Economy & Market
Creating larger societal value
Published
11 years agoon
By
admin
ACC has a firm commitment to create larger societal value. The company initiated its community development activities in pre-independence era and since then it has continued to engage with development initiatives with a host communities around its operations.
The communities living around ACC?s operations are the key stakeholders of the organisation. The company actively assists these communities in identifying, prioritising and meeting their developmental aspirations. It has adopted participatory community self-reliance initiatives across its sites in India by creating forums such as community advisory panel (CAP) which acts as a platform for the community, local district administration, NGOs and other opinion groups to come together and implement projects. The panels have proven to be valuable in presenting stakeholder views, review the progress of community projects, obtain timely feedback from stakeholders, and ensuring appropriate delivery of plan initiatives in a participatory method.
New CSR policy
In 2013, ACC revisited its CSR policy in view of the emerging regulatory framework. ACC?s Board constituted a CSR committee to particularly focus on guiding and monitoring of CSR initiatives of the company.
According to Pratyush Panda, Head – CSR, ACC, a wide range of social development initiatives were undertaken in partnership with local communities, government and non-government organisations. ?The initiatives reached out to people residing around ACC?s operational areas as well as to various disasters hit areas around the country. Focus of these initiatives were mainly on enhancing literacy and education for community, preventive health and sanitation, livelihood, employability and income generation, women empowerment, augmentation of community infrastructure, environment and other CSR initiatives such as promotion of local arts, culture and sports,? he says.
During 2013, ACC?s community development initiatives mainly focused on 132 villages, having a population of 0.6 million, located primarily around its 14 plants.
Education for society?s future
?ACC?s initiatives in education benefited 18,380 children in the neighbourhood communities. It has established schools at all its locations, where employees? children and those from surrounding communities are provided quality education,? says Panda. Management of these schools is outsourced to reputed educationists, thereby ensuring that the schools maintain high standards of education. Since most plants are situated in remote hinterlands, the ACC schools are at once the most accessible and invariably among the best in the region. The schools are supported by providing funds and infrastructure for initial construction, meeting a part of the teachers? salaries and up-gradation activities.
ACC continued to support seven Government-run Industrial Training Institutes (ITI), under a Public Private Partnership scheme (PPP), through a joint initiative with the Ministry of Labour and Employment, Government of India. Its support focuses on enhancing the skills and employability of the students passing out of these institutes by upgrading the quality of education offered there.
ACC also runs two technical training institutes of its own, both of which enjoy considerable repute as centres providing technical training. The Sumant Moolgaokar Technical Institute (SMTI) at Kymore was first established in 1949 to train young men in specialized trades to become artisans, foremen and first line supervisors. It had its own independent curriculum and certification. Since 2008, the institute works with a revised objective of complementing the education received by engineering diploma trained candidates. In 2013, SMTI trained 120 young men through an 18 month course as Diesel Mechanic-cum-Fitter and Electrical Instrumentation. The other institute managed by it is the ACC Cement Technology Institute (ACTI) which offers specialized technical training to young engineering graduates. ACTI trained 166 boys and 32 girls during the year with both class room and practical trainings in operation and maintenance of cement plants.
Community development
The thrust in this respect comprises promoting health, women?s empowerment and creating livelihoods. These initiatives benefited more than 109,000 people directly while twice as many people were indirect beneficiaries.
Promoting health: Panda elaborates on AAC?s initiatives on promoting health. ?Health being one of the prime concerns of the community and critical for general wellbeing of ACC?s stakeholders, significant initiatives were undertaken in this domain. Total 109,450 people benefited from our various health and nutrition related initiatives.? ACC?s health initiatives mainly focus on preventive health of the community. Active awareness campaigns are undertaken to enhance communities understanding about various disease prevention and healthy ways of living. Regular preventive health support to the community is reached out through health camps and mobile health vans. Most of these plant sites are situated in remote parts of the country, with little access to adequate healthcare and medical services. ACC supports the local administration in promoting national health campaigns on important issues such as malaria, prevention and immunisation and DOTS. During 2013, 3,273 general and special health camps were conducted to reach out preventive care to community members. In addition, regular support to the ACC hospitals support was also extended to various government Primary Health Care centres and Community Health Care centres.
