The cement industry, vital for global infrastructure, faces the dual challenge of meeting rising demand while addressing environmental concerns. Kanika Mathur explores how innovative practices and sustainable solutions are transforming the sector towards a greener future.

The cement industry, a cornerstone of global infrastructure development, has long been associated with significant environmental challenges. Cement production is responsible for approximately seven per cent to eight per cent of global CO2 emissions, making it one of the most carbon-intensive industries. However, with increasing awareness and global commitments to combat climate change, the industry is undergoing a green transformation.
This article delves into the critical aspects of sustainability in the cement industry, highlighting innovative practices, technological advancements, and policy frameworks that are reshaping the sector.

Environmental impact
Cement production involves the calcination of limestone, a process that releases large amounts of CO2. Additionally, the energy-intensive nature of the industry contributes to emissions from fossil fuel combustion. The environmental impact extends to resource depletion, dust emissions, and water usage, emphasising the need for sustainable practices.
In India, where demand for cement is expected to grow exponentially due to infrastructure projects, addressing these challenges is critical. Companies must adopt sustainable strategies to balance economic growth with environmental stewardship.

Low carbon cement and clinker substitutes
One of the most effective ways to reduce emissions in cement production is by replacing clinker, the most carbon-intensive component, with alternative materials. Fly ash, slag, and natural pozzolans are commonly used substitutes that reduce the clinker factor in cement.
Björn Fahle, Technical Sales and Project Engineer, Westeria, says, “Sustainability is a critical concern for the cement industry, especially in the context of reducing CO2 emissions. India has made remarkable progress in achieving its 2030 carbon emission targets, and the cement sector has been a significant contributor to this effort. By integrating alternative fuels into their operations, cement producers can significantly lower their carbon footprint.”
“We also foresee advancements in green cement production, with materials such as clay coming into the picture. Our work helps the cement industry transition towards greener practices by promoting the use of alternative fuels and improving the efficiency of fuel feeding systems. Sustainability is no longer optional—it is imperative for long-term environmental and industrial health. By reducing coal consumption and utilising alternative raw materials, we are steadily contributing to the industry’s shift toward sustainable operations” he adds.
For example, India’s Ambuja Cement has developed a range of low-carbon cement products that use supplementary cementitious materials (SCMs), significantly lowering their carbon footprint. Such innovations are key to achieving industry-wide sustainability.

Alternative fuels and raw materials
The use of alternative fuels and raw materials (AFR) is gaining momentum as a sustainable practice in cement manufacturing. Waste materials like industrial by-products, municipal solid waste, and biomass are increasingly being utilised as fuel sources, reducing dependency on fossil fuels. UltraTech Cement has pioneered the use of AFR in India, implementing co-processing technologies to convert waste into energy. This not only cuts emissions but also addresses waste management challenges, contributing to a circular economy.

Energy efficiency
Energy accounts for a significant portion of the costs and emissions in cement production.
Energy-efficient technologies, such as vertical roller mills, preheater-precalciner systems, and waste heat recovery (WHR) systems, play a crucial role in reducing energy consumption.
“The journey towards net zero is advancing steadily. In 2018, we at Dalmia Cement announced our carbon-negative and net zero roadmap during COP24. This commitment inspired other companies worldwide to adopt similar strategies. By COP26 in Glasgow, the Global Cement and Concrete Association committed to achieving net-zero cement and concrete by 2050,” says Mahendra Singhi, Member of Board of Governors and Strategic Advisor, Dalmia Cement (Bharat).
“The global cement sector has been proactive, embracing new technologies and sustainability practices. Indian companies, too, are leading the way with innovative strategies and strong commitments. I am optimistic that within the next 10 to 25 years, the Indian cement industry will make significant strides towards achieving net zero, setting a benchmark for other industries globally,” he adds.
Dalmia Cement has set a benchmark in India with its commitment to energy efficiency. The company’s investments in WHR systems have reduced reliance on grid electricity and lowered overall energy costs. Such initiatives demonstrate the dual benefits of cost savings and sustainability.

