Product development
World class engineering capabilities is our strength
Published
14 years agoon
By
admin
Polysius India has completed 32 years of existence in India and has gone on to become the most preferred cement supplier. Malay Das, Executive Director, Polysius India talks to Indian Cement Review about the host of products that the company offers and their future plans.Tell us about the range of products and services provided by Polysius India to cement manufacturers in India.Polysius India is a division of ThyssenKrupp Industries India and one of very few companies which can offer entire range of cement plant machinery starting from limestone crushing up to cement despatch. World class engineering capabilities is our strength based on which total cement manufacturing facility can be catered to from under one roof.Our range includes dynamic air separators, ball mills, vertical roller mills, high pressure grinding rolls (Polycom) for grinding of raw materials, fuel and clinker, preheater, rotary kiln, fuel burning systems and clinker cooler from pyro-processing sections. In addition, we also engineer and supply raw material and fuel blending systems, alternate fuel handling and conveying systems, robotic laboratory packages for analysis of samples (Polab) with different variants. As regards services, we offer services to upgrade, modernize & optimize the plants, and also provide supervision of erection and commissioning services.What are the various types of cement machinery manufactured by Polysius India? What is the size of the cement machinery market in India and what is the market share of Polysius India in cement machinery?
Traditionally addition of new capacities and expansion of existing capacities in India happen in a staggered way. In certain years, substantial capacities are ordered out and finalized whereas at other times very few orders are decided. As such size of cement machinery market is always fluctuating and does not follow any trend. Generally, 8 – 10 per cent year on year growth is the trend. Market share also varies from time to time. For example last two to three years, our share was 40 / 45 per cent. If market share is averaged out on a long term it would be of the order of 28 per cent – 30 per cent.How does Polysius India keep pace with technological developments in cement and cement machinery manufacturing? What is your R&D spend and what kind of innovative products or technologies has your R&D created?
Research & Development Centre of ThyssenKrupp Polysius group is based at Ennigerloh, near group headquarters at Beckum in Germany. ThyssenKrupp Polysius has a history of engineering excellence which is more than 150 years old, and it has evolved over these years by way of own research and developmental work. It has highly qualified professionals and specialized tools created with extensive planning and foresight for development of new products, technological upgradation of existing products based on the operational feedback.Many new products / equipments like different type of dynamic air separators, POLCAL calciner, new generation kiln burners have been developed at our R&D centre. Besides, they have also been successful in developing technologies to meet challenges of ever stringent environmental demands and norms.However major breakthrough was achieved by them when high pressure grinding roll (POLYCOM), new generation vertical roller mill (QUADROPOL) and POLYTRACK cooler without under grate spillage were developed and launched successfully.Which major cement manufacturing plants have you erected and commissioned till date? Which major cement companies in India and overseas are your clients and how do you plan to increase your clients in India and overseas?
Polysius India has been in the forefront of building the Indian cement industry for past 32 years and has been the preferred supplier of major cement producers within India like Ambuja Cement and ACC who are now part of Holcim group, India Cements, B.K. Birla group of companies, Jaiprakash Associates, Aditya Birla group. We have built many plants for these torchbearers of the Indian cement industry which speaks for itself about their faith in Polysius technology for meeting their complete requirements.Recent entrants in the field of cement production like Nirma, Wonder, Vicat of France, Goldstone, Nava Durga and Reliance Cementation, who have very ambitious growth plans, have trusted us as their long term growth partners.We have also succeeded in expanding our horizons beyond Indian boundaries by making successful forays in Middle East and South East Asia and African continent.Latest European (Polysius) technology, competitive Indian prices and top quality services have been the driving wheels of our growth in past and we are confident that they will drive our growth in times to come also. We believe in supporting our clients through prompt and effective after sales services which nurture a satisfied client who makes us partner in their further growth.Which regions in India are your major markets? How do you propose to penetrate other markets and expand your reach of products and services?
While we service the expansion efforts of existing customers, we add to our reference list new names also on regular basis. All major cement producers, by way of merger and acquisition and greenfield expansion routes have spread their manufacturing facilities across India. As our clients are spread across the length and breadth of the country, we are indirectly catering to the requirements of all regions within India. There are of course regional players, single plant entities etc. who are also our clients. They cater to the requirements of respective areas/region in which they are located.What kind of features do your cement plants and machinery have to make them sustainable and environment-friendly?
Cement production involves very energy and heat intensive process and its sustainability should be looked at from the point of view of conserving these scarce resources. Polysius backed by the extensive research and developmental efforts and engineering capabilities has been on the forefront in this area by introducing energy saving grinding systems like POLYCOM for finish grinding of raw material, modifying the burning system for fuels to make them suitable for accepting alternate / waste material as fuels and also development of waste heat recovery systems.Polysius cement plants are highly environment-friendly and meet all current world standards for dust particle emissions and NOx and SOx emissions. Special processes have been developed to keep NOx & SOx levels within prescribed levels.How extensive is your after-sales service and what is the response time for addressing the complaints of your clients?Prompt after sales service is a key to the satisfied client and we have always ensured that we have well trained and experienced engineers on our rolls to assist our clients during erection and commissioning phase of plants, and also for trouble shooting. Our engineers also receive specialized training at ThyssenKrupp Polysius offices in Germany as well as various plant sites.We back our clients all the way during difficult periods which is well known in the industry and much appreciated in view of the short response time. If necessary, specialists from Germany are also called in at short notice to ensure that client’s operations are back on track as fast as possible.What are your future plans for India and how do you propose to implement them?With our contemporary technology and first class manufacturing facilities we have already established ourselves as one of the top cement plant and equipment suppliers in India and South East Asia. We are now focusing on improving our market share further and remain the leader in years to follow. Our future plans for Polysius India also includes diversification in to mineral processing and beneficiation sector.
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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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