Environment
Approximately 40 per cent of our MHE are supplied to the cement sector
Published
14 years agoon
By
admin
Says P K Madappa, Managing Director, Macmet India Ltd, in a candid interview with Indian Cement Review. Read on, to know about the future plans, strategies and various services offered by Macmet India.Please tell us the genesis of Macmet India.Macmet India Ltd was started in 1974 as an agency house, representing foreign companies in India. In the early 1980s the company set up a workshop to manufacture components for material handling systems. From mid-1980s the company started manufacturing bulk material handling systems for cement, steel and mining industries. Today, Macmet is one of the leading supplier of bulk material handling systems.Please describe in detail about the material handling products you offer for the cement industry? We provides reliable, material handling solutions such as overland conveyors, pipe conveyors and curved belt conveyors to cement plants, power plants, steel plants, mines and ports. The design, the selection of material and manufacturing methods ensure reliable installations that have minimum down time and provide lowest ‘cost of ownership’.Macmet is the first company in India to indigenously design, supply, erect, test and commission a long distance overland conveyor with curves for the Kymore Works of ACC Ltd to transport limestone from the mines to the plant. The total route length of the conveyor is 10.6 km. Such long conveyors normally follow the contour of the terrain which often involves curves in both horizontal and vertical planes. Availability of high strength steel cord belting and sophisticated dynamic model analysis for assessing the behaviour of the conveyor along the curves have encouraged customers to opt for long distance conveyors.We are also the leading supplier of pipe conveyors in India. Our company was the first to supply an indigenously designed pipe conveyor for ACC Limited. Macmet has also supplied India’s longest (2.4 km) EP belting pipe conveyor for ACC Ltd’s Chaibasa Unit. India has recently commissioned the world’s second longest pipe conveyor (7 km) carrying 1,500 tonne of coal per hour from mines to O P Jindal Super Thermal Power Plant. Macmet manufactures belt trippers, either fixed or travelling type with one/two/three way chutes, used for intermittent side discharge of material from the belt conveyor. Macmet also supplies travelling hoppers used for transfer of material associated with short period, intermediate storage.Please tell us about the various milestones achieved by material handling division? We have supplied the maximum number of pipe conveyors in India. We are the only Indian company that has sold pipe conveyors internationally. Macmet has the distinction of building the world’s second longest pipe conveyor (7 km). The company is presently executing more than 15 km of pipe conveyor projects. Macmet is also executing a 21 km cross country belt conveyor system, the longest such system in India.Please tell us about the awards and certificates received by the material handling division?We have been the recipient of Certificate of Excellence from the Engineering Export Promotion Council, Eastern Region, for the past 8 years.Who are your domestic buyers and what is your share in domestic market and export? Ambuja Cements, ACC Limited, TISCO, Jindal Steel & Power, Hindalco are some of our esteemed customers.What are the latest material handling technologies manufactured by you that controls environment pollutions?The pipe conveyor is one of the most innovative solutions for control of environment pollution when transporting bulk raw material. Pipe conveyors are an environmental-friendly solution for conveying bulk material with zero spillage and ability to cover terrain, difficult to negotiate by conventional conveyors.What all strategies has the company adopted to increase its market shares in the cement industry?Macmet believes in delivering systems that are engineered efficiently. We lay stress on timely deliveries. We design systems that help reduce power consumption and increase working life of our systems.What is the share of cement industry’s in your total material handling equipment business?Approximately 40 per cent of our bulk material systems (MHE) are supplied to the cement sector.Please tell us about technical collaboration, if anyMacmet has been working closely with Bridgestone TPE and other noted experts in the field of material handling.Please describe in detail about your R&D department? We have an engineering department where a lot of time is devoted to providing efficient engineering solutions to the client. This includes reduction in the quantities of steel in manufacturing the system, reducing power consumption of the conveyor systems and increasing the efficiency of the system to reduce down time and costs. These benefits are incorporated into our projects.What are the new material handling products that you are going to introduce for the cement industry?We have a tie-up with Taim Weser for the manufacture and supply of stackers, reclaimers, ship loaders and unloaders. We plan to introduce these products in the near future. Further, we are looking to complement our material handling systems with other equipment that go with bulk material handling.What growth do you foresee in the next five years for the cement material handling equipment? Which would be the growth drivers? Bulk material handling business is expected to more than double in the next 5 years. With an expected increase in cement capacity, there will be requirement for material handling systems. With mines located at a distance from cement plants, long distance cross country conveyors will