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Adoption of New Concepts in Material Handling

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Jai P Gupta and Rakesh Kalra of Holtec Consultancy write about concepts which could substantially reduce loading and unloading time, area for grinding units and reduce the quantity of material movement.Indian cement industry has witnessed rapid growth in past 2-3 decades. The overall production capacity of the industry, which used to be approximately 60 million tonnes in early 90’s, has more than quadrupled in about 20 years. Such rapid growth has posed several challenges in front of the industry, some of which are:??Easy to access limestone deposits are no more available and industry is facing difficulties in land availability/ acquisition. ??Growing demands and need of flyash based PPC production, forcing the industry to go for grinding units close to thermal power plant.??Unit sizes becoming larger to harness economies of scales.Due to above issues, the needs of high capacity material movement at fast pace has substantially increased. As the road network in India is inadequate, majority of pressure goes on rail transportation. Therefore the paper covers majority of suggestion relating to the material movement through rail routes.This paper covers certain concepts which could substantially reduce loading and unloading time, area for grinding units or reduce the quantity of material movement and have been successfully employed by the Holtec in cement as well as other industries.New Concepts in Material HandlingThe paper covers the following four concepts:In Motion Loading of Clinker in Railway RakesFor the clinkrization units, having split located grinding units and transport connectivity through railways, clinker loading is usually done through overland hoppers, constructed on top of the railway tracks and clinker is being loaded through telescopic chutes.This paper suggest loading of rail rakes in motion (Rapid loading system). With Rapid loading system rake 0.6 to 0.7 km/ hr below loading hopper, that means a full rake of clinker (about 650 m in length) is likely to get loaded in about 1 hr of time as compared to conventional system of rail loading, required 3 to 6 hrs.Lower investment cost, less number of operations and less drivers make this system more advategous as compared to the conventional systems.For the hauling of railway rake at a constant speed of 0.6 to 0.7 km/hr, creep drive need to be installed in the locomotive as a prerequisite of this system.
Use of Bottom Discharge Wagons for Coal and Clinker Transport and its Easy Unloading
Traditionally, cement industry has been using normal BOX/BOXN type of wagons for the transportation of coal and clinker. For the unloading of these wagons, wagon tipplers are installed, through which these wagons are unloaded. A full rake of 58 wagons need 3-4 hrs of time (i.e. 15-18 wagons unloading per hour) for unloading.Holtec designed a simple but effective system for lignite unloading, which is running successfully since last 10 years. One more system is under execution for other materials such as coal, copper concentrated and rock phosphate.If the industry insists for bottom discharge wagons from railways, similar systems could be used in the industry, for coal and clinker unloading. The system proposed is quite simple, effective, fast and economical more reliable and less prone to dust nuisance as compared to the conventional systems.Initially could be difficult for the industry to switch over to bottom discharge wagons, as railways have limited quantity of such wagons, but gradually they need to switch over.Use of Wagon TraverserNowadays the trend is to go for large capacity clinkrization units, located close to the limestone deposit and construct split located grinding units near to the source if flyash (Thermal Power Plants). These grinding units receive clinker through railway rakes and need to install wagon tipplers. For the effective utilisation of wagon tipplers it becomes must to have sufficient space (equivalent to one rake length) on either side of wagon tippler. Therefore, railway facilities need much bigger area as compared to grinding unit. The plot size for the railway shall be approx. 50 m wide x 1500 m long.Keeping in mind the limitations of land, wagon traverse is being considered for one of the project of Holter.After the wagon is unloaded on wagon tippler, side arm charger places empty wagon on traverser table, wagon is shifted to another rail track (Exit track) through a wagon traverse where pusher ejects out empty wagon from traverse to exit track.This way the space requirement for the rail tracks reduces to almost half. However, one parallel rail track needs to be constructed besides the track for removal of wagons.Benefits of wagon traverse are usually case specific and in some of the cases, its inclusion could help the grinding greatly.Fly-Ash BlendingIn last 2 decades of economic growth, shortage of electrical energy government policies, have pushed private companies to enter into mega thermal power plants. These thermal power plants, along with existing ones are generating huge quantity of flyash.As the biggest user of Flyash (PPCproduction), cement producers are finding it lucrative to maximise use of Flyash. Some clients are setting grinding units, whereas in one case Holtec designed one Flyash blending unit. This concept drastically reduced the material and improved the consistency of PPC produced.The concept of Flyash blending unit is dependent in the fact, that Flyash generated by power plant is usually of approximate 2,000 blaines That mean if the Flyash is separated between coarse and fine fraction, which needs grinding with the cement.This concept is particularly useful for the cement producers, who bring in Flyash from long distance (for example cement producer, who bring in Flyash from a distance of approximately 1500 km of distance). If their Flyash movement could be reduced to half (only coarse fraction) and on the other side of bulker movement, they carry out OP, the can substantially gain on cost of transportation.ConclusionThe primary purpose of this paper is to make people aware about new material handling concepts available and help the industry in adoption of the same. Such adoption of new material handling concept, could reduce the investment cost, handling time, number of equipment, dust generation and make the system more reliable. However such adoptions are usually case specific and vary with project requirement.(Extracted from the proceedings of the 12th NCB International Seminar on Cement and Building Materials held from 15th to 18th November 2011 at New Delhi.)

