Product development
Indian Cement Industry: Challenges Ahead
Published
15 years agoon
By
admin
Indian cement industry has made great strides during the last two decades. It has achieved place of pride in innovations especially in the use of alternate fuels, overall energy and fuel efficiency and control of particulate emissions to surpass the international environmental norms.A K Jain a ‘Bharat Gaurav’ recipient has played significant role in revision of IS 456 :2000 and formulation of various codes on cement, fly ash, ggbs and RMC.The installed capacity of cement in the country has grown at an average rate of 8.3 per cent CAGR during the period 1991 to 2011 while production increased at the rate of 8 per cent during the same period. The Table gives the installed capacity and production of cement between 1991-2011.Thermal EnergyThe thermal energy consumption has seen marginal improvement over the years. Against the world’s best ranges between 680-690 Kcal/kg clinker, India’s average stands at 730-742 Kcal/kg clinker (26 plants). Though some plants are able to match the best average, industry as a whole has challenges before it to further improve on this account.Electric Energy EfficiencyThe average consumption of electric energy (26 plants) was 77 Kwh/t cement. The electric consumption has virtually reached a plateau and shows very little improvement. The best operated plants have brought down the consumption in the range of 65-68 Kwh/t cement, however, industry as a whole has scope for further improvement.Environmental PerformanceThe National Ambient Air Quality Requirement as per CPCB for particulate matter (PM) or dust emission of more than 200 tpd, is 150 mg/Nm3 and 50 mg/Nm3 for new cement plants. The modern cement plants are able to adhere to these norms. The new generation plants with capacity 8000 tpd and above are even excelling the norms.Challenges Ahead: LimestoneLimestone will continue to be the life line of cement manufacture. For 350 million tonnes installed targeted capacity by the end of XI Plan (2012), nearly 600 million tonne of cement grade limestone will be needed annually. Keeping in view the rapid expansion, the NCB initiated the task of preparation of national inventory of cement grade limestone. The proven category reserves are only 22,476 million tonne which are likely to last for next 35 to 40 years at the present rate of production. Sizable reserves are located in inaccessible areas, difficult terrains reserved forests, bio-zones and coastal regulatory zones, etc. Apart from limited availability of measured reserve for greenfield projects, about 27 per cent of the total reserves are of marginal grade which can only be utilised with sweetener or after up-gradation through beneficiation. Availability of cement grade limestone will be becoming a major challenge for the cement industry in the future.CoalAvailability of coal is proving another bottleneck for the cement industry. The coal demand of cement industry by 2012-13 is estimated to touch 39.72 million tonne as against 13.47 million tonne in 2000-01. During the last decade, coal demand has gone up almost four times. The infrastructure deficiencies at ports are causing problems in importing coal and availability of indigenous coal to cement industry is not assured. The cost of coal is escalating every year and posing challenge before the cement industry. The situation is likely to aggravate in future.Blending Materials: Fly ashAlthough large quality of fly ash is generated in India, in many cases the location of thermal power plants is far away from cement plants and in the absence of proper infrastructure for transportation and handing of fly ash, most of it remains unutilised. About 175 million tonne of fly ash was generated during the 11th Five Year Plan period. The cost of fly ash is continuously increasing due to transportation and permission given to thermal power plants to charge for it instead of giving free. The mega thermal plants located in East UP, West Bengal, North Bihar and generally in Eastern part of India have very few cement plants in close vicinity. The availability of good quality fly ash at reasonable cost is also going to be major factor before the cement industry in coming years.ChallengesAt present, the cement industry is facing two fold problems of high input costs and infrastructural weakness. The costs of key inputs coal, power and transport by rail or road are spiraling year-on-year. The coal is of poor quality, with high ash and low calorific value content. There is need to introduce competition for improving quality, regularity in supply and reduced prices. The power from public utilities is of poor quality due to frequent power cuts and fluctuating voltage.Transport by rail or road is a cost-intensive component and amounts to almost 15-20 per cent of the delivered cost to the consumers. The railway tariff is high and need to be rationalised for an essential product like cement. Road transport on the other hand, provides limited alternative because of inadequacy of road network and rising cost of road transport due to continuously rising fuel cost. Inland water transport is eco-friendly and cheap mode especially for bulk commodities like cement. Coastal shipping and inland waterways will help in bringing down the transportation cost.To Increase Use Of CementCement is not the end-use product for the consumer. Concrete and mortar are the real end-products. Use of concrete at present is very low, about 0.5 tonne per head annually against World’s average of 1.0 tonne. Use of concrete and cement based products need to be promoted especially in the following sectors to increase the demand of cement.
- Concrete roads
- White topping over existing bitumen roads
- Cement-based bricks/blocks for walling in lieu of clay bricks
- Pre-fab components for mass housing in lieu of conventional systems for roofing, flooring, walling etc.
- Cement concrete lining to canals to reduce seepage losses.
- Development of inland water ways and linking of rivers
The average consumption of cement per head is very low in India, in the range of 180-190 kg while world average is about 400 kg and in developed countries it is 600-800 kg. Cement-concrete is more durable than other conventional materials and the use of concrete in construction will bring down the life cycle of civil works and will be more eco-friendly and sustainable.
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Economy & Market
Conveyor belts are a vital link in the supply chain
Published
8 months agoon
June 16, 2025By
admin
Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.
In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.
Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.
How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.
How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.
What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.
How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.
What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.
How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.
What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.
Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.
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Our strategy is to establish reliable local partnerships
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