The combilift and mini silos from Meher Velsycon is a new-age solution that saves cost, improves efficiency and averts pollution to contribute towards ?Clean India? drive, writes Anil Tandon.
Converting bags to bulk is a win-win for all stake holders. Meher Velsycon, Mumbai has introduced a new Combilift & Mini Silo system, which helps cement companies as much as it increases efficiency for builders and logistics service providers.
Several big users of cement are already using silos and get cement and fly ash in bulkers. But there are many others who do not have silos. And hence are not able to take advantages of loose bulk. This new solution consists of a truck with combilift, making deliveries to various client sites in 16-20 tonne mini silos. The truck leaves the cement filled silo at construction site and comes back to pick up empty silo, only when the customer has used the cement.
At construction site, the user does not require any infrastructure at all. No silos, no compressors, no godowns, nothing at all.
With labour and space becoming an ever-increasing challenge, mechanisation and optimum usage of space is the only way to complete projects in time. Mini silo is a major solution to help overcome these challenges and a cost-effective alternative in the current work practices. Vertical storage in mini silos and that too movable to the place of consumption of cement are a big plus.
Cement industry in India is largely dominated by bag market with the cement mostly available in 50 kg bag unit. But since last few years, when infrastructure projects started picking up, there was a real need to complete the projects as fast as possible. This demanded efficiency at work site and more work to be done on a daily basis. Cement was demanded in loose bulk, in bulkers. It was practically not possible to handle so many bags each day and hence cement bulkers was a solution.
But in the last 10 years, out of 100 per cent of cement bag market, only 15-20 per cent got converted into bulk. The remaining 80 per cent is still in bags. With this new system, hopefully, another 20-25 per cent will get converted to loose bulk as the benefits are many.
Cement companies need not invest in new packers as more and more cement can be despatched in loose bulk. Construction companies would prefer this system, as after pouring concrete with RMC, the secondary work can now be sped up. A lot of downstream mechanisation is possible with mini silos. One can connect pumps, plastering machines, and mixers etc to mini silo outlets and can convey materials to higher floors as well.
New solution savings
The customers today don?t want to invest a huge amount in erecting silos and install accessory equipment like compressor, as the project demand does not justify such an infrastructure. Combilift and mini silos have addressed this problem effectively and economically. The mini silo can be used to transport cement in bulk that involves zero cost on bags, labour charge, and storage. This also saves from contamination, theft, etc. In this system, the end-user, the client of the cement company, does not have to pay anything since there is no need of silo, power, labour, godown and machine. Cement company or its transporter will come with the truck with the loaded silo to project site, and the driver by himself will unload and erect the silo as the truck is capable to do this. Neither founda?tion, nor special flooring is required, just well compacted soil is fine.
After the erection of the silo, the driver will go back with the truck. The silo will remain at the site till the cement is completely used. The cement inside the silo can be accessed through a butterfly valve, which can open and the cement will flow down with gravitational force. Once the cement is consumed, the cement company will send a new truck with filled silo which comes, erects the new filled silo and take back the empty silo.
The silo comes in various capacities of 5 tonne to 30 tonne. It?s a win-win for all stake holders
Benefit to cement companies
Each truck fitted with Combilift can save more than 3,00,000 bags per year. Three lakh bags not be be bought, not to be filled, not to be handled, with just one Combilift and few silos.
It provides quick despatches from plants and grinding units, and better capacity utilisation. The whole process is environment-friendly and very safe. Cement companies will have great advantage as their carbon footprint will improve because of the power saving by not using bagging machine. Another advantage is that there is no pollution and a good working environment for people, which is a corporate social responsibility. There will be no spillages and no wastage. The plant will become less accident prone because of less people, less machine, etc are involved. All these are big benefits to cement companies.
Benefit to transporter
The transporter is the second element of this logistics chain. With one truck, he can handle many mini silos. Thus his output per truck goes up. He does not have to wait at loading/unloading points, so his number of trips goes up. Now even in the night, or very early morning, the truck can deliver and erect the silo. In such a delivery system, the transporter can employ 2-3 drivers a day on 8 hour duty round-the-clock, because he has to only go, leave the filled silo, pick the empty silo and come back. So, at the end of the month, the revenue generated per vehicle goes up tremendously, which is the bottom line for him.
