Economy & Market
AAC production in cement plant
Published
10 years agoon
By
adminCement companies can manufacture AAC blocks and can compete with stand alone AAC units in the country.
The raw materials required for AAC production are readily available in any cement manufacturing plant. The process does not require installation of a steam boiler or a power plant and can utilise the waste-heat from the clinker cooler exhaust gases for steam curing of aerated concrete. The method also earns carbon credits not only for the green product being made, but also for waste-heat utilisation. Although, there are more than 35 standalone AAC manufacturing units in India, very limited attempts have been made to manufacture AAC by the cement plants. One reason behind this is the lack of awareness about the new technologies that were developed recently in this field. DS Venkatesh elaborates on the technology offered by Cemeng for AAC production in a cement plant.
What is AAC
AAC is lightweight autoclaved aerated concrete, which is completely cured, inert and stable form of calcium silicate hydrate. It is a structural material, approximately one quarter in weight of the conventional concrete. It is composed of minute cells/air pockets, which give the material its lightweight and high thermal insulation characteristics. It is available as blocks and as pre-cast reinforced units for building floors, roofs, walls and lintels.
Raw material
Raw materials for AAC vary with the manufacturer and the location. The kinds of materials that could be used are detailed in the ASTM C1386 specifications. They include some, or all, of the following: fine silica sand; Class F fly ash; hydraulic cements; calcined lime; gypsum; expansive agents such as finely ground aluminium powder or paste; and water.
AAC is produced by mixing quartz sand and/or pulverised fly ash (PFA), lime, cement, gypsum/anhydrite, water and aluminium and is hardened by steam-curing in autoclaves. The silica is obtained from silica sand, fly ash (PFA), crushed silica rock and/or stone. It is possible to obtain silica as a by-product coming from other processes such as foundry sand or burgee from glass grinding; although, it can be used only if the levels of alkali or other impurities are not too high. The calcium is obtained from quick lime, hydrated lime and cement. Gypsum acts as a catalyst and enhances the properties of AAC. Careful regulation of the amount of aluminium powder gives accurate control over the density of the final product.
Cement with the least per cent of clinker would be the cheapest and suitable, e.g., Portland limestone cement. If milling of siliceous material is required, Cemeng suggests grinding of a composite mix of siliceous materials together with cement clinker, lime and gypsum/anhydrous. The ground material can be stored in a single bin. It also eliminates the need for multiple handling of individual constituents and weigh batchers. Cemeng employs a PSRG mill function in open circuit to produce the desired fineness of the composite mix.
Process flow
Cemeng has simplified the process flow to minimise the number of equipment and material handling requirements in mini AAC plants. The process gets rid of ?wet cutting? the green cake as it is possible only if the plant is involved in exclusive production of smaller blocks. Other AAC products with or without reinforcement certainly require ?dry milling? of cured cakes for profiling. Cemeng moulds for AAC are wheel-mounted units with a base plate and sliding sidewalls. There is no need for rotation or dismantling and re-assembling of side plates. Loaded moulds are transferred directly into the autoclaves for steam curing. Cemeng autoclaves generate the required steam in the autoclave itself. Separate boiler is not required. For mini AAC plants, Cemeng suggests after-cutting/milling of cured blocks for economic benefits.
The important unit operations involved in AAC production are gravimetric proportioning and mixing of constituents with water to form the slurry. This is followed with secondary mixing with expansive agents, pouring the slurry into casting moulds and then allowing sufficient time for initial hydration. Once the material is hydrated it gains enough strength to support its own weight and can undergo de-moulding/cutting. The cakes are then transferred into autoclave for high pressure steam curing. Once cooled, the autoclaved blocks are ready for after-cutting/milling as per the required profile. The AAC cost depends mainly on the cost of mineral binders and the expansive agents used. The cost of silica can vary from location to location.
