and unloading too gets escalated with this, the end customer gets quality cement in quality packing.

What are the challenges faced by cement companies in last mile delivery?
The challenge in last mile delivery is that today we have lesser number of stockists. Now nobody wants to stock cement in warehouses. The rental charges of warehouses are too high for stocking a low margin product like cement. So dealers prefer ordering the material straight from the plant to the consumer site.

Now consumers require quick delivery, and on several occasions the delivery is to be made in congested city areas. These locations often have limitations on the size of trucks that could ply on the roads. Hence, we have to use smaller vehicles, which are cost inefficient. Companies then have to set up a very good network of warehouses close to the market so as to be able to reach the customer as quickly as possible. But again, setting up a warehouse means additional loading and unloading at the company?s expense. The moment you create an additional node in your supply chain, the cost of handling and distribution goes up. Plus, dispatch from these warehouses is also costly since transporters are moving material over short distances. So the cost of transport per tonne per km is high.

What are the constraints that you have to deal with in cement transport?
We put cement delivery process in two buckets. One is from plant to the warehouse and the other is where we transport cement from warehouse to the site. When we are moving cement from the plant to the warehouse we have the loading and unloading process and the associated cost in our control. The material is transported in multi-axle carriers with a capacity of around 27 tonnes. Mostly the approach road to the warehouse is good and the time required to load and unload is fixed and short. So here the costs are very much in the company?s control.

The challenge is to move cement from the warehouse to the consumer?s site. Many cities have restrictions on the size of trucks that can move round the clock. Cities like Nagpur, Bhopal, etc., do not allow trucks with more than 8-tonne capacity to ply on the roads. While at some places like Rajasthan, where highways are good we transport cement in 60-tonne trailers. Often the size of order placed by end consumers is small and we have to dispatch 4-5 tonnes of material.

Today the customers to want delivery of cement as and when required. They usually do not have space to store cement and other construction materials. Storing cement is a hassle and implies additional cost. Simply handling a cement bag costs Rs 2-3 and so everyone tries to avoid it. The traders to want the cement to be delivered directly from company warehouse to the site, not to the shop.

What can be done to cut down that cost?
We have a system where dealers can order at ex-warehouse price and can arrange for their own vehicle. That creates a synergy since the dealer can ship other items such as steel, paint, bricks, etc., in the same truck.

How about outsourcing this function?
We have been considering outsourcing this function. However, service providers do not find cement transport as profitable as they would find transporting high value retail products like electronic goods, etc. In cement the margins are low, and so it is less attractive to external logistics service providers.

Railways have plenty of surplus land, however they do not have clear policy for land allotment. Most major companies have their own cement siding. What the industry needs is rail side warehouses. We are looking for opportunities to set up terminals close to siding. Having a rail side warehouse minimises cost of product handling.

How to you manage the fluctuations in cement demand?
There are basically two types of fluctuations, the seasonal and the demand driven. Seasonal changes are seen in the trade segment while demand driven fluctuations are seen in non-trade segment. We have kept a balance of having trade to non-trade segment in 70:30 ratio. That stabilises the demand pattern.

The industry generally experiences good demand during the October-June period. This is the time when the company builds up reserve stock of cement at the plant. The industry experiences low demand during the July-August period. During this period we conduct operation and maintenance tasks at the plant.

Major fluctuations are taken care by the surplus stocks at the plant while minor fluctuations are dealt with at the warehouse level.

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Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

Dalmia Bharat Acquires Jaiprakash Associates Cement Assets for ₹2,850 Crore

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Dalmia Cement executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra, to acquire 5.2 MnTPA of cement capacity across Madhya Pradesh and Uttar Pradesh.

Dalmia Cement (Bharat) announced on May 22, 2026 that it had signed a Business Transfer Agreement with Jaiprakash Associates Limited and Adani Infra (India) Limited for the acquisition of cement plants located at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh. The deal was struck at an enterprise value of ₹2,850 crore and is expected to close within two weeks of execution.

The acquired assets from Jaiprakash Associates include 5.2 MnTPA of cement capacity and 3.3 MnTPA of clinker capacity. The package also covers 99 MW of thermal power capacity and railway sidings at Rewa, Chunar, and a common siding at Churk. This infrastructure gives the acquisition immediate operational utility beyond just production tonnage.

The transaction has a long backstory. Dalmia Cement had originally entered into a framework agreement with Jaiprakash Associates in December 2022, covering the sale of these business assets along with a long-term clinker supply arrangement. However, before the deal could be completed, Jaiprakash Associates was admitted to insolvency proceedings under the Insolvency and Bankruptcy Code. The earlier agreements could not be consummated as a result.

In an official statement, Puneet Dalmia, Managing Director & CEO, Dalmia Bharat, said, “I am very excited about addition of these assets in our portfolio. This serves as a great strategic fit for Dalmia. It helps us move forward in our journey to be a pan India player and provide a strong head start to serve the high potential markets in Central region. I am optimistic that the expansion potential of these assets along with close proximity with Dalmia’s captive mines will help us create a capacity hub for the future”.

Following the approval of Adani Group’s resolution plan for Jaiprakash Associates under the IBC framework, Dalmia approached the new management to revive discussions. The fresh Business Transfer Agreement was executed to settle all pending disputes, legal proceedings, and arbitration matters arising from the original framework agreement with Jaiprakash Associates.

Expanding market reach

Dalmia added, “Our familiarity with these assets under the earlier tolling arrangement gives us a deep understanding of the facilities and helps us establish strong connect with channel partners and vendors. We believe that this will help us in faster ramp up of capacities and quicker inroads into the market. As we look forward, I am very confident that we will be able to leverage the strengths of Dalmia to operate these assets in a manner where we can maximise value creation for all our stakeholders.”

With the addition of these plants, Dalmia Bharat’s total installed cement capacity will rise to 54.7 MnTPA upon consummation. The company has further expansion projects underway at Belgaum, Pune, and Kadapa, which are expected to take overall capacity to 66.7 MnTPA by Q2 to Q3 FY28.

The Central India location of the Jaiprakash Associates plants gives Dalmia Bharat faster access to markets in Madhya Pradesh and Uttar Pradesh than a greenfield build would have allowed. The company also cited debottlenecking and brownfield expansion as near-term opportunities at the acquired sites. Dalmia Bharat said the assets were expected to contribute positively to EBITDA and overall returns, given the pricing environment in the region and the company’s cost structure.

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