Special initiatives in healthcare and nutrition are taken for women and children in coordination with health authorities. Communities are mobilised to participate in programmes for immunisation, anti natal care, post natal care and birth spacing methods. Iron folic acid tablets were provided to prevent anemia among pregnant mothers and adolescent girls.
?The support to Anganwadi initiative would be one such example. Anganwadis are integral part of Integrated Child Development Scheme (ICDS) that plays a vital role in rural areas for overall development of children as well as support to pregnant and lactating mothers. ACC provided support to 132 Anganwadis that are serving the host communities. This has resulted in better supply and use of government?s medicine supplies through AWC which has direct impact on infant and maternal mortality,? explains Panda.
Other support activities included health and accidental insurance for Self Help Group (SGH) members and drivers in ACC?s supply chain, subsidised ambulance facility to villagers for their emergency needs and subsidised hospitalization of villagers.
Women?s empowerment: Various initiatives are pursued to promote skill building and income generating schemes for local women groups. Women SHGs are imparted relevant training in their selected livelihoods and supported in the establishment of micro-enterprises. As many as 737 SHGs were organised during the year. Members of these new as well as old SHGs were provided training for group cohesiveness, book-keeping, product development, marketing of the products, market linkages, bank linkages and exposure to best practices in SHG functioning. Some of these groups have initiated their own micro enterprises. Through bank linkages and inter- loaning, these members generated a total savings of Rs 1.52 crore.
ACC AHEAD (Association for Health, Education and Development), the volunteering wing of the company?s ladies clubs at all plants, set up in 2008, continued to support social volunteering and community programmes with special emphasis on empowering women. The group has been successful in creating livelihood opportunities for numerous community women in the areas of tailoring, embroidery, knitting, making masala, pickles, fancy bags, gloves and in making, disposable cups and plates.
Livelihood and employability: ?ACC believes in empowerment of people and assisting them in sustainability of their livelihood, as that will make the community self-reliant and increase their self-respect,? says Panda. During the year, ACC?s various initiatives in this direction benefited 17,288 people. Under its employability initiatives, it supported training of 3,579 youth from poor families in the host community, of which, 2,501 persons were placed with various employers enabling a similar number of families to live above poverty line.
Building infrastructure for liveable neighborhoods
ACC plays a vital role in facilitating the creation and maintenance of basic infrastructure around all its operations such as roads, safe drinking water, deepening of ponds, and repairs to schools, Anganwadi and other community amenities. ACC makes every possible effort to make these basic necessities available to the neighbourhood communities, according to Panda.
Wherever needed, NGO partners join in to ensure quality execution of the projects. Efforts are also taken to bring benefits of government schemes for the welfare of village communities. Previously, ACC?s initiatives for infrastructure development benefited 435,392 people. Each plant contributed in creation of water harvesting structures and installation of hand pumps for drinking water. Excavation of pond for irrigation and other water uses, directly and indirectly benefited 272,418 people, whereas drinking water initiatives benefited 72,294 people.
Disaster response initiatives
ACC?s disaster relief support initiatives in these disaster affected areas of Uttarakhand and Maharashtra benefited 8,703 people. Uttarakhand faced devastation during disastrous flash floods in June 2013. ACC?s Disaster Response Team (DRT) reached out to affected villages in Uttarkashi region. 24 volunteers from various units of north region joined hands with Sales Unit, Dehradun. ACC?s DRT provided relief to the people through ACC Mobile Health Unit, doctors, nurses and pharmacists, along with safe drinking water, food and clothing.
CSR activities ACC?s corporate social responsibility helps the company in various ways. From building a more motivated workforce to becoming a sustainable entity, ACC aligns its initiatives keeping in mind its goals. Some such examples are as below:
Alternate fuels & raw materials (AFR): The concept of AFR involves substituting mainstream non-renewable fuel resources like coal with replenishable alternate fuels. A subsidiary activity of AFR is waste co-processing which is basically a means of waste management. Under the mainstream AFR activities, currently the Gagal plant is using mill scale (a reject from steel rolling mills) as a substitute for iron ore.
