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Finding Funds for Growth

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What are the different ways cement companies can find funds – for various aspects of running a cement manufacturing organisation? Whether it is working capital, capex or hybrid consisting of debt or equity – what are the best options? K C Birla expostulates on the various modes and explains that companies should have systematic approach of risk management relating to leveraging and debt servicing.

The demand for cement in India over the past several years has grown in tandem with domestic economic growth, making the country the second largest consumer of cement in the world, after China. In the last decade, cement demand has grown consistently at a multiple of ~ 1 – 1.2 times of domestic GDP growth underpinned by the rising demand for housing and infrastructure.

As of March, 2011, India’s cement market was the second largest in the world with a capacity of 300 million mtpa from over 165 plants owned by 52 producers. Top 6 players control more than 60 per cent of the market share. Another 100 million mtpa is expected to be added by FY15.

Indian Cement Sector Outlook:

Aggressive capacity addition resulting in overcapacity, rising raw material and energy costs is adversely affecting the profitability of cement producers. However low per capita cement consumption at 173 kgs as against the world average of 425 kgs, expected government spending on infrastructure (XIIth Five Year plan expected spending: USD 1 Trillion), demand for mass housing reflects potential for future growth. The current overcapacity in the industry seems temporary.

Financing Requirement:

The industry requires financing for its working capital and capital expenditure requirement. Working capital cycle starts right from the time of material procurement, production and sale of finished goods till the realisation of sales proceeds. The primary requirement is in building up raw materials, additives, fuels, stores & spares, clinker and finished goods inventory. Debtors are generally in non-trade segment of business. The sector incurs capital expenditure for its regular capex requirement, expansion of existing capacities and setting up of new capacities.

The development of industry post decontrol was dependant on fiscal incentives, financing from international institutions (IBRD etc.) and local developmental financial institutions. With the passage, just as the industry has evolved, the Development Financial Institutions too have become banks.

During the early stages, capacity addition was dependent on promoters and leveraging capabilities. The Debt Equity ratio of sector used to be 2 to 2.5 times of debt to equity. The sector profitability was weak so promoters / companies used to survive on fiscal incentives provided by the government. The construction activities were weak and companies were not having the financial motivation to expand. Thus, despite being one of the oldest industry, no company could acquire / add sizeable capacities to reckon with.

With the opening up of the economy in 2001, together with a flourish in information technology, communication and entertainment (ICE) sectors, the demand for cement saw a sustainable growth of 8 per cent. The sector profitability improved which was ploughed back in further capacity addition.

The financing needs of sector are broadly categorized into Working Capital, Capex and General Corporate purposes.

Working Capital Financing:

  • Fund Based – To meet core and other working capital requirements.
  • Non Fund Based – Letters of credit to be given to suppliers of raw material, fuel, spares, capital expenditure payments etc.; Bank Guarantees to be given to Railways, coal suppliers and performance guarantees, etc.

Working Capital: Working capital needs are met through traditional Banking channels.

Companies opt for working capital arrangements through i) Consortium Banking arrangement or ii) Multiple Banking arrangement. The common modes of financing working capital are Cash Credit, WCDL, Export Packing Credit, etc. However the following two products also help companies in managing working capital.

Buyers Credit & Suppliers Credit:

Apart from use of Cash Credit, WCDL & Packing Credit, companies also use Buyers Credit & Supplier’s credit facilities provided by various Banks. Under the Buyers Credit facility, Banks pay to the company’s import vendors and company pays to the Bank on a pre-determined date with interest. Similarly companies also use supplier’s credit facility.

Channel Financing:

To reduce debtors in their books, companies use "Channel Financing" for its large dealers. Bankers do their own "Due Diligence" and provide credit facilities to dealers which are exclusively used for payment or clearing dues of the company. The onus on the company is the continuity of dealership. If there is disruption, companies are required to inform the Banks.

Financing of Capital Expenditure or General Corporate Purpose (Long Term Financing): Companies need Long Term financing usually for expansion, setting up of new capacities, setting up of Captive power capacities, acquisition of other companies. etc. Long Term financing usually takes the form of Equity, Debt, Hybrid (Mix of Debt & Equity).

Equity: It is a permanent form of money which is mobilised by the promoters and through public participation. Raising money through equity depends on the capital structure of the company. In case of an established company promoters can invite Private Equity (PE) funds to fund the company’s growth plans. Besides companies can also look forward to issuing ADRs/GDRs in foreign capital markets.
Debt: Companies access the Debt market through Banks and other FIs. Depending on the financial strength, companies evaluate the various debt raising options. Debt raising can be done in i) Foreign Currency and ii) Rupee and can be further segregated into Secured and Unsecured borrowings depending on whether any collateral has been provided to the Banks/FIs for securing their exposure.