Benefit to construction company
The construction company doesn?t have to invest either in godowns or in machines, bag opening, labour, etc. They only have to give a place for the silo, and their savings are huge. Normally, cement bags are stored in the godown and moved to the point of consumption either by people or by elevators or cranes etc. From mini silos, one can directly pump it to 30-40 floors. and even higher floors by pumping again. First-in-first-out will now bring better quality in construction. Usually, we order more bags of cement when the earlier is about to be finished. So, once the new lot comes in, the bags down below do not get used and overtime will become non-usable. This is wastage and also decreases the quality of construction. This is completely eliminated by the new system.
Add-ons
The mini silo can be connected to a wide range of ancillary equipment. To facilitate heavy-duty cement pumping for the construction of high-rise buildings, Meher Velsycon supplies a pump fitted with a battery and diesel genset. On-site mixers together with plastering spray guns and other machinery is also available.
Efficiency and faster completion
This is a significant advantage. With this mechanisation, the buildings can be completed earlier than planned, and the construction projects can be completed ahead of time. This is a big saving of Interest on Capital cost. A project of Rs 50-100 crore when completed earlier, by a month, can bring in great savings. Bigger project will have much bigger savings.
Total cost advantage
When a cement company does not have to buy a bag costing Rs 10-12, it doesn?t have to fill and load at a cost of Rs 5-6 per bag, and unloading at site Rs 5-6 per bag.
So the overall cost saving for the whole chain is Rs 20-25 per bag which is huge. Further savings of no godown at site, wastage of 2-3 per cent, are extra and would vary from site to site. Pollution free and environment friendliness are added advantages.
Flexibility and multi-function
During monsoon and low season period, when construction sites are not working as fast requirement of these silos can be less. During these occasions, the cement company or the transporter will have the truck available to use. With some minimal changes, the truck with Combilift can do bag deliveries during this period. Bags can be palletised or just put inside a container or body.
Way ahead
Availability of labour and space is a major challenge. We are sitting on an upcoming construction boom and mechanisation is the only way forward. In this scenario, the Combilift & Mini Silos from Meher Velsycon is going to be a new revolution in the market.
Mini silos at Ambuja Cement
Ambuja Cement has recently bought 20 silos from Meher Trailers, in which 10 units are deployed in Mumbai and 10 in Kolkata for service.
Digital twins and spatial AI are transforming cement logistics by enabling real-time visibility, predictive decision-making, and smarter multi-modal operations across the supply chain. Dijam Panigrahi highlights how immersive AR/VR training is bridging workforce skill gaps, helping companies build faster, more efficient, and future-ready logistics systems.
As India accelerates infrastructure investment under flagship programs such as PM GatiShakti and the National Infrastructure Pipeline, the pressure on cement manufacturers to deliver reliably, efficiently, and cost-effectively has never been greater. Yet for all the modernisation that has taken place on the production side, the end-to-end logistics chain, from clinker dispatch to the last-mile delivery of bagged cement to construction sites, remains a domain riddled with inefficiencies, opacity and manual decision-making. The good news is that a new generation of spatial computing technologies is now mature enough to transform this reality. Digital twins, spatial artificial intelligence (AI) and immersive augmented and virtual reality (AR/VR) training platforms are converging to offer cement producers something they have long sought: real-time visibility, autonomous decision-making at the operational edge, and a scalable solution to the persistent skills gap that hampers workforce performance.