Cement plant and Cemeng mini AAC production line
Cemeng mini AAC production line can be installed in an existing cement plant. Cement plants are already processing and handling both siliceous and mineral binder constituents, except for lime and sand. Also, ground raw meal, preheater ESP dust, pre-calcined meal from bottom most stage of preheater can partially or wholly replace lime. Sand may be replaced by ground slag and cinder. Clinker dust from cooler ESP and gypsum can replace cement. Besides, clinker cooler exhaust air may be effectively utilised for production of steam required for autoclaving, thus eliminating the need for a separate boiler set up.
AAC production capacity, on a thumb rule basis, can be considered as twenty cubic meter per day for every 100 tpd production capacity of the clinkerisation unit. This is based on steam production using gases only from the from clinker cooler exhaust.
Manufacturing process
To make AAC, sand is ground to the required fineness in a ball mill and is stored along with other raw materials. The raw materials are then batched by weight and are delivered to the mixer. Measured amounts of water and expansive agent is added to the mixer to prepare a cementitious slurry.
Preparation of slurry
Slurry preparation is a batch process. When AAC is being made from dry constituents, Cemeng employs separate weighbin augur dosers for each constituent the Cemeng weighbin augur doser, which uses a combination of weight and volumetric filling. A vertical auger looks like a corkscrew. The auger rotates in the hopper filled with lose powder. As it turns, it drives the powder through the bottom of the hopper into a narrow tube, where the powder is drawn down by a turning screw. The auger runs through the narrow tube, creating a tight fit. As the screw turns, it pulls the prescribed amount of powder down the tube. The agitator keeps the feed flowing to the centre of the auger. You can control the amount of powder delivered by setting the number of revolution made by the auger.
The augur screw discharges into a tubular disc conveyor for conveying and transferring directly into the AAC mixer. Subsequently, aluminium paste is added, secondary mixing is carried out and the final slurry is discharged into the AAC moulds.
Casting in moulds
Steel moulds are prepared to receive fresh AAC. If reinforced AAC panels are to be produced, steel reinforcing cages are secured within the moulds. After mixing, the slurry is poured into the moulds. The expansive agent creates small, finely dispersed voids in the fresh mixture, which increases the volume by about 50 per cent within three hours. The moulding of AAC in the mould box, holding for initial strength and de-moulding prior to autoclaving is an important step in reducing the material handling. Conventionally, the base of the moulds-box and three sides are welded together with only one side plate of mountable type. This calls for mould rotation to load the green mould on to the mountable side plate.
Cemeng moulds for AAC are trolley-mounted units with a base plate and sliding sidewalls. During casting, the sidewalls are slided inwards to form a box holding the slurry. The sidewalls keep space all around the green cake for the passage of steam. No rotation or dismantling of the side plates and reassembling are required. After curing in autoclaves, the cake is picked up by a grab and is transferred to the trolley.
Cemeng also offers ?FlexiMold? wherein rectangular shaped pre-stitched permeable cloth bags with open top are held at the base of the trolley. The flexibag is filled half with slurry and the top half is left empty to allow for expansion. As the green cake attains strength, it attains the shape of the flexibag. The telescopic brackets are then lowered. The bracket is held in its lowest position when the trolley is moved into the autoclave. The green cake along with FlexiMold is left undisturbed. After curing, the trolley is moved out and the cured cake in the moulding bag is lifted and transferred to storage. FlexiMold serves as a protective cover for cured block and it is also disposable. The size of the green cake can be set as required and several green cakes can be mounted on a single trolley.
Autoclaving
Autoclaving is steam curing at high temperature and pressure. It is required to achieve the desired structural properties and dimensional stability. The chemical reactions that produce the final calcium silicate hydrate structure happen in the autoclave. The process takes about eight to 12 hours under pressure of about 174 psi (12 bar) and a temperature of about 360?F (180?C), depending on the grade of material produced. Preferably, two autoclaves are used with the casting and precuring section in between. The mixing station is located near the discharge end of the autoclave. The thermic fluid reservoir is located at the feed end of the autoclave. This permits the precuring shed to store the cast moulds for the required duration. The waste heat from grate cooler exhaust is utilised for the heating the thermic fluid in a simple heat exchanger. It is estimated that at least 350-400 kg/hr of steam could be generated per 100 tpd production capacity of clinkerisation unit. To initiate the curing cycle, the thermic fluid, heated to 205?C, is passed through the coils in the reservoir at the bottom of each autoclave to generate steam. The hot steam pressure rises up to 1.75Mpa.