A few of waste management initiatives undertaken by ACC are as follows:
Maddukrrai Solid Waste Management Initiative: ACC Maddukarrai Cement Works in association with the local Panchayat, and NGO Hand in Hand/SEED Trust launched the ?Clean & Green Madukkarai?. The vision behind the initiative was to make Madukkarai a plastic and garbage-free community by 2015.
Team Madukkarai also plans to set up a bio-gasifier plant which consumes the bio-waste and produce methane gas which will be converted to electricity. This electricity will be used for lighting the local street lamps.
Co-processing of pine needles as alternative fuel at Gagal: Every year, particularly during the summer months, large numbers of such fires create havoc in the forests of the sub Himalayas. Forest fires cause immense loss of nutrient, organic material from the soil, damage to soil micro-organisms, change in soil structure, destruction of plantations and local extermination of small animals and plants.
One of the main reasons of the fire spreading to a large region is the presence of large spreads of dry leaves and wood at the bottom of the forest cover. ACC Gagal proposed a workable solution to AK Thakur, DFO of Suket Forest Division, to permit the company?s CSR team along with local villagers to collect pine needles (locally called Chalaru) for co-processing in the cement kiln at Gagal.
Green Building Centres (GBC)
The ACC GBC is designed to be a state-of-the-art one-stop-shop for housing expertise which will offer locally produced, eco-friendly, easy-to-use and reasonably priced construction products.
oVisitors to the centre get a first-hand glimpse of locally produced and reasonably priced construction products, with ready access to knowledge and training on how to use and apply these products in a rural context. The ACC GBC comes fully equipped with a quality control laboratory. The centre also has equipment which enables builders to manufacture the products on their own and thus achieve further savings,? says Panda.
ACC has collaborated with architects and experts who can provide consultations regarding the project, product detail, application and design.
ACC associates with well-established enterprises as well as NGOs to promote local entrepreneurial talent. While the entrepreneur is responsible to manage the centre, ACC supports the venture by providing its branded products backed with proven technical expertise. The entrepreneur runs it as a business and thus has an incentive to work for its success, creating local jobs along the way. This helps in the development of talent among the local rural population. The materials available at the ACC GBC are produced from local resources and incorporate waste materials like fly ash, helping to reduce its carbon footprint significantly and in preserving earth?s natural resources, while simultaneously keeping costs down.
ACC?s stellar employees
ACC?s understands that CSR activities go a long way in building relationships. ACC has a large workforce of about 9,000 people, comprising experts in various disciplines assisted by a dedicated workforce of skilled persons. ACC employees, referred to as the ACC parivar, come from all parts of the country and belong to a variety of ethnic, cultural and religious backgrounds. This helps ACC in connecting better with various communities across the country and to understand their needs. The dedication of the employees to pursue the CSR goal of the company reflects the special stellar qualities they possess. This has led to ACC employees being recognized as ?value-adding? human capital in the industry.
Pratyush Panda, Head – CSR, ACC
ACC believes in empowerment of people and assisting them in sustainability of their livelihood, as that will make the community self- reliant and increase their self-respect.
SEEPEX introduces BN pumps with Smart Joint Access (SJA) to improve efficiency, reliability, and inspection speed in demanding rock blasting operations.
Designed for abrasive and chemical media, the solution supports precise dosing, reduced downtime, and enhanced operational safety.
SEEPEX has introduced BN pumps with Smart Joint Access (SJA), engineered for the reliable and precise transfer of abrasive, corrosive, and chemical media in mining and construction. Designed for rock blasting, the pump features a large inspection opening for quick joint checks, a compact footprint for mobile or skid-mounted installations, and flexible drive and material options for consistent performance and uptime.

