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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.

Economy & Market

Leonard Unveils Dual-Head Robotic Arm for Hazardous Industrial Demolition

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 Leonard unveils Descender Duo, a dual-head robotic demolition arm designed to improve industrial safety and reduce shutdown time by up to 50 per cent.

Industrial robotics and refractory services specialist Leonard has launched Descender Duo, a dual-head robotic demolition arm designed to improve safety, accelerate maintenance and reduce shutdown times in hazardous industrial environments. The system made its debut at Lisahally Power Station in Northern Ireland, removing 25 tonnes of slag material within hours.

Developed for the cement, metals, waste-to-energy and petrochemical industries, Descender Duo enables remote-controlled refractory demolition, anchor cutting and welding, and refractory spraying inside boilers, calciners and silos. Its vertical-access design eliminates the need for personnel to enter confined, high-risk spaces during these operations.

Weighing less than two tonnes, the pre-assembled system requires an access opening of just 1.2 m². Supported by an external overhead hoist, it uses electrically operated hydraulic stabilising legs to secure itself inside vessels. The robotic arm offers 360-degree rotation and is suited to vessels approximately 9 m in diameter, with its operating reach extendable through strategically positioned access points.

Equipped with two independently controlled robotic heads, Descender Duo can perform identical or different tasks simultaneously, including refractory demolition, anchor cutting and spraying. Its remote-control system incorporates live camera feeds, allowing operators to monitor operations without entering hazardous environments.

According to Leonard, the technology can deliver time savings of up to 50 per cent compared with manual methods. Its ability to operate at temperatures exceeding 100°C allows maintenance to begin as early as 24 hours after burner shutdown. An all-electric power supply further supports cleaner and more cost-efficient operations.

First Deployment Demonstrates Shutdown Efficiency

The system was first deployed at Burmeister & Wain Scandinavian Contractor’s (BWSC) Lisahally Power Station in Londonderry, Northern Ireland. The facility generates electricity from grade C waste wood, supplying approximately 40,000 homes and businesses.

Leonard and BWSC collaborated to develop a customised solution for the plant’s 26-metre furnace, where extensive external pipework created significant access challenges.

Mark Leonard, Managing Director, Leonard, said, “It required new thinking and rather than step away from the problem we were committed to solving it for the customer, with the customer. We’re relentless in our approach to tackling complex challenges, head-on. We took our years of cement plant experience, coupled with our working knowledge of the BWSC plant, and designed, engineered and tested a completely new vertical solution within just seven weeks from that initial conversation with the customer. That solution was the Descender Duo as we know it today.”

Traditionally, the furnace required a cooling period of up to 36 hours before preparatory work could begin, followed by manual slag removal using rope-access personnel. With Descender Duo, work commenced just 24 hours after shutdown, reducing downtime by up to one day.

The deployment removed 25 tonnes of slag within hours, eliminated the need for at least six workers to enter the hazardous furnace interior and saved 26 hours in the shutdown programme.

“The effectiveness exceeded expectation,” said Martin Doran, Plant Manager at Lisahally Power Station.

“When the Descender Duo concept was first discussed, we had to spend some time with the team from Leonard looking at how it was going to be moved into the furnace. Every site is different and that presented its own challenges, but nothing that the team couldn’t overcome. Once it was installed we were hugely impressed by its efficiency.”

Expanding Industrial Robotics Applications

Descender Duo joins Leonard’s existing portfolio of robotic maintenance solutions, including the Axis horizontal-access arm, Nano confined-space access arm, Charger cement mill media recharging system and Calibre cement mill media grading system.

Headquartered in Northern Ireland, Leonard provides robotic refractory demolition, installation, inspection and industrial maintenance services across the cement, metals, energy, biomass, glass and civil engineering sectors.

Formerly known as G Leonard, the company has more than 35 years of industry experience and operates across Europe, North America, the Middle East, Africa and Asia-Pacific.

The latest innovation reinforces Leonard’s focus on replacing hazardous manual processes with robotic systems that improve workforce safety, enhance operational efficiency and minimise industrial downtime.

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Concrete

Martin Engineering Appoints Ashwini Khunte as India General Manager

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Martin Engineering names Ashwini Khunte India General Manager to strengthen operations and drive growth across key bulk material handling sectors.