After-cutting/milling of cured AAC Blocks
Steam cured AAC blocks can be transported directly to the marketing yards. After-cutting can be carried out by the stockists or at the construction site itself. Existing granite/stone cutting and polishing units at different cities in the marketing zone can be used to saw the AAC blocks to the required size/dimensions. It is always possible to saw cut the large size AAC blocks to the required size at the construction site. Any broken pieces could be used as lightweight filler, thus nothing is wasted.
Conclusion
Every cement plant has to take green initiatives to safeguard sustainability. Using waste-heat for steam generation is highly cost effective and adds to the profits of AAC production. Besides, the plant will also be a captive consumer of cement. Every cement plant can produce AAC at considerably lower cost and can compete with standalone AAC units. AAC products can save time, labour, cement and sand during construction.
References
Eco-Care Building products: www.primeaac.com
Raw material formulae: Dearye Brick machine
Silica, calcium joined in premium products, by Sandy Herod Pit and Quarry Dec 1987 Pg.72 – 74
Brick manufacture in a Cement Plant by DS Venkatesh, Cemtec Engineering, Secunderabad. Indian Cement Review May 1989, Pages ICR-19 to ICR-25 Green Concrete by Yuvraj Patil, Flycrete. Indian Cement Review, May 2014 ?Let us employ PSRG Milling Technology? by DS Venkatesh, Indian Cement Industry Desk Book, March 2014. www.victoryenergy.com
DS Venkatesh,
Freelance Industrial Consultant
Email: dsvenkatesh40@gmail.com
Former CEO and Director of Cemtec Engineering at Secunderabad, DS Venkatesh is currently working as a freelance industrial consultant. He started as a Design Engineer at ACC and later had a long stint at Holtec-India holding several responsible positions. He has been one of the lead consultants to many rotary based mini cement plants and expansions.
DS Venkatesh has provided technical know-how, design and manufacturing drawings for cement production machinery to many Indian machinery manufacturers. Re-engineering and retrofitting of plant/machinery for enhanced productivity is his forte. His work has helped in enhancement of PSRG milling technology applied in media grinding.
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Lohia Corp Expands Global Footprint With Acquisitionof J.j. Jenkins Inc and Strategic Joint Venture With Omgm
Published
1 month agoon
October 22, 2024By
adminLohia Corp Limited (LCL) is pleased to announce two significant milestones that mark our
expansion in the global market.
We have successfully acquired J.J. Jenkins Inc. a respected name in machine manufacturing for
high-tech industries, through our US subsidiary, Leesona Corp, a 130-year-old pioneer in winding
machines. This acquisition aligns perfectly with our strategic vision to expand our specialty yarns
and tapes portfolio in medical and defence applications.
In addition, we have formed a strategic Joint Venture with Italy’s O.M.G.M. sas, leading to the
creation of OMGM Extrusiontechnik Srl. With LCL holding the majority stake. This JV represents
a significant diversification of our product portfolio, introducing solutions in Extrusion and
Winding systems for a variety of technical applications.
These advancements are not just about growth; they’re about bringing cutting-edge solutions to
our customers and contributing to industries that make a difference. Stay tuned for more updates
as we continue to push the boundaries of technology and engineering excellence.
Mr. R K Lohia, Chairman & Managing Director of Lohia Corp Limited, expressed his enthusiasm
about the new ventures “Both these new partnerships are a pivotal move that will broaden our
product offerings and provide our customers with even more choices and will enhance our
presence in the North America and European market, at the same time strengthen our presence
in all other global markets.”
About Lohia Corp Limited
Lohia Corp Limited (LCL) stands as a testament to the power of innovation and commitment to
excellence. As the flagship company of the Lohia Group, LCL has established itself as a global
leader in providing comprehensive solutions for the raffia industry.