Advancing logistics with digital twins The cement supply chain is uniquely complex. A single integrated plant may manage limestone quarrying, kiln operations, grinding, packing and despatch simultaneously, with finished product flowing through rail, road, and waterway networks to reach hundreds of regional depots and distribution points. Coordinating this network using spreadsheets, siloed ERP data, and phone calls is not merely inefficient; it is a structural liability in a competitive market where delivery reliability is a key differentiator. Digital twin technology offers a way out. A cement logistics digital twin is a continuously updated, three-dimensional virtual replica of the entire supply chain, from the truck loading bays at the plant to the inventory levels at district depots. By ingesting data from IoT sensors on conveyor belts and packing machines, GPS trackers on road and rail fleets, weighbridge records, and weather feeds, the digital twin provides planners with a single, authoritative picture of where every ton of cement is, in real time. The value, however, goes well beyond visibility. Because the digital twin mirrors the physical system in dynamic detail, it can run scenario simulations before decisions are executed. If a primary rail corridor is disrupted, logistics managers can model alternative routing options, shifting volumes to road or coastal shipping, and assess the cost and time implications within minutes rather than days. If a packing line at the plant is running below capacity, the twin can automatically recalculate dispatch schedules downstream and alert depot managers to adjust receiving resources accordingly. For cement companies operating multi-plant networks across geographies as varied as Rajasthan and the North-East, this kind of end-to-end situational awareness is transformative. It collapses information latency from hours to seconds, enables proactive rather than reactive logistics management, and creates the data foundation upon which AI-driven decision-making can be built. Companies that have deployed logistics digital twins in comparable heavy-industry contexts have reported reductions in transit time variability of up to 20 per cent and meaningful decreases in demurrage and detention costs, savings that flow directly to the bottom line.
Smart logistics operations A digital twin is only as powerful as the intelligence layer that sits on top of it. This is where Spatial AI becomes the critical differentiator for cement logistics. Traditional logistics management systems are reactive. They record what has happened and flag exceptions after the fact. Spatial AI systems, by contrast, are proactive. They continuously analyse the state of the logistics network as represented in the digital twin, identify emerging bottlenecks before they crystallise into delays, and recommend corrective actions. At the plant gate, AI-powered visual inspection systems using spatial depth-sensing cameras can assess truck conditions, verify load integrity and confirm seal tamper status in seconds, replacing the manual checks that currently slow throughput. At the depot level, Spatial AI can monitor stock drawdown rates in real time, cross-reference them against pending customer orders and inbound shipment ETAs, and automatically trigger replenishment orders when safety thresholds are approached. In transit, AI systems processing GPS and telematics data can detect anomalous vehicle behaviour, including extended stops, route deviations, speed irregularities and alert fleet managers instantly. Perhaps most significantly for Indian cement logistics, Spatial AI can optimise the complex multi-modal routing decisions that are central to competitive cost management. Given the variability in road quality, seasonal accessibility, rail rake availability, and regional demand patterns across India’s vast geography, the combinatorial complexity of routing optimisation is beyond human planners working with conventional tools. AI systems can process this complexity continuously and adapt routing recommendations as conditions change, reducing empty running, improving vehicle utilisation and cutting fuel costs. The agentic dimension of modern AI is particularly relevant here. Agentic AI systems do not merely analyse and recommend; they act. In a cement logistics context, this means an AI system that can, within pre-authorised boundaries, directly communicate revised dispatch instructions to plant teams, update booking confirmations with freight forwarders and reallocate available rail rakes across plant locations, all without waiting for a human to process a recommendation and make a call. For logistics executives, this represents a genuine shift from managing a workforce to setting the rules of engagement and reviewing outcomes. The operational tempo achievable with agentic AI simply cannot be matched by human-in-the-loop systems working at the pace of emails and phone calls.