“Operators can inspect joints quickly and rely on precise pumping of shear-sensitive and abrasive emulsions,” said Magalie Levray, Global Business Development Manager Mining at SEEPEX. “This is particularly critical in rock blasting, where every borehole counts for productivity.” Industry Context
Rock blasting is essential for extracting hard rock and shaping safe excavation profiles in mining and construction. Accurate and consistent loading of explosive emulsions ensures controlled fragmentation, protects personnel, and maximizes productivity. Even minor deviations in pumping can cause delays or reduce product quality. BN pumps with SJA support routine maintenance and pre-operation checks by allowing fast verification of joint integrity, enabling more efficient operations.
Always Inspection Ready
Smart Joint Access is designed for inspection-friendly operations. The large inspection opening in the suction housing provides direct access to both joints, enabling rapid pre-operation checks while maintaining high operational reliability. Technicians can assess joint condition quickly, supporting continuous, reliable operation.
Key Features
- Compact Footprint: Fits truck-mounted mobile units, skid-mounted systems, and factory installations.
- Flexible Drive Options: Compact hydraulic drive or electric drive configurations.
- Hydraulic Efficiency: Low-displacement design reduces oil requirements and supports low total cost of ownership.
- Equal Wall Stator Design: Ensures high-pressure performance in a compact footprint.
- Material Flexibility: Stainless steel or steel housings, chrome-plated rotors, and stators in NBR, EPDM, or FKM.
Operators benefit from shorter inspection cycles, reliable dosing, seamless integration, and fast delivery through framework agreements, helping to maintain uptime in critical rock blasting processes.
Applications – Optimized for Rock Blasting
BN pumps with SJA are designed for mining, tunneling, quarrying, civil works, dam construction, and other sectors requiring precise handling of abrasive or chemical media. They provide robust performance while enabling fast, reliable inspection and maintenance.With SJA, operators can quickly access both joints without disassembly, ensuring emulsions are transferred accurately and consistently. This reduces downtime, preserves product integrity, and supports uniform dosing across multiple bore holes.
With the Smart Joint Access inspection opening, operators can quickly access and assess the condition of both joints without disassembly, enabling immediate verification of pump readiness prior to blast hole loading. This allows operators to confirm that emulsions are transferred accurately and consistently, protecting personnel, minimizing product degradation, and maintaining uniform dosing across multiple bore holes.
The combination of equal wall stator design, compact integration, flexible drives, and progressive cavity pump technology ensures continuous, reliable operation even in space-limited, high-pressure environments.
From Inspection to Operation
A leading explosives provider implemented BN pumps with SJA in open pit and underground operations. By replacing legacy pumps, inspection cycles were significantly shortened, allowing crews to complete pre-operation checks and return mobile units to productive work faster. Direct joint access through SJA enabled immediate verification, consistent emulsion dosing, and reduced downtime caused by joint-related deviations.
“The inspection opening gives immediate confidence that each joint is secure before proceeding to bore holes,” said a site technician. “It allows us to act quickly, keeping blasting schedules on track.”
Framework agreements ensured rapid pump supply and minimal downtime, supporting multi-site operations across continents
Concrete
Digital process control is transforming grinding
Published
2 weeks agoon
February 20, 2026By
admin
Satish Maheshwari, Chief Manufacturing Officer, Shree Cement, delves into how digital intelligence is transforming cement grinding into a predictive, stable, and energy-efficient operation.
Grinding sits at the heart of cement manufacturing, accounting for the largest share of electrical energy consumption. In this interview, Satish Maheshwari, Chief Manufacturing Officer, Shree Cement, explains how advanced grinding technologies, data-driven optimisation and process intelligence are transforming mill performance, reducing power consumption and supporting the industry’s decarbonisation goals.
How has the grinding process evolved in Indian cement plants to meet rising efficiency and sustainability expectations?
Over the past decade, Indian cement plants have seen a clear evolution in grinding technology, moving from conventional open-circuit ball mills to high-efficiency closed-circuit systems, Roller Press–Ball Mill combinations and Vertical Roller Mills (VRMs). This shift has been supported by advances in separator design, improved wear-resistant materials, and the growing use of digital process automation. As a result, grinding units today operate as highly controlled manufacturing systems where real-time data, process intelligence and efficient separation work together to deliver stable and predictable performance.