With an impressive installation base of over 2,250 extrusion lines and 95,000 Circular Looms
across more than 100 countries, LCL’s influence in the plastic woven fabric and bag sector is
unparalleled. The company’s dedication to quality and efficiency has resulted in an astounding
plastic processing capacity of 7.7 million metric tons per annum of PP & PE.
LCL’s products, ranging from packaging systems for solid bulk materials to roof underlays and
tarpaulins, are not just industrial applications; they are the building blocks of industries
worldwide.
The company’s commitment to sustainability and innovation is the driving force that makes it the
world’s largest producer of machines for the raffia sector. As we look to the future, LCL’s legacy
of excellence is more than just a benchmark; it is a continuous journey towards pushing the
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Concrete
Adani acquires Orient Cement at INR 8,100 crore equity value
Published
1 month agoon
October 22, 2024By
adminAcquisition adds 16.6 MTPA capacity (8.5 MTPA operational, 8.1 MTPA Ready to Execute).
Accelerates Ambuja’s journey to achieve 100+ MTPA operational capacity in FY 25
Provides 6 MTPA potential additional capacity in North India, leveraging OCL’s high quality limestone reserves in Rajasthan
EDITOR’S SYNOPSIS
- Ambuja enters into a binding agreement to acquire 46.8% stake in Orient Cement Ltd (OCL). The acquisition helps to move towards target capacity of 140 MTPA by 2028.
- OCL has an existing 5.6 MTPA clinker and 8.5 MTPA cement operational capacity, 95 MW CPP, 10 MW WHRS, 33 MW Renewable Energy spread across the states of Telangana, Karnataka and Maharashtra. It improves Adani Group’s market share pan-India by 2% in the cement industry.
- OCL has secured a concession from Madhya Pradesh Power Generating Company Ltd (“MPPGCL”) to set up 2.0 MTPA Cement GU within the premises of Satpura Thermal Power Station in Sarni, MP.
- OCL also has a large high quality limestone mining lease in Chittorgarh, Rajasthan, providing the potential to set up additional 6 MTPA capacity in North India.
- The acquisition of OCL complements Ambuja’s existing cement footprint, reducing overall lead distances and logistics costs for the cement business and improving market share in our core markets.
- Acquisition will be funded through internal accruals, Ambuja remains debt free.
Ahmedabad, 22 October 2024: Ambuja Cements, the cement and building material company of Adani Cement and part of the diversified Adani Group, today announced the signing of a binding agreement for the acquisition of Orient Cement Ltd (OCL) at an equity value of Rs. 8,100 crore. Ambuja will acquire 46.8% shares of OCL from its current promoters and certain public shareholders. The acquisition will be fully funded through internal accruals.
“This timed acquisition marks another significant step forward in Ambuja Cements’ accelerated growth journey, increasing cement capacity by ~30 MTPA within two years of Ambuja’s acquisition,” said Mr Karan Adani, Director of Ambuja Cements. “By acquiring OCL, Ambuja is poised to reach 100 MTPA cement capacity in FY 25. The acquisition will help to expand Adani Cement’s presence in core markets and improve its pan-India market share by 2%. OCL’s assets are highly efficient, equipped with railway sidings and well supported by captive power plants, renewable energy, WHRS and AFR facilities. OCL’s strategic locations, high-quality limestone reserves and requisite statutory approvals present an opportunity to increase cement capacity in the near term to 16.6 MTPA.”
Mr CK Birla, Chairman of Orient Cement and the CK Birla Group, said, “The CK Birla Group is continuously reallocating capital to sharpen its focus on consumer centric, technology driven and service-based businesses. I take pride in Orient Cement’s impressive track record of building premium brands and maintaining a leading market share in the geographies it operates in. We are confident that the Adani Group, with its strong focus on cement and infrastructure, is the ideal new owner to drive continued growth at Orient Cement for our people and stakeholders”.
Ms Amita Birla, Co-Chairman, CK Birla Group, added, “Orient Cement has a strong market presence, with sustainability initiatives, particularly in renewable energy, being a significant part of its DNA. I am convinced that Ambuja Cements is the right home for all our colleagues at Orient Cement, as well as our customers.”