Carbon capture, utilisation and storage
Carbon capture, utilisation, and storage (CCUS) technologies are emerging as a game-changer for the cement industry. These technologies capture CO2 emissions from production processes and either store it underground or use it to create new products.
Saurabh Rai, CEO, Arahas, says, “One of the most promising technologies emerging in the cement industry is carbon capture, utilisation and storage (CCUS). CCUS allows companies to capture CO2 emissions before they are released into the atmosphere and either store them or repurpose them for other uses. This technology not only reduces emissions but also turns carbon into a valuable resource. Captured CO2 can be used in the production of synthetic fuels or other materials, adding an innovative twist to what was once considered waste.”
“Beyond CCUS, cement manufacturers are increasingly moving away from traditional fossil fuels, which have historically been a significant source of emissions. In their place, alternative energy sources like biomass and waste-derived fuels are being utilised. These renewable fuels not only help to cut emissions but also align with circular economy principles, where waste is redefined as a resource rather than a burden,” he adds.
Though still in its nascent stages in India, CCUS projects have shown promise globally. Indian
cement companies are beginning to explore partnerships and pilot projects to adapt these technologies to
local conditions, paving the way for large-scale implementation.
“India’s commitment to a net zero target by 2070 faces significant challenges, according to the World Economic Forum (WEF). The nation is the third-largest emitter of GreenHouse Gases after China and the US, and has the potential to meet this goal; they emphasise the need for more concrete sectoral targets, trajectories, and short-term milestones. The urgency for this initiative is underscored by India’s status as home to some of the world’s most polluted cities, contributing to high pollution-related mortality rates. Additionally, funding remains a critical issue as achieving the 2070 target requires an investment of $10.1 trillion; if the goal is accelerated to 2050, this figure increases to $13.5 trillion,” says Pushpank Kaushik, CEO & Head of Business Development (Subcontinent, Middle East and SouthEast Asia), Jassper Shipping.

Circular economy and waste management
The adoption of a circular economy model is essential for sustainable cement production. This involves using industrial waste as raw material, recycling by-products, and minimising waste generation. Fly ash from thermal power plants, slag from steel mills, and waste-derived fuels are valuable resources in this context. For instance, JSW Cement’s focus on utilising industrial waste has allowed the company to manufacture Portland Slag Cement (PSC), which not only reduces emissions but also conserves natural resources. Circular economy practices offer a win-win solution for industry and the environment.

Digital technologies for sustainability
Digitalisation is transforming the cement industry, enabling better resource management and emission control. Technologies like IoT, AI, and big data analytics allow companies to monitor emissions, optimise production, and enhance energy efficiency.

MSR Kaliprasad, Chief Digital and Information Officer, Shree Cement, says, “Our commitment to sustainability is deeply embedded in our digital strategy. We integrate power and production data captured through sensors with SAP S4 HANA, enabling real-time tracking of power efficiency and consumption, optimising energy use across operations. Renewable energy projects, such as the solar plant in Beawar (Rajasthan) and wind plants in Kushtagi and Jath, are monitored digitally to ensure optimal performance. Digital tools effectively help monitor, manage and reduce our environmental footprint, aligning with our sustainability goals.”
Companies like ACC Cement are leveraging digital solutions to create ‘smart factories’ that minimise environmental impact while maximising operational efficiency. These tools are crucial for achieving sustainability goals and improving competitiveness.
Utssav Gupta, Director, Supertech Fabrics, says, “Globally, energy balance structures are being implemented as part of bottom-up strategies. We need to determine where energy costs can be optimised, such as through renewable energy sources. For example, in emission control systems, power costs are a significant concern. Our innovation efforts target two primary areas: reducing the power costs associated with emission control and achieving
lower emissions levels. My pitch to stakeholders is to consider a one-time investment in renewable energy to address these challenges. With this approach, emissions are reduced, recovery is improved, and everyone benefits.”

Sustainable logistics
Transportation contributes significantly to the carbon footprint of cement. Sustainable logistics solutions, such as using energy-efficient vehicles, optimising transport routes, and shifting from road to rail, can significantly reduce emissions. Indian Railways’ initiatives to promote freight corridors for bulk transportation have provided cement companies with an opportunity to transition to more sustainable logistics solutions. Such collaborations between industry and infrastructure providers are critical for long-term sustainability.