Common Modes of Long Term Financing: Local Markets: Equity, Debentures, Rupee Term Loan etc. Foreign Markets: ECB, Buyers Credit, ECA, FCCB, GDR etc.

  • Capacity expansion in the industry is funded through a mix of internal accruals and Long Term loans.

Determinant of Financing Mode:

For raising Long Term funds the industry uses various financing instruments in the domestic as well as the foreign capital markets depending upon the ultimate interest cost, accessibility to various markets and risk appetite etc.

Besides that various State Government also provide incentives for capital investments in their States in the form of Interest Free Loans (Conversion of Sales Tax Liability into interest free loan). In the recent past Sales Tax Deferment loan have constituted a significant portion of the total loan component.

Credit Rating:

Credit rating plays an important role in deciding a company’s access to capital markets and the overall cost of financing. Companies in the sector frequently get their Long term and Short Term debt rated by the rating agencies which support their quest for financing. Under Basel II norms Banks are required to make provision based on credit rating of the companies. Higher rated (investment grade) companies get cheaper financing relative to companies with lower rating.
  • Debentures: Over the years industry has reduced the use of Debentures as a mode of financing due to high interest as well as compliance cost. Proportion of Debentures as a % of total loan portfolio has reduced drastically from 34% in FY06 to 14% in FY10.

FC/Rupee Term Loan: Appeal of Foreign currency loans in the form of ECBs due to its low cost and Rupee term loan due to its relatively low cost and flexible end use requirement has increased as is evident from the increase in its proportion of 48% in FY 06 to 57% in FY10.

  • Sales Tax Deferment Loan: Industry players often put up Projects in States where in fiscal incentives are provided by State Govt. Appeal of incentives provided by various government has attracted the industry which is evident from the increase in Sales Tax Deferment loan as a % of total loan. Interest Free Sales Tax deferment loan also improves the overall weighted average cost of the borrowings.
  • Foreign Currency Convertible Bonds (FCCB): Some of the players in the sector also accessed the international markets by issuing FCCB. It had an option to convert the Bonds into equity at a pre-determined price on a specific date. The companies faced lot of problem in converting these into equity due to fall in share prices, hence these continued as loan.
  • Many players have tied up with International Finance Corporation (Washington) for financing their capex needs. Companies can also access ECA financing from the Exim Banks of the countries from where they are importing major equipments i.e. Hermes and Coface .
  • The companies in recent past also used equity route to finance their growth plans. The private equity players played key role in development or expansion of some of today’s large cement cos.

MNCs Financing Pattern:

MNC’s generally borrow in local markets for local expansion and for acquisition financing they opt for offshore financing based on cost benefit analysis.

Risk Management:

Risk management is becoming an integral part of financing decisions. Companies borrow in foreign currency at cheaper rates, however the same has inherent interest rate and currency fluctuation risk. These risks can be limited / eliminated with the use of various derivative instruments viz. Interest Rate Swap (IRS), Currency Swaps, Options etc. The sector has started the use of various derivative instruments as part of their risk management strategies and financing decisions.

However the sector faces the following challenges:

  • With rise in capital cost and longer time for implementation, judicious mix of internal accrual, equity and debt became critical.
  • Locally long term maturity debt papers can be placed only with life insurance companies or some banks.
  • Cost of borrowing in Foreign Currency (ECBs) is still competitive with full hedging as compared to domestic borrowings. But keeping the currency risk and interest rate risk unhedged may result / put companies into deep trouble.
  • With over capacity in the sector, the equity route for mobilizing money is also not cheap. Equally PE money is costlier as PE funds require exit route at a higher price.

Hence companies should have systematic approach of risk management relating to leveraging and debt servicing. K C Birla is a professional working with a listed public company. The views expressed in the article are personal.

Concrete

The primary high-power applications are fans and mills

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Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.

As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.

How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.

What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.

Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.

Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.

How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.

What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.

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Concrete

We conduct regular internal energy audits

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Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.

In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.

How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.

What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.

How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.

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Concrete

Digitalisation is pivotal in driving energy efficiency

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As energy costs continue to dominate the cement industry, efficiency and sustainability are proving to be vital components. MM Rathi, Joint President, Power Management, Shree Cement, explains the company’s long-term strategy is focused on cutting emissions while powering growth with renewable energy solutions.