become more popular. Old cement plants are being revamped and their capacity augmented. This also results in increase in demand for material handling systems.What is your turnover? What was the growth in the last five years? Macmet has targeted a turnover of Rs 200 crores in 2012. This is more than double its turnover in 2009.What are your future plans for the material handling division? Macmet will continue to develop innovative solutions to help customers move bulk material faster and cheaper. We will introduce Taim Weser’s range of products such as stackers, reclaimers, ship loaders and unloaders. Further, other systems that complement our conveyor system at the loading and unloading end will be introduced in the latter half of 2011.In the next five years, 200 million tonnes will be added to the cement capacity? Is the material handling industry geared-up to the demand?Yes, Macmet is geared up to meet the increasing demand for higher capacity, more efficient material handling systems.Who are your major competitors – Domestic and International? Locally, FLS Minerals, ThyssenKrupp Industries India, Elecon are our competitors. Internationally, Koch (now FLS Minerals), ThyssenKrupp AG and various local manufacturers are our competition.It requires skilled manpower to operate the material handling equipment, so while delivering the equipment, do you train your client’s operator or provide skilled operator to the client? After commissioning our system we generally remain at site for 2-3 months to fine tune the system and train customer’s personnel. We provide a ‘hand holding’ period for the customer to feel comfortable while operating the system. We always insist on customers deputing some skilled manpower during the commissioning phase so as to get the customer acquainted with the technology, system and any problems that may arise during operation.How do you rate your conveying systems in comparison to other domestic supplier and imported? Macmet’s conveyor systems are at par with the best available in the country. We have completed many unique projects that are running successfully. Repeat orders are our best indication of customer satisfaction.What is the latest development in MHE technology with regard to environment and pollution control?The pipe conveyor is one of the important technologies that have emerged in the last few years for controlling pollution when transporting bulk material. Technology for dust extraction and dust suppression has also improved. Covered storage of raw material helps control pollution.
Concrete
India donates 225t of cement for Myanmar earthquake relief
Published
2 weeks agoon
June 17, 2025By
admin
On 23 May 2025, the Indian Navy ship UMS Myitkyina arrived at Thilawa (MITT) port carrying 225 tonnes of cement provided by the Indian government to aid post-earthquake rebuilding efforts in Myanmar. As reported by the Global Light of Myanmar, a formal handover of 4500 50kg cement bags took place that afternoon. The Yangon Region authorities managed the loading of the cement onto trucks for distribution to the earthquake-affected zones.
Concrete
Reclamation of Used Oil for a Greener Future
Published
2 weeks agoon
June 16, 2025By
admin
In this insightful article, KB Mathur, Founder and Director, Global Technical Services, explores how reclaiming used lubricants through advanced filtration and on-site testing can drive cost savings, enhance productivity, and support a greener industrial future. Read on to discover how oil regeneration is revolutionising sustainability in cement and core industries.
The core principle of the circular economy is to redefine the life cycle of materials and products. Unlike traditional linear models where waste from industrial production is dumped/discarded into the environment causing immense harm to the environment;the circular model seeks to keep materials literally in continuous circulation. This is achievedthrough processes cycle of reduction, regeneration, validating (testing) and reuse. Product once
validated as fit, this model ensures that products and materials are reintroduced into the production system, minimising waste. The result? Cleaner and greener manufacturing that fosters a more sustainable planet for future generations.
The current landscape of lubricants
Modern lubricants, typically derived from refined hydrocarbons, made from highly refined petroleum base stocks from crude oil. These play a critical role in maintaining the performance of machinery by reducing friction, enabling smooth operation, preventing damage and wear. However, most of these lubricants; derived from finite petroleum resources pose an environmental challenge once used and disposed of. As industries become increasingly conscious of their environmental impact, the paramount importance or focus is shifting towards reducing the carbon footprint and maximising the lifespan of lubricants; not just for environmental reasons but also to optimise operational costs.
During operations, lubricants often lose their efficacy and performance due to contamination and depletion of additives. When these oils reach their rejection limits (as they will now offer poor or bad lubrication) determined through laboratory testing, they are typically discarded contributing to environmental contamination and pollution.
But here lies an opportunity: Used lubricants can be regenerated and recharged, restoring them to their original performance level. This not only mitigates environmental pollution but also supports a circular economy by reducing waste and conserving resources.
Circular economy in lubricants