OCL has 5.6 MTPA clinker capacity and 8.5 MTPA cement capacity along with statutory clearance to increase the clinker capacity by another 6.0 MTPA and cement capacity by another 8.1 MTPA. In addition, OCL also has a limestone mining lease in Chittorgarh for setting up an Integrated Unit (IU) with clinker of 4 MTPA and a split Grinding Unit (GU) of 6 MTPA in North India. OCL has also secured a concession from MPPGCL, Madhya Pradesh for setting up a Grinding Unit within the premises of Satpura Thermal Power Plant. Both these complement the Adani Group’s existing cement footprint. (Refer Annexure – 1 for OCL’s location wise cement capacity and other assets and Annexure – 2 for Adani Cement’s footprint post-acquisition of OCL.)
OCL has recently commissioned a WHRS in Chittapur IU and is in the final stage of commissioning 16 MW solar in Chittapur and 3.7 MW solar in Jalgaon. OCL’s efficient plants, highly motivated teams, strong balance sheet and well-distributed dealer network will be excellent additions to the Adani Group’s existing cement business. OCL’s existing dealers will move to Adani Cement’s market network, creating formidable synergies.
Ambuja plans to optimize OCL’s overall capacity utilization to enhance its cost and competitiveness and improve its operating performance while leveraging the synergies inherent in the existing cement business.
About Ambuja Cements Ltd (ACL)
Ambuja Cements Ltd is one of India’s leading cement companies and a member of the diversified Adani Group – the largest and fastest growing portfolio of diversified sustainable businesses. Ambuja, with its subsidiaries ACC Ltd, Penna Cement Industries Ltd and Sanghi Industries Ltd, has taken the Adani Group’s cement capacity to 88.9 MTPA, with 20 integrated cement manufacturing plants, 20 cement grinding units and 12 bulk terminals across the country. Ambuja has been recognized among ‘India’s Most Trusted Cement Brand’ by TRA Research in its Brand Trust Report, 2024 and among ‘Iconic Brands of India’ by The Economic Times. Ambuja has provided hassle-free, home-building solutions with its unique sustainable development projects and environment-friendly practices since it started operations. The company has many firsts to its credit – a captive port with six terminals that facilitates timely, cost-effective and cleaner shipments of bulk cement to its customers. Its innovative products like Ambuja Cement, Ambuja Plus, Ambuja Compocem and Ambuja Kawach are now listed in the GRIHA product catalogue. These products not only fulfil important customer needs but also help in significantly reducing their carbon footprints. Being a frontrunner in sustainable business practices, Ambuja Cements ranks among ‘India’s Top 50 companies contributing to inclusive growth’ by SKOCH and ‘India’s Top 50 Most Sustainable Companies’ Cross-Industry by BW Businessworld.
For further information on this release, please contact: roy.paul@adani.com
Annexure -1 | Existing Cement Assets of Orient Cement Limited
Plant | Clinker
(MTPA) |
Cement
(MTPA) |
CPP/WHRS/Solar | Railway Siding |
Devapur IU, Telangana | 3.5 | 3.5 | CPP – 50 MW | Yes |
Chittapur IU, Karnataka | 2.1 | 3.0 | CPP – 45 MW
WHRS – 10 MW Solar – 16 MW* |
Yes |
Jalgaon GU, Maharashtra | – | 2.0 | Solar – 13.5 MW+
3.7 MW* |
Yes |
Operational Capacity | 5.6 | 8.5 |
* capacity is in commissioning stage
Annexure – 2 | Footprint of Adani Group – Cement business post OCL Acquisition
Economy & Market
Fornnax Announces a Major Launch With Sr Max Series: Sr-max2500 Primary Shredder a Revolutionary and Game-changer
Published
1 month agoon
October 18, 2024By
adminFornnax, a renowned shredding and recycling equipment provider with years of experience in designing and developing SR-Series dual shaft shredders, has unveiled its advanced level SR-MAX2500 shredder specially designed for the Municipal Solid Waste category.
The launch was held IFAT India 2024, a most prestigious event in the waste management industry, on October 16th, 2024, at the Bombay Exhibition Centre in Mumbai.