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Price hikes, drop in input costs help cement industry to post positive margins: Care Ratings

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Region-wise,the southern region comprises 35% of the total cement capacity, followed by thenorthern, eastern, western and central region comprising 20%, 18%, 14% and 13%of the capacity, respectively.

The cement industry is expected to post positive margins on decent price hikes over the months, falling raw material prices and marked drop in overall production costs, said an analysis of Care Ratings.

Wholesale and retail prices of cement have increased 11.9% and 12.4%, respectively, in the current financial year. As whole prices have remained elevated in most of the markets in the months of FY20, against the corresponding period of the previous year.

Similarly, electricity and fuel cost have declined 11.9% during 9M FY20 due to drop in crude oil prices. Logistics costs, the biggest cost for cement industry, has also dropped 7.7% (selling and distribution) as the Railways extended the benefit of exemption from busy season surcharge. Moreover, the cost of raw materials, too, declined 5.1% given the price of limestone had fallen 11.3% in the same aforementioned period, the analysis said.

According to Care Ratings, though the overall sales revenue has increased only 1.3%, against 16% growth in the year-ago period, the overall expenditure has declined 3.2% which has benefited the industry largely given the moderation in sales.

Even though FY20 has been subdued in terms of production and demand, the fall in cost of production has still supported the cement industry by clocking in positive margins, the rating agency said.

Cement demand is closely linked to the overall economic growth, particularly the housing and infrastructure sector. The cement sector will be seeing a sharp growth in volumes mainly due to increasing demand from affordable housing and other government infrastructure projects like roads, metros, airports, irrigation.

The government’s newly introduced National Infrastructure Pipeline (NIP), with its target of becoming a $5-trillion economy by 2025, is a detailed road map focused on economic revival through infrastructure development.

The NIP covers a gamut of sectors; rural and urban infrastructure and entails investments of Rs.102 lakh crore to be undertaken by the central government, state governments and the private sector. Of the total projects of the NIP, 42% are under implementation while 19% are under development, 31% are at the conceptual stage and 8% are yet to be classified.

The sectors that will be of focus will be roads, railways, power (renewable and conventional), irrigation and urban infrastructure. These sectors together account for 79% of the proposed investments in six years to 2025. Given the government’s thrust on infrastructure creation, it is likely to benefit the cement industry going forward.

Similarly, the Pradhan Mantri Awaas Yojana, aimed at providing affordable housing, will be a strong driver to lift cement demand. Prices have started correcting Q4 FY20 onwards due to revival in demand of the commodity, the agency said in its analysis.

Industry’s sales revenue has grown at a CAGR of 7.3% during FY15-19 but has grown only 1.3% in the current financial year. Tepid demand throughout the country in the first half of the year has led to the contraction of sales revenue. Fall in the total expenditure of cement firms had aided in improving the operating profit and net profit margins of the industry (OPM was 15.2 during 9M FY19 and NPM was 3.1 during 9M FY19). Interest coverage ratio, too, has improved on an overall basis (ICR was 3.3 during 9M FY19).

According to Cement Manufacturers Association, India accounts for over 8% of the overall global installed capacity. Region-wise, the southern region comprises 35% of the total cement capacity, followed by the northern, eastern, western and central region comprising 20%, 18%, 14% and 13% of the capacity, respectively.

Installed capacity of domestic cement makers has increased at a CAGR of 4.9% during FY16-20. Manufacturers have been able to maintain a capacity utilisation rate above 65% in the past quinquennium. In the current financial year due to the prolonged rains in many parts of the country, the capacity utilisation rate has fallen from 70% during FY19 to 66% currently (YTD).

Source:moneycontrol.com

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Wonder Cement shows journey of cement with new campaign

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The campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV…

ETBrandEquity

Cement manufacturing company Wonder Cement, has announced the launch of a digital campaign ‘Har Raah Mein Wonder Hai’. The campaign has been designed specifically to run on platforms such as Instagram, Facebook and YouTube.