Bridging the skills gap Technology investments in digital twins and spatial AI will deliver diminishing returns if the human workforce cannot operate effectively within the new systems they create. This is a challenge that India’s cement industry cannot afford to underestimate. The sector relies on a large, geographically dispersed workforce, including truck drivers, depot managers, despatch supervisors, fleet maintenance technicians, many of whom have been trained on paper-based processes and manual workflows. Retraining this workforce for a digitised, AI-augmented environment is a substantial undertaking, and conventional classroom or on-the-job training methods are poorly suited to the scale and pace required. Immersive AR and VR training platforms offer a fundamentally different approach. By creating photorealistic, interactive simulations of logistics environments, such as a plant dispatch bay, a depot yard, the interior of a cement truck cab, allow workers to practice complex procedures and decision-making scenarios in a safe, consequence-free virtual environment. A depot manager can work through a simulated rail rake delay scenario, making decisions about customer allocation and communication without the pressure of real orders being affected. A truck driver can practice the correct procedure for securing a load of bagged cement without the risk of a road incident. The learning science case for immersive training is compelling. Studies consistently show that experiential, simulation-based learning produces faster skill acquisition and higher retention rates than didactic instruction, with some research indicating retention rates three to four times higher for VR-based training compared to classroom methods. For complex operational procedures where muscle memory and situational awareness matter as much as conceptual knowledge, the advantage of immersive simulation is even more pronounced. Today’s leading cloud-based spatial computing platforms enable high-fidelity AR and VR training experiences to be delivered on standard mobile devices, removing the hardware barrier that has historically made immersive training impractical for large, distributed workforces. This is particularly relevant for cement companies with depots and logistics operations in tier-two and tier-three locations, where access to specialised training hardware cannot be assumed. The integration of AR into live operations also creates ongoing learning opportunities beyond formal training programs. As an example, maintenance technicians equipped with AR overlays can receive step-by-step guidance for equipment procedures directly in their field of view, reducing error rates and service times for critical plant and fleet assets.
New strategy, new horizons India’s cement industry is entering a period of intensifying competition, rising logistics costs, and demanding customers with shrinking tolerance for delivery variability. The companies that will lead over the next decade will be those that treat logistics not as a cost centre to be minimised, but as a strategic capability to be built. Digital twins, spatial AI and immersive AR/VR training are not distant future technologies, they are deployable today on infrastructure that Indian cement companies already operate. The question is not whether to adopt them, but how quickly to do so and where to begin.
About the author: Dijam Panigrahi is Co-Founder and COO of GridRaster Inc., a provider of cloud-based spatial computing platforms that power high-quality digital twin and immersive AR/VR experiences on mobile devices for enterprises. GridRaster’s technology is deployed across manufacturing, logistics and infrastructure sectors globally.
Dr SB Hegde, Global Cement Industry Leader discusses the imperative need for modern cement plants to recognise packaging and bag traceability as critical components of quality assurance and supply chain management.
In cement manufacturing, considerable attention is given to clinker quality, kiln operation, grinding efficiency and laboratory control. Yet the final stage of the process, cement packaging and despatch, often receives less strategic focus. The cement bag leaving the plant gate represents the final interface between the manufacturer and the customer. Even if clinker chemistry, fineness and strength development are well controlled, weaknesses in packaging, handling, or distribution can affect product quality before it reaches the construction site. Operational experience from cement plants across different regions shows that packaging efficiency and bag traceability have a significant influence on product reliability, logistics performance and brand credibility. In modern cement plants, packaging systems are no longer viewed merely as despatch equipment. They are increasingly recognised as an important part of quality assurance, supply chain management and customer confidence.
Operational importance of packaging Cement packaging systems must operate with high speed, accuracy and reliability to support efficient despatch operations. Rotary packers equipped with electronic weighing systems have improved packing accuracy and productivity in many plants. However, maintaining operational discipline remains essential. Regular calibration of weighing systems, maintenance of packer spouts and proper bag application are important for maintaining consistent bag weights and preventing cement loss. Operational benchmarks observed in many cement plants are summarised in Table 1. Plants that improved calibration discipline and equipment maintenance have reported packing loss reductions of about 1 per cent to 1.5 per cent, which represents significant annual savings.
Quality assurance beyond the plant gate Quality control in cement plants traditionally focuses on laboratory parameters such as fineness, compressive strength and chemical composition. However, the condition of cement when it reaches the customer is equally important. Cement bags may travel through several stages including plant storage, transport vehicles, dealer warehouses and retail outlets before reaching the construction site. During this journey, cement may be exposed to humidity, rough handling and improper storage conditions. Table 2 shows common factors that may affect cement quality during distribution. Studies indicate that cement stored under humid conditions for long periods may experience 10 per cent to 20 per cent reduction in early strength. Therefore, maintaining proper packaging integrity and traceability is essential.