Fornnax’s successful track record of developing many proven machines for different types of tires, ferrous and non-ferrous metals, which are the most difficult applications has made them a pioneer in the shredding and recycling equipment manufacturing global market over the decade now. The design of the SR-Series machine, a legacy that has prevailed for over a decade, continues to be used in the design of SR-MAX series machines. The advanced SR-MAX2500 shredder features high capacity, modern engineering, and innovative technology.
The remarkable event was inaugurated by Mr Ulhas Parlikar, Ex-Director of Geocycle India; Mr Sanjay Shripatrao Katkar IAS (Municipal Commissioner and Administrator) MBMC; Mr Sharad Nanegaonkar Executive Engineer (Water Supply and Sewerage Department) MBMC; Mr Deepak Khambit (City Engineer) MBMC; Mr Jignesh Kundaria CEO & Director of Fornnax Technology Pvt. Ltd.;
Mr Manoj Kumar Sure, JK Cement Head AFR; Mr Manoj Kumar Modha, Director of Millennium Multi Trade Pvt. Ltd.
Jignesh Kundaria, CEO and Director of Fornnax, shared insights into their newly launched innovation, “With the SR-MAX2500, we’re poised to transform the waste management landscape in India and beyond. Our goal is to line up municipal waste recycling industries with a robust, efficient, and sustainable solution. Our commitment to sustainability and enhancing recycling process is a step forward towards achieving PM’s vision of a Net Zero emissions future by 2050.”
Revolutionizing Waste Reduction: The SR-MAX2500 Advantage We’re excited to introduce the Fornnax SR-MAX2500, a revolutionary primary shredder designed for efficient volume reduction of diverse materials. This high-capacity machine boasts advanced modern engineering and technology, featuring hydraulic motors driving each shaft for optimal power and torque. Its unique cutter design, replaceable cutting table, and shaft design make it an ideal solution for various applications.
Waste Management Reimagined! SR-MAX2500 Primary Applications Our primary focus for the SR-MAX2500 is serving large-scale municipal waste recyclers, cement plants, waste-to-energy plants, mechanical biological treatment facilities, materials recovery centres, construction and demolition recyclers, aluminium recyclers, and other applications requiring highcapacity machines and robust technology.
The SR-MAX2500’s Impressive ROI Streak The SR-MAX2500 offers several commercial benefits, including increased efficiency, reduced operational costs, and enhanced productivity as it is specially designed for the Indian market. Its robust design and advanced technology ensure minimal downtime, maximizing profitability for our customers. Additionally, our commitment to quality and reliability helps build long-term relationships with clients, fostering loyalty and repeat business.
Innovation Meets Efficiency: Why Choose the SR-MAX2500? Fornnax has carved out a distinctive niche in the highly competitive market and its relevance stems from a unique, tailored approach that addresses specific needs. Thus, the SR-MAX2500 shredder differentiates itself through its versatility, catering to a diverse array of waste management and user needs, specifically designed for Indian waste, which is highly contaminated compared to global waste. Additionally, our unwavering focus on innovation, quality, and customer-centricity sets us apart from competitors and establishes our position in the market.
Turning Trash into Treasure with MSW Waste As you see due to the rapid urbanization and over population, India is among the world’s top 10 countries generating municipal solid waste (MSW) and generates around 62 million tons of waste in a year. Therefore, it is extremely critical to prioritize recycling and conversion of MSW into RDF fuel. Cement industry, which uses a significant amount of coal. Cement industries substituting coal with RDF or alternate fuel to reduce the greenhouse gas emissions, conserve natural resources like coal and more and ultimately minimise the waste disposal issues.
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Fornnax’s Unwavering Commitment to R&D and Innovative Solutions Fornnax stays updated with global advancements in recycling technology and sustainability practices through several key strategies, such as we invest heavily in research and development to ensure our equipment are at the forefront of technological innovation. Our team closely monitors industry trends, emerging technologies, and regulatory changes to identify potential opportunities for improvement. We also actively seek feedbacks from our valued clients to understand their evolving needs and challenges. This input helps us identify areas where we can boost our meet market demands.
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