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New Trends in Intelligent Motor Management

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Intelligent Motor Control Centers (i-MCC) provide more information, early warnings and enhanced data transparency from individual motor feeders to the plant operator. This helps prevent tripping, failure and sudden shut-down of motor, says Mayank Nigam, Industry Sector, Control Products – Business Development, Siemens India.Process industries are increasingly getting more complex where various small processes are closely linked with each other. Some of these process industries are power, cement, steel, oil & gas etc. In process industry, each motor is a critical part in the production chain and its tripping, failure or sudden shut-down can lead to a huge monetary loss. In conventional MCC, these failures are caused due to limited motor protections like overload and short-circuit, massive control wiring from MCC to control room, no alarm or diagnostics and so on. In order to prevent these failures, we need to have more sophisticated control & protection system. At the same time, plant operator should have more information, early warnings and enhanced data transparency from the individual motor feeders.Above requirements are nowadays achieved by Intelligent Motor Control Centers (i-MCC). i-MCC has become very popular in last few years and is now a standard of process industry. In i-MCC, intelligent motor management relays are used on which a communication port is available. This communication port is directly connected to a Distributed Control System (DCS) by a single communication cable. This communication cable replaces numerous control and signaling cables of a conventional MCC. Features such as multiple protection, monitoring and logical functions is integrated into a compact communication capable intelligent relays.The motor management relay is the main component in an Intelligent Motor Control Center and it comprises of various essential functionalities in a single device like:

  • stand-alone motor protection
  • motor control logic (DOL, R-DOL, Star-Delta etc.)
  • monitoring of motor feeder data
  • data measurement, evaluation and storage
  • communication with a DCS system

Since the volume of data from MCC to DCS and back from DCS to MCC is quiet high & the response required is very fast, the most preferred communication protocol followed in process industry is Profibus. i-MCC offers multiple protections like overload, over & under current, over & under voltage, stalled rotor… almost all protection needed for a LT motor. In addition it provides data transparency, low maintenance cost, profibus communication, low downtime etc.The known benefits of an i-MCC are numerous but at the same time one should ensure that basic requirements that were considered in conventional MCC are also met in i-MCC. One of these key requirements is Type-2 co-ordinated feeder.Type 2 co-ordination in i-MCCTwo protections are necessary in all conventional MCC. One is overload protection by overload relay and another is short circuit protection by a circuit breaker. Overload relay (OLR) is used to save motor from burning due to overload and short circuit protection device (SCPD) from short-circuit. Since, both the faults are a form of over-current it is very important to ensure OLR operates in overload zone and SCPD operates in short circuit zone.In an i-MCC, intelligent relay replaces OLR which provide overload protection whereas SCPD remains the same. Like conventional MCC it is also recommended to use tested Type-2 co-ordinated feeder in i-MCCs. Recommended and tested Type-2 charts are published by the manufacturers of intelligent motor management relay which provides tested combination of SCPD, intelligent relay and contactor. These charts should be adhered to for complete motor protection and safety of plant & personnel.Safety integrated in i-MCC

Safety of working personnel is paramount importance for any manufacturer. Generally, automation systems and components are responsible for safety-related tasks in many applications (process industry, machines, conveyor systems etc.). This means that the health and safety of persons as well as protecting equipment and the environment depends on the correct functioning of the relevant systems and components.Today, the proper functioning of systems and components is covered by the term "Functional Safety". This is especially documented in Standard IEC 61508 "Functional safety of electrical, electronic and programmable electronic safety-related systems" and IEC 62061 "Safety of machinery – Functional safety of safety-related electrical, electronic and programmable electronic control systems". Functional safety relates to the principles of machine or plant safety that depends on the control and protective equipment functioning properly.The focus is on protecting personnel and equipment itself which should not suffer damage in the event of malfunctions. Every person who comes into contact with the system must be protected against the hazards emanating from the machine. But the machine and system itself must be protected against hazards to avoid damage to the investment and production losses.The system implies use of safety relays or safety automation systems which monitor critical components of a machine or plant. Some of these critical devices are E-stop, pull-cord switch, limit switch, contactors main contacts etc. which if malfunction then it may lead to an accident. Monitoring of these devices will help in safe disconnection of feeder during accidents.Depending on the application, the component of safety system can vary widely. Safety system always comprises of a chain of sensors, evaluation devices and actuators. In safety technology, the requirements regarding cost-saving potential can be especially fulfilled by selecting the appropriate installation system. In standard technology, the move to distributed concepts and the use of modern fieldbuses have already resulted in significant cost savings. Further cost savings in the future will be achieved by transferring additional safety-related signals along existing standard fieldbuses, e.g Profi-safe.Flexibility of integrating safety system in i-MCC is now possible and the same can be followed to ensure personnel and plant safety. In i-MCC, intelligent device, e.g. SIMOCODE, is integrated with safety circuit by using Digital Expansion Failsafe Module (DMF) of an intelligent relay (see picture below).The critical inputs of field are taken to DMF inputs and the failsafe DMF outputs are used to disconnect control supply of the switching device (contactors). The safety signals are taken from i-MCC to PLC or DCS through Profibus or if required Profisafe. These failsafe signals sent from DMF through intelligent device are then processed at automation level. It goes without saying that i-MCC,that are already influencing today’s automation environment; new trends in it will soon be found with Type-2 co-ordinated feeders and safety integrated.

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Economy & Market

Power Build’s Core Gear Series

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A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

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Economy & Market

Conveyor belts are a vital link in the supply chain

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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.

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Economy & Market

Impactful Branding

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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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