Role of cement bag traceability systems Traceability systems allow manufacturers to identify when and where cement was produced and despatched. These systems connect packaging operations with production records and logistics data. When customer complaints occur, traceability enables manufacturers to identify:
Production batch
Packing date and time
Plant location
Laboratory test results
Several technologies are used to implement bag traceability, as shown in Table 3. Among these technologies, QR code authentication systems are becoming popular because customers can verify product authenticity through smartphones.
Digital transformation Digital technologies are transforming cement packaging operations. Modern packing lines now integrate:
automated rotary packers
electronic bag counting systems
robotic palletising systems
ERP-based despatch management
digital supply chain monitoring
These technologies improve operational efficiency and transparency across the supply chain. Such systems help manufacturers track cement movement across the distribution network and respond quickly to quality concerns.
Case Study: Digital Cement Bag Authentication Several cement manufacturers in Asia and the Middle East have implemented QR code-based bag authentication systems to improve supply chain transparency. In one integrated cement plant, QR codes were integrated into the rotary packing machine. Each cement bag received a unique digital identity linked to the production database. The QR code contained information such as: • plant location • manufacturing date and time • product type • batch number
Customers and dealers could scan the code using a mobile application to verify product authenticity. After implementation, the company reported: • reduction in counterfeit bag circulation • improved despatch data accuracy • faster resolution of customer complaints • better visibility of distribution networks
The system was also integrated with the company’s ERP platform, enabling real-time monitoring of production and despatch activities.
Future-Smart Packaging Systems The future of cement packaging lies in the integration of Industry 4.0 technologies with logistics and supply chain management. Packaging lines will increasingly become part of connected digital ecosystems linking production, quality control, despatch and market distribution. Artificial intelligence and data analytics may also help detect abnormalities in bag weight variations, equipment performance and despatch patterns.
Global benchmark indicators Global benchmarking of cement packaging operations highlights the increasing importance of efficiency, automation and digital traceability in modern cement supply chains. Leading cement plants are now focusing on key performance indicators such as packer availability, bag weight accuracy, packing losses, truck turnaround time and digital traceability coverage. Studies show that overall equipment effectiveness (OEE) in many industrial operations is still around 65 per cent to 70 per cent, whereas world-class plants aim for levels above 85 per cent, indicating significant scope for improvement in operational efficiency. At the same time, the global cement packaging sector is expanding steadily, supported by growing infrastructure demand and increased emphasis on reliable and moisture-resistant packaging solutions. The cement packaging market is projected to grow steadily in the coming decade as companies adopt automation, smart packaging technologies and integrated logistics systems to improve despatch efficiency and supply chain transparency. In this context, benchmarking against global indicators helps cement plants identify performance gaps and adopt best practices such as automated bagging systems, QR-based traceability, ERP-linked despatch monitoring, and predictive maintenance of packing equipment.
Strategic Recommendations To fully benefit from packaging and traceability systems, cement manufacturers should consider the following approaches. • Packaging systems should be treated as an integral part of the manufacturing value chain rather than simply despatching equipment. • Investments in modern packers, automated loading systems and digital traceability technologies should be encouraged. • Industry associations may also promote standard traceability practices to reduce counterfeit products and improve transparency in the cement market. Finally, continuous training of plant personnel in packaging operations and maintenance practices is essential for sustaining operational efficiency.
Conclusion Cement packaging has evolved from a routine mechanical operation into a strategic component of modern cement manufacturing. Efficient packaging systems ensure that the quality achieved within the plant is preserved during transportation and distribution. Traceability technologies allow manufacturers to track cement movement, investigate complaints and prevent counterfeit products. As the cement industry moves toward digitalisation and integrated supply chains, packaging and bag traceability will play an increasingly important role in quality assurance, operational efficiency and customer confidence. Ultimately, the cement bag leaving the plant carries not only cement but also the reputation and responsibility of the manufacturer.