Energy efficiency has always been a cost-saving lever for the cement industry. Today, it is the backbone of sustainability and competitiveness. Cement manufacturers are under growing pressure to optimise consumption, diversify power sources and align with decarbonisation targets. Shree Cement has been at the forefront of this transformation, significantly scaling up its green power capacity and embedding advanced technologies across operations. In this exclusive conversation, MM Rathi, Joint President – Power Management, Shree Cement, shares insights on the company’s approach to energy efficiency, challenges in brownfield modernisation and long-term strategies for achieving net zero alignment.

What percentage of your total operational cost is attributed to energy consumption?
At Shree Cement, energy is one of the most significant components of production cost, accounting for nearly 30 per cent to 40 per cent of total operational expenses. Within this, thermal energy typically contributes around 20 per cent to 25 per cent, while electrical energy forms about 10 per cent to 15 per cent. The exact share varies depending on factors such as the fuel mix (coal, pet coke or alternative fuels and raw materials), the power source (grid-based or captive like solar, wind or thermal), raw mix quality, and regional fuel and electricity price variations. This makes energy efficiency and the adoption of sustainable power sources a key focus area, both from a cost and sustainability perspective.

How has your company improved energy efficiency over the past five years?
Over the past five years, Shree Cement has consistently invested in enhancing energy efficiency across operations. Our green power capacity, covering wind, solar and Waste Heat Recovery (WHR), has more than doubled from 245 MW in 2020 to 592 MW in 2025. All grinding units are now equipped with biomass firing facilities, reducing dependence on conventional fuels. From the project stage itself, we prioritise efficiency by selecting advanced technologies such as six-stage kilns with integrated WHR, CFD-designed plants, and equipment fitted with VFDs, centrifugal compressors and high-efficiency fans. We also review and upgrade equipment systematically, replacing fans, compressors, blowers, pumps, boilers and turbines with more efficient options. This continuous approach has reduced costs while significantly advancing our sustainability journey.
What technologies or practices have shown the highest energy-saving potential in cement production?
WHR stands out as one of the most effective solutions, offsetting a significant portion of electricity required for clinker production. Hot air recirculation has also proven highly beneficial in reducing heat losses. Additionally, regular energy audits help us identify opportunities for improvement and implement corrective measures in daily operations. Together, these practices play a critical role in optimising energy efficiency and driving sustainable operations.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
The biggest challenge is the significant upfront investment required for upgradation. Retrofitting existing facilities often involves complex civil and structural modifications, which add costs and extend downtime. Integration is another hurdle, as new high-efficiency equipment may not align seamlessly with older kiln systems, fans, mills or automation setups. These factors make the transition in brownfield plants more resource-intensive and time-consuming compared to greenfield projects.

How do you measure and benchmark energy performance across different plants?
We track key performance indicators such as specific heat consumption and specific power consumption for each unit, benchmarking them against internal and external standards. Thermal Substitution Rate (TSR percentage) is another critical metric, measuring the share of alternative fuels in the thermal energy mix. Internally, we benchmark performance across plants to encourage best practice sharing. Externally, we compare against national averages and align with the Bureau of Energy Efficiency’s PAT (Perform, Achieve, Trade) scheme, which sets Specific Energy Consumption (SEC) baselines and targets for cement plants. This multi-layered approach ensures continuous monitoring, improvement, and industry leadership in energy efficiency.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation is pivotal in driving energy efficiency at Shree Cement. IoT sensors integrated with SCADA and DCS systems allow real-time monitoring of parameters like heat consumption and energy use, moving beyond periodic reports. Our digital platforms consolidate plant data, enabling management to compare metrics such as SPC, SHC, kWh per tonne and kcal per kg across units in real time. This visibility supports data-driven decisions, faster corrective actions, and higher operational efficiency.

How do government policies and incentives influence your energy-saving decisions?
Government policies and incentives strongly shape our energy-saving decisions. The Perform, Achieve, Trade (PAT) scheme sets plant-specific SEC targets. Non-compliance incurs penalties, while compliance earns tradable energy-saving certificates. This ensures energy efficiency is both cost-driven and regulatory. Additionally, subsidies and viability gap funding for renewable energy projects in wind, solar and AFR co-processing help reduce payback periods and make energy-saving investments more viable.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
Our long-term strategy aligns energy efficiency with India’s net zero 2070 goals. Key levers include improving efficiency, expanding green electricity, producing more blended cement, and increasing alternative fuel use. Today, more than 60 per cent of our electricity comes from green sources such as solar, wind, and WHR, the highest in India’s cement industry. Our blended cement products, which reduce limestone and fuel consumption, further lower emissions. These products are certified under the GreenPro ecolabel by CII, validating our sustainability practices and environmental standards.

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