From a sustainability perspective, these developments directly reduce specific power consumption, improve equipment reliability and lower the carbon footprint per tonne of cement produced.
How critical is grinding optimisation in reducing specific power consumption across ball mills and VRMs?
Grinding is the largest consumer of electrical energy in a cement plant, which makes optimisation one of the most effective levers for improving energy efficiency. In ball mill systems, optimisation through correct media selection, charge design, diaphragm configuration, ventilation management and separator tuning can typically deliver power savings of 5 per cent to 8 per cent. In VRMs, fine-tuning airflow balance, grinding pressure, nozzle ring settings, and circulating load can unlock energy reductions in the range of 8 per cent to 12 per cent. Across both systems, sustained operation under stable conditions is critical. Consistency in mill loading and operating parameters improves quality control, reduces wear, and enables long-term energy efficiency, making stability a key operational KPI.
What challenges arise in maintaining consistent cement quality when using alternative raw materials and blended compositions?
The increased use of alternative raw materials and supplementary cementitious materials (SCM) introduces variability in chemistry, moisture, hardness, and loss on ignition. This variability makes it more challenging to maintain consistent fineness, particle size distribution, throughput and downstream performance parameters such as setting time, strength development and workability.
As clinker substitution levels rise, grinding precision becomes increasingly important. Even small improvements in consistency enable higher SCM utilisation without compromising cement performance.
Addressing these challenges requires stronger feed homogenisation, real-time quality monitoring and dynamic adjustment of grinding parameters so that output quality remains stable despite changing input characteristics.
How is digital process control changing the way grinding performance is optimised?
Digital process control is transforming grinding from an operator-dependent activity into a predictive, model-driven operation. Technologies such as online particle size and residue analysers, AI-based optimisation platforms, digital twins for VRMs and Roller Press systems, and advanced process control solutions are redefining how performance is managed.
At the same time, workforce roles are evolving. Operators are increasingly focused on interpreting data trends through digital dashboards and responding proactively rather than relying on manual interventions. Together, these tools improve mill stability, enable faster response to disturbances, maintain consistent fineness, and reduce specific energy consumption while minimising manual effort.
How do you see grinding technologies supporting the industry’s low-clinker and decarbonisation goals?
Modern grinding technologies are central to the industry’s decarbonisation efforts. They enable higher incorporation of SCMs such as fly ash, slag, and limestone, improve particle fineness and reactivity, and reduce overall power consumption. Efficient grinding makes it possible to maintain consistent cement quality at lower clinker factors. Every improvement in energy intensity and particle engineering directly contributes to lower CO2 emissions.
As India moves toward low-carbon construction, precision grinding will remain a foundational capability for delivering sustainable, high-performance cement aligned with national and global climate objectives.
How much potential does grinding optimisation hold for immediate energy
and cost savings?
The potential for near-term savings is substantial. Without major capital investment, most plants can achieve 5 per cent to 15 per cent power reduction through measures such as improving separator efficiency, optimising ventilation, refining media grading, and fine-tuning operating parameters.
With continued capacity expansion across India, advanced optimisation tools will help ensure that productivity gains are not matched by proportional increases in energy demand. Given current power costs, this translates into direct and measurable financial benefits, making grinding optimisation one of the fastest-payback operational initiatives available to cement manufacturers today.
Concrete
Refractory demands in our kiln have changed
Published
2 weeks agoon
February 20, 2026By
admin
Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, points out why performance, predictability and life-cycle value now matter more than routine replacement in cement kilns.
As Indian cement plants push for higher throughput, increased alternative fuel usage and tighter shutdown cycles, refractory performance in kilns and pyro-processing systems is under growing pressure. In this interview, Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, shares how refractory demands have evolved on the ground and how smarter digital monitoring is improving kiln stability, uptime and clinker quality.