References
Hewlett, P.C., & Liska, M. (2019). Lea’s Chemistry of Cement and Concrete. Butterworth-Heinemann.
Schneider, M., Romer, M., Tschudin, M., & Bolio, H. (2011). Sustainable cement production. Cement and Concrete Research, 41(7), 642–650.
International Cement Review. (2023). Advances in cement packaging and logistics systems.
World Business Council for Sustainable Development (2021). Cement Industry Supply Chain Innovation Report.
Gartner, E., & Hirao, H. (2015). Reducing CO2 emissions in cement production. Cement and Concrete Research.
ScienceDirect Industry Studies. (2024). Operational efficiency benchmarks and overall equipment effectiveness in industrial manufacturing systems.
World Cement Association. (2022). Digital Transformation in Cement Manufacturing and Logistics. London.
Towards Packaging Research. (2024). Global cement packaging market trends and technology outlook. Industry Market Analysis Report.
Towards Packaging Research. (2024). Global cement packaging market trends and technology outlook. Industry Market Analysis Report.
About the author: Dr SB Hegde is a Professor at Jain College of Engineering, Karnataka, and Visiting Professor at Pennsylvania State University, USA. With 248 publications and 10 patents, he specialises in low-carbon cement, Industry 4.0, and sustainability, consulting with cement companies to support India’s net-zero goals.
Table 1. Key Operational Parameters for Cement Packaging Systems
Parameter Typical Industry Range Recommended Target Operational Significance Rotary packer capacity 2400–3600 bags/hr 3000–4000 bags/hr Improves despatch efficiency Bag weight tolerance ±0.5 kg ±0.25 kg Reduces customer complaints Bag leakage rate 1 per cent to 2 per cent <0.5 per cent Minimises cement loss Packing accuracy 98 per cent to 99 per cent >99.5 per cent Ensure compliance with standards Truck loading time 30–45 minutes 20–30 minutes Improves logistics efficiency
Table 2. Causes of Cement Quality Degradation During Distribution Factor Typical Cause Impact on Cement Moisture exposure Poor storage or rain exposure Lump formation Long storage duration Slow inventory turnover Loss of early strength Bag damage Rough handling Cement loss Improper stacking Excessive loading Bag rupture Counterfeit bag reuse Refilling of empty bags Brand damage
Table 3. Comparison of Cement Bag Traceability Technologies Technology Advantages Limitations Printed batch code Low cost and simple Limited traceability Barcode Fast scanning Requires equipment QR code Smartphone verification Requires digital platform RFID tagging Automated tracking Higher cost Blockchain systems High transparency Complex implementation
The new facility strengthens SEW-EURODRIVE India’s manufacturing, assembly and service capabilities
SEW-EURODRIVE India has inaugurated a new Drive Technology Centre (DTC) in Chennai, marking a significant expansion of its manufacturing and service infrastructure in South India. The facility is positioned to enhance the company’s responsiveness and long-term support capabilities for customers across southern and eastern regions of the country.
Built across 12.27 acres, the facility includes a 21,350-square-metre assembly and service setup designed to support future industrial growth, evolving application requirements and capacity expansion. The centre reflects the company’s long-term strategy in India, combining global engineering practices with local manufacturing and service capabilities.
The new facility has been developed in line with green building standards and incorporates sustainable features such as natural daylight utilisation, solar power generation and rainwater harvesting systems. The company has also implemented energy-efficient construction and advanced climate control systems that help reduce shopfloor temperatures by up to 3°C, improving production stability, product quality and working conditions.
A key highlight of the centre is the 15,000-square-metre assembly shop, which features digitisation-ready assembly cells based on a single-piece flow manufacturing concept. The facility also houses SEW-EURODRIVE India’s first semi-automated painting booth, aimed at ensuring uniform surface finish and improving production throughput.
With the commissioning of the Chennai Drive Technology Centre, SEW-EURODRIVE India continues to strengthen its manufacturing footprint and reinforces its long-term commitment to supporting industrial growth and automation development in India.