Pune

Martin Engineering, a global provider of bulk material handling solutions, has appointed Ashwini Khunte as General Manager of its India business, strengthening its leadership as the company expands its presence across the country’s cement, mining, steel, power and infrastructure sectors.

Khunte brings more than a decade of experience with Martin Engineering, having joined its Indian operations in 2013 as a Design Engineer, shortly after the company established its presence in the country in 2012.

A mechanical engineer by qualification, she spent her initial five years developing bulk material handling solutions in collaboration with the company’s operations team. During this period, she gained extensive experience addressing operational challenges in the steel, cement and coal industries. She subsequently moved into project engineering, managing major engineering, procurement and construction (EPC) and original equipment manufacturer (OEM) projects from initial enquiry to commissioning. Her responsibilities later expanded to overseeing Martin Engineering’s conveyor product portfolio in India, involving customer engagement, technical presentations and site visits across heavy industries.

In 2024, Khunte was promoted to Head of Sales & Marketing for the company’s Europe, Middle East, Africa and India (EMEAI) region. The position broadened her international market exposure and strengthened her strategic and commercial leadership capabilities.

Commenting on her appointment, Ashwini Khunte, General Manager, Martin Engineering India, said: “India represents a tremendous opportunity for Martin Engineering. The country’s continued investment in cement, mining, steel, power and infrastructure is creating increasing demand for safer, cleaner and more productive bulk material handling, and that’s exactly what we do. My priority will be to build on the strong foundations already established in India, while continuing to develop our people, strengthen customer relationships and bring practical solutions to the challenges faced by our industry.”

Robert Whetstone, Area Vice President – EMEAI, Martin Engineering, highlighted Khunte’s technical expertise, market understanding and leadership experience.

“Ashwini brings an exceptional combination of technical understanding, customer knowledge and commercial leadership. She has grown as Martin Engineering has grown, and has consistently demonstrated outstanding capability to transform her expertise into practical solutions. Her knowledge of the Indian market, together with her international experience, makes her ideally suited to lead our India business through its next stage of growth for years to come.”

Since establishing its Indian business in 2012, Martin Engineering has expanded its local workforce, manufacturing capabilities and dealership network. The company supplies conveyor products, transfer point solutions, material flow aids, training and technical support to bulk material handling industries. Khunte’s appointment positions the company to further strengthen customer relationships and expand its solutions portfolio in India’s growing industrial and infrastructure markets.

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Concrete

Fornnax Wins AIRIA’s Special Export Award for Rubber Machinery in 2025-26

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Fornnax Technology Pvt. Ltd. has been honoured with the Special Export Award – Rubber Machinery for 2025–26 by the All-India Rubber Industries Association (AIRIA), in recognition of its highest exports of tyre recycling plants to the European region.

With more than a decade of experience in India’s tyre recycling industry, Fornnax has contributed to the development of advanced recycling technologies and infrastructure. The company currently holds a 90% market share in India’s domestic tyre recycling sector, while exports account for 30% of its business, spanning markets such as Europe, Australia and the GCC.

The award marks another milestone for Fornnax, whose tyre recycling lines and advanced shredding technologies are supporting the growth of the circular economy in India and international markets.

Commenting on the recognition, Mr. Jignesh Kundaria, Founder and Director of Fornnax, said:

“This honour from AIRIA is a reflection of an incredible journey we have undertaken over the years. When we started Fornnax, there was no established recycling industry in India to follow. We chose to build for the future instead. Today, when you see India’s tyre recycling sector, it has already transformed into a dynamic, high-growth industry and we are extremely proud to have played our part in building it.”

Unlike standalone equipment suppliers, Fornnax focuses on developing complete, high-capacity recycling infrastructure. Its integrated systems combine multiple stages of shredding and size reduction to enable efficient, continuous operations. This system-level engineering approach helps recycling operators improve throughput, equipment reliability and operational consistency.

The recognition reinforces Fornnax’s commitment to developing engineering technologies that contribute to a more efficient and circular recycling ecosystem.

Looking ahead, the company aims to expand its international presence while continuing to develop advanced shredding and recycling solutions to address the growing volumes and evolving requirements of the global recycling industry.

For more information, visit: www.fornnax.com

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