Role of policy and regulation
Government policies and regulations are instrumental in driving sustainability in the cement industry. In India, initiatives like the PAT (Perform, Achieve, Trade) scheme under the National Mission for Enhanced Energy Efficiency (NMEEE) encourage energy-efficient practices. The Cement Sustainability Initiative (CSI), a global effort under the World Business Council for Sustainable Development (WBCSD), also provides guidelines for sustainable practices. Indian companies actively participating in such frameworks are better positioned to align with global sustainability goals.

Future trends in sustainable cement manufacturing
The future of sustainability in the cement industry lies in innovation and collaboration. Technologies like green hydrogen, advanced CCUS, and zero-carbon fuels are on the horizon. Collaboration between governments, industry players, and technology providers will be critical for achieving these breakthroughs. In India, the transition to green energy sources, coupled with innovations in production and logistics, will determine the industry’s ability to meet its ambitious sustainability targets. Companies that invest in R&D and embrace a long-term vision will lead this transformation.

Conclusion
Sustainability in the cement industry is no longer an option—it is a necessity. With growing pressures from regulators, consumers, and global environmental commitments, the industry must adopt innovative and responsible practices. From low-carbon cement and AFR to digitalisation and sustainable logistics, the path forward is filled with opportunities for growth and transformation.
India, as one of the largest cement producers in the world, has the potential to set an example in sustainable practices. By embracing new technologies, prioritising energy efficiency, and fostering a culture of innovation, the cement industry can contribute to a greener, more sustainable future while ensuring its own long-term success.

MSR Kaliprasad, Chief Digital and Information Officer, Shree Cement, shares his ideas about digitalisation with Kanika Mathur.

Digitalisation is revolutionising the cement manufacturing process, driving efficiency, sustainability, and innovation across operations. Understanding the impact of digitalisation on plant performance and efficiency involves getting an insider’s perspective. Through this interview, we endeavour to bring various aspects of technology that are affecting the march towards Net Zero.

How has digitalisation transformed operational efficiency and productivity in the cement manufacturing process?
Digitalisation has revolutionised our operational efficiency and productivity by centralising control and enhancing real-time decision making . Each of our plants has a central control room equipped with SCADA and PLC systems that manage the entire manufacturing process. Key parameters captured from numerous sensors are stored in our IIoT historian, providing a comprehensive view of operations from limestone mining to cement dispatch. This integration has minimised manual interventions and enabled near real-time operational insights through BI dashboards accessible at all management levels. As a result, we have seen significant improvements in process optimisation, resource utilisation and overall productivity, ensuring we consistently meet production targets and deliver high-quality cement to our customers.

Can you share examples of advanced technologies currently being adopted in cement manufacturing, such as AI, IoT, or machine learning?
We are actively integrating advanced technologies to enhance our manufacturing processes. Our platform leverages IoT to collect and store data from various sensors across the plant. Additionally, robotic systems are employed for sample collection, preparation and testing using XRF and XRD machines, ensuring precise quality control. Machine learning and AI are being utilised for predictive maintenance, where models predict equipment failures before they occur, reducing downtime and maintenance costs. Automated process control and blending optimisation technologies deployed in our cement and raw mills enhance efficiency and consistency.

What role does automation play in improving the accuracy and speed of processes across cement production?
Automation plays a critical role in improving both accuracy and speed across our production processes. By automating operations through SCADA systems and PLCs, we ensure precise control over key manufacturing parameters, reducing human error and increasing consistency. Robotic systems used for sample handling and automated testing accelerate quality assurance while providing reliable data. Automated process control further streamlines production, enabling faster adjustments and minimising downtime while maintaining high-quality standards.

How has digitization helped in predictive maintenance for critical equipment in cement plants, and what benefits have you observed?
Digitalisation has been pivotal in shifting our maintenance strategy to a predictive approach. By capturing granular data on key parameters and equipment vibrations, we are building AI/ML models that predict potential failures before they occur. This proactive approach reduces maintenance costs and improves equipment uptime and availability. Predictive models address issues in critical machinery
before they lead to costly breakdowns, enhancing operational reliability.

Could you discuss the impact of digital tools on quality control and consistency in cement production?
Digital tools have significantly improved quality control and consistency in cement production. All quality data, including results from bomb calorimeters, compression strength testing machinery and other equipment, are centrally stored in our historian. This centralised repository enables seamless analysis and reporting, ensuring consistent quality standards across all production stages. Automated testing and
robotic sample handling minimise human error, further enhancing the accuracy and reliability of our quality assessments.