In the world of industrial machinery, lubricating oils while essential; are often misunderstood in terms of their life cycle. When oils are used in machinery, they don’t simply ‘DIE’. Instead, they become contaminated with moisture (water) and solid contaminants like dust, dirt, and wear debris. These contaminants degrade the oil’s effectiveness but do not render it completely unusable. Used lubricants can be regenerated via advanced filtration processes/systems and recharged with the use of performance enhancing additives hence restoring them. These oils are brought back to ‘As-New’ levels. This new fresher lubricating oil is formulated to carry out its specific job providing heightened lubrication and reliable performance of the assets with a view of improved machine condition. Hence, contributing to not just cost savings but leading to magnified productivity, and diminished environmental stress.
Save oil, save environment
At Global Technical Services (GTS), we specialise in the regeneration of hydraulic oils and gear oils used in plant operations. While we don’t recommend the regeneration of engine oils due to the complexity of contaminants and additives, our process ensures the continued utility of oils in other applications, offering both cost-saving and environmental benefits.
Regeneration process
Our regeneration plant employs state-of-the-art advanced contamination removal systems including fine and depth filters designed to remove dirt, wear particles, sludge, varnish, and water. Once contaminants are removed, the oil undergoes comprehensive testing to assess its physico-chemical properties and contamination levels. The test results indicate the status of the regenerated oil as compared to the fresh oil.
Depending upon the status the oil is further supplemented with high performance additives to bring it back to the desired specifications, under the guidance of an experienced lubrication technologist.
Contamination Removal ? Testing ? Additive Addition
(to be determined after testing in oil test laboratory)
The steps involved in this process are as follows:
1. Contamination removal: Using advanced filtration techniques to remove contaminants.
2. Testing: Assessing the oil’s properties to determine if it meets the required performance standards.
3. Additive addition: Based on testing results, performance-enhancing additives are added to restore the oil’s original characteristics.
On-site oil testing laboratories
The used oil from the machine passes through 5th generation fine filtration to be reclaimed as ‘New Oil’ and fit to use as per stringent industry standards.
To effectively implement circular economy principles in oil reclamation from used oil, establishing an on-site oil testing laboratory is crucial at any large plants or sites. Scientific testing methods ensure that regenerated oil meets the specifications required for optimal machine performance, making it suitable for reuse as ‘New Oil’ (within specified tolerances). Hence, it can be reused safely by reintroducing it in the machines.
The key parameters to be tested for regenerated hydraulic, gear and transmission oils (except Engine oils) include both physical and chemical characteristics of the lubricant:
- Kinematic Viscosity
- Flash Point
- Total Acid Number
- Moisture / Water Content
- Oil Cleanliness
- Elemental Analysis (Particulates, Additives and Contaminants)
- Insoluble
The presence of an on-site laboratory is essential for making quick decisions; ensuring that test reports are available within 36 to 48 hours and this prevents potential mechanical issues/ failures from arising due to poor lubrication. This symbiotic and cyclic process helps not only reduce waste and conserve oil, but also contributes in achieving cost savings and playing a big role in green economy.
Conclusion
The future of industrial operations depends on sustainability, and reclaiming used lubricating oils plays a critical role in this transformation. Through 5th Generation Filtration processes, lubricants can be regenerated and restored to their original levels, contributing to both environmental preservation and economic efficiency.
What would happen if we didn’t recycle our lubricants? Let’s review the quadruple impacts as mentioned below:
1. Oil Conservation and Environmental Impact: Used lubricating oils after usage are normally burnt or sold to a vendor which can be misused leading to pollution. Regenerating oils rather than discarding prevents unnecessary waste and reduces the environmental footprint of the industry. It helps save invaluable resources, aligning with the principles of sustainability and the circular economy. All lubricating oils (except engine oils) can be regenerated and brought to the level of ‘As New Oils’.
2. Cost Reduction Impact: By extending the life of lubricants, industries can significantly cut down on operating costs associated with frequent oil changes, leading to considerable savings over time. Lubricating oils are expensive and saving of lubricants by the process of regeneration will overall be a game changer and highly economical to the core industries.
3. Timely Decisions Impact: Having an oil testing laboratory at site is of prime importance for getting test reports within 36 to 48 hours enabling quick decisions in critical matters that may
lead to complete shutdown of the invaluable asset/equipment.
4. Green Economy Impact: Oil Regeneration is a fundamental part of the green economy. Supporting industries in their efforts to reduce waste, conserve resources, and minimise pollution is ‘The Need of Our Times’.
About the author:
KB Mathur, Founder & Director, Global Technical Services, is a seasoned mechanical engineer with 56 years of experience in India’s oil industry and industrial reliability. He pioneered ‘Total Lubrication Management’ and has been serving the mining and cement sectors since 1999.