#HarRaahMeinWonderHai is a one-minute video, designed and conceptualised by its digital media partner Triature Digital Marketing and Technologies Pvt Ltd. The entire journey of the cement brand from leaving the factory, going through various weather conditions and witnessing the beauty of nature and wonders through the way until it reaches the destination i.e., to the consumer is very intriguing and the brand has tried to showcase the same with the film.

Sanjay Joshi, executive director, Wonder Cement, said, "Cement as a product poses a unique marketing challenge. Most consumers will build their homes once and therefore buy cement once in a lifetime. It is critical for a cement company to connect with their consumers emotionally. As a part of our communication strategy, it is our endeavor to reach out to a large audience of this country through digital. Wonder Cement always a pioneer in digital, with the launch of our IGTV campaign #HarRahMeinWonderHai, is the first brand in the cement category to venture into this space. Through this campaign, we have captured the emotional journey of a cement bag through its own perspective and depicted what it takes to lay the foundation of one’s dreams and turn them into reality."

The story begins with a family performing the bhoomi poojan of their new plot. It is the place where they are investing their life-long earnings; and planning to build a dream house for the family and children. The family believes in the tradition of having a ‘perfect shuruaat’ (perfect beginning) for their future dream house. The video later highlights the process of construction and in sequence it is emphasising the value of ‘Perfect Shuruaat’ through the eyes of a cement bag.

Tarun Singh Chauhan, management advisor and brand consultant, Wonder Cement, said, "Our objective with this campaign was to show that the cement produced at the Wonder Cement plant speaks for itself, its quality, trust and most of all perfection. The only way this was possible was to take the perspective of a cement bag and showing its journey of perfection from beginning till the end."

According to the company, the campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV. No other brand in this category has created content specific to the platform.

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In spite of company’s optimism, demand weakness in cement is seen in the 4% y-o-y drop in sales volume. (Reuters)

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Cost cuts and better realizations save? the ?day ?for ?UltraTech Cement, Updated: 27 Jan 2020, Vatsala Kamat from Live Mint

Lower cost of energy and logistics helped Ebitda per tonne rise by about 29% in Q3
Premiumization of acquired brands, synergistic?operations hold promise for future profit growth Topics

UltraTech Cement
India’s largest cement producer UltraTech Cement Ltd turned out a bittersweet show in the December quarter. A sharp drop in fuel costs and higher realizations helped drive profit growth. But the inherent demand weakness was evident in the sales volumes drop during the quarter.

Better realizations during the December quarter, in spite of the 4% year-on-year volume decline, minimized the pain. Net stand-alone revenue fell by 2.6% to ?9,981.8 crore.

But as pointed out earlier, lower costs on most fronts helped profitability. The chart alongside shows the sharp drop in energy costs led by lower petcoke prices, lower fuel consumption and higher use of green power. Logistics costs, too, fell due to lower railway freight charges and synergies from the acquired assets. These savings helped offset the increase in raw material costs.

The upshot: Q3 Ebitda (earnings before interest, tax, depreciation and amortization) of about ?990 per tonne was 29% higher from a year ago. The jump in profit on a per tonne basis was more or less along expected lines, given the increase in realizations. "Besides, the reduction in net debt by about ?2,000 crore is a key positive," said Binod Modi, analyst at Reliance Securities Ltd.

Graphic by Santosh Sharma/Mint
What also impressed analysts is the nimble-footed integration of the recently merged cement assets of Nathdwara and Century, which was a concern on the Street.

Kunal Shah, analyst (institutional equities) at Yes Securities (India) Ltd, said: "The company has proved its ability of asset integration. Century’s cement assets were ramped up to 79% capacity utilization in December, even as they operated Nathdwara generating an Ebitda of ?1,500 per tonne."

Looks like the demand weakness mirrored in weak sales during the quarter was masked by the deft integration and synergies derived from these acquired assets. This drove UltraTech’s stock up by 2.6% to ?4,643 after the Q3 results were declared on Friday.

Brand transition from Century to UltraTech, which is 55% complete, is likely to touch 80% by September 2020. A report by Jefferies India Pvt. Ltd highlights that the Ebitda per tonne for premium brands is about ?5-10 higher per bag than the average (A cement bag weighs 50kg). Of course, with competition increasing in the arena, it remains to be seen how brand premiumization in the cement industry will pan out. UltraTech Cement scores well among peers here.

However, there are road bumps ahead for the cement sector and for UltraTech. Falling gross domestic product growth, fiscal slippages and lower budgetary allocation to infrastructure sector are making industry houses jittery on growth. Although UltraTech’s management is confident that cement demand is looking up, sustainability and pricing power remains a worry for the near term.

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