How does your company use digital technology to monitor and reduce environmental impact and emissions?
Our commitment to sustainability is deeply embedded in our digital strategy. We integrate power and production data captured through sensors with SAP S4 HANA, enabling real-time tracking of power efficiency and consumption, optimising energy use across operations. Renewable energy projects, such as the solar plant in Beawar (Rajasthan) and wind plants in Kushtagi and Jath, are monitored digitally to ensure optimal performance. Digital tools effectively help monitor, manage and reduce our environmental footprint, aligning with our sustainability goals.

What challenges have you faced in implementing digital solutions in cement manufacturing, and how have these been overcome?
Implementing digital solutions in cement manufacturing necessitates change management. Transitioning to a digitalised environment required a significant shift in organisational culture and employee mindset. To address this, we launched a capability-building programme to train our workforce at all levels on new technologies and ways of working. Additionally, integrating diverse digital systems like IIoT historian and SAP S4 HANA require meticulous planning and a robust IT infrastructure. We are fostering a culture of continuous learning and investing in our technology backbone with future-ready cloud computing tools that support advanced analytics and AI/ML.

How has digitalisation improved the supply chain and logistics in cement distribution?
Digitalisation has significantly enhanced supply chain and logistics operations. GPS tracking across our truck fleet provides real-time visibility to both our supply chain team and customers via our apps. This track-and-trace capability ensures timely deliveries and improves customer satisfaction. Our ongoing supply chain transformation project leverages digital tools to implement a robust Sales and Operations Planning (S&OP) process. This initiative helps us optimise logistics costs and increase reach while meeting our EBITDA goals. Advanced
network optimisation tools alongside an intelligent GIS platform and a prescriptive order management solution for trade customers ensure effective service at optimised costs.

What impact has technology had on enhancing workplace safety in high-risk areas of cement production?
Technology has played a crucial role in enhancing workplace safety across high-risk areas in cement production. Our Hazard Identification and Risk Assessment (HIRA) system proactively identifies and mitigates potential risks before an incident occurs. Regular safety inspections, mock drills and ongoing training ensure consistency and effectiveness. Our mobile-first ‘boots on ground’ tool empowers frontline personnel to report safety issues directly from the field. The SAP PM module further enhances safety by tracking walk-by inspections, breakdowns and remedial actions in real time. These technologies foster a ‘zero-injury’ culture by ensuring safety protocols are rigorously followed.

Looking forward, which digital or technological advancements do you see as having the greatest potential to shape the future of the cement industry?
Several digital and technological advancements hold immense potential to shape the cement industry’s future. GenAI will scale AI/ML across the value chain, enabling foundation models to be leveraged at all locations without specific ML models. Use cases like cement strength prediction, fineness optimisation and cyclone jamming prediction will further enhance efficiency and quality. Advanced pricing analytics will enable targeted customer strategies to ensure profitability. These advancements, coupled with a customer-centric approach and a future-ready workforce, will keep us at the forefront of innovation in the cement industry.

The cement industry’s evolution hinges on innovations in bagging, packaging, and palletising—critical processes that ensure product quality, operational efficiency and customer satisfaction. Kanika Mathur delves into the latest trends, challenges and advancements shaping these processes in India’s dynamic cement sector.

The cement industry stands at the crossroads of rapid transformation, driven by demands for higher operational efficiency, reduced costs, and sustainable practices. Among the various processes’ integral to the production and distribution of cement, bagging, packaging, and palletising are crucial for ensuring product quality, customer satisfaction, and logistical effectiveness. These processes not only determine how efficiently the product is delivered to the market but also influence the overall profitability and reputation of cement manufacturers.
In India, where the cement industry is one of the largest in the world, these operations have seen significant advancements over the years. However, challenges such as manual labour dependency, outdated technology, and environmental concerns continue to hinder optimal performance. This article explores the current trends, innovations, and challenges in bagging, packaging, and palletising within the cement industry, highlighting real-world examples and strategies for future growth.

Trends in cement packaging
Packaging has evolved significantly in the cement