How have refractory demands changed in your kiln and pyro-processing line over the last five years?
Over the last five years, refractory demands in our kiln and pyro line have changed. Earlier, the focus was mostly on standard grades and routine shutdown-based replacement. But now, because of higher production loads, more alternative fuels and raw materials (AFR) usage and greater temperature variation, the expectation from refractory has increased.
In our own case, the current kiln refractory has already completed around 1.5 years, which itself shows how much more we now rely on materials that can handle thermal shock, alkali attack and coating fluctuations. We have moved towards more stable, high-performance linings so that we don’t have to enter the kiln frequently for repairs.
Overall, the shift has been from just ‘installation and run’ to selecting refractories that give longer life, better coating behaviour and more predictable performance under tougher operating conditions.
What are the biggest refractory challenges in the preheater, calciner and cooler zones?
• Preheater: Coating instability, chloride/sulphur cycles and brick erosion.
• Calciner: AFR firing, thermal shock and alkali infiltration.
• Cooler: Severe abrasion, red-river formation and mechanical stress on linings.
Overall, the biggest challenge is maintaining lining stability under highly variable operating conditions.
How do you evaluate and select refractory partners for long-term performance?
In real plant conditions, we don’t select a refractory partner just by looking at price. First, we see their past performance in similar kilns and whether their material has actually survived our operating conditions. We also check how strong their technical support is during shutdowns, because installation quality matters as much as the material itself.
Another key point is how quickly they respond during breakdowns or hot spots. A good partner should be available on short notice. We also look at their failure analysis capability, whether they can explain why a lining failed and suggest improvements.
On top of this, we review the life they delivered in the last few campaigns, their supply reliability and their willingness to offer plant-specific custom solutions instead of generic grades. Only a partner who supports us throughout the life cycle, which includes selection, installation, monitoring and post-failure analysis, fits our long-term requirement.
Can you share a recent example where better refractory selection improved uptime or clinker quality?
Recently, we upgraded to a high-abrasion basic brick at the kiln outlet. Earlier we had frequent chipping and coating loss. With the new lining, thermal stability improved and the coating became much more stable. As a result, our shutdown interval increased and clinker quality remained more consistent. It had a direct impact on our uptime.
How is increased AFR use affecting refractory behaviour?
Increased AFR use is definitely putting more stress on the refractory. The biggest issue we see daily is the rise in chlorine, alkalis and volatiles, which directly attack the lining, especially in the calciner and kiln inlet. AFR firing is also not as stable as conventional fuel, so we face frequent temperature fluctuations, which cause more thermal shock and small cracks in the lining.
Another real problem is coating instability. Some days the coating builds too fast, other days it suddenly drops, and both conditions impact refractory life. We also notice more dust circulation and buildup inside the calciner whenever the AFR mix changes, which again increases erosion.
Because of these practical issues, we have started relying more on alkali-resistant, low-porosity and better thermal shock–resistant materials to handle the additional stress coming from AFR.
What role does digital monitoring or thermal profiling play in your refractory strategy?
Digital tools like kiln shell scanners, IR imaging and thermal profiling help us detect weakening areas much earlier. This reduces unplanned shutdowns, helps identify hotspots accurately and allows us to replace only the critical sections. Overall, our maintenance has shifted from reactive to predictive, improving lining life significantly.
How do you balance cost, durability and installation speed during refractory shutdowns?
We focus on three points:
• Material quality that suits our thermal profile and chemistry.
• Installation speed, in fast turnarounds, we prefer monolithic.
• Life-cycle cost—the cheapest material is not the most economical. We look at durability, future downtime and total cost of ownership.
This balance ensures reliable performance without unnecessary expenditure.
What refractory or pyro-processing innovations could transform Indian cement operations?
Some promising developments include:
• High-performance, low-porosity and nano-bonded refractories
• Precast modular linings to drastically reduce shutdown time
• AI-driven kiln thermal analytics
• Advanced coating management solutions
• More AFR-compatible refractory mixes
These innovations can significantly improve kiln stability, efficiency and maintenance planning across the industry.
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