The Indian cement industry has reached a critical juncture in its sustainability journey. In a landmark move, the Ministry of Environment, Forest and Climate Change has, for the first time, announced greenhouse gas (GHG) emission intensity reduction targets for 282 entities, including 186 cement plants, under the Carbon Credit Trading Scheme, 2023. These targets, to be enforced starting FY2025-26, are aligned with India’s overarching ambition of achieving net zero emissions by 2070.
Cement manufacturing is intrinsically carbon-intensive, contributing to around 7 per cent of global GHG emissions, or approximately 3.8 billion tonnes annually. In India, the sector is responsible for 6 per cent of total emissions, underscoring its critical role in national climate mitigation strategies. This regulatory push, though long overdue, marks a significant shift towards accountability and structured decarbonisation.
However, the path to a greener cement sector is fraught with challenges—economic viability, regulatory ambiguity, and technical limitations continue to hinder the widespread adoption of sustainable alternatives. A major gap lies in the lack of a clear, India-specific definition for ‘green cement’, which is essential to establish standards and drive industry-wide transformation.
Despite these hurdles, the industry holds immense potential to emerge as a climate champion. Studies estimate that through targeted decarbonisation strategies—ranging from clinker substitution and alternative fuels to carbon capture and innovative product development—the sector could reduce emissions by 400 to 500 million metric tonnes by 2030.
Collaborations between key stakeholders and industry-wide awareness initiatives (such as Earth Day) are already fostering momentum. The responsibility now lies with producers, regulators and technology providers to fast-track innovation and investment.
The time to act is now. A sustainable cement industry is not only possible—it is imperative.

Hindalco Buys US Speciality Alumina Firm for $125 Million

Star Cement launches ‘Star Smart Building Solutions’

Nuvoco Vistas reports record quarterly EBITDA

UltraTech Cement increases capacity by 1.4Mt/yr

Shree Cement reports 2025 financial year results

Hindalco Buys US Speciality Alumina Firm for $125 Million

Star Cement launches ‘Star Smart Building Solutions’

Nuvoco Vistas reports record quarterly EBITDA

UltraTech Cement increases capacity by 1.4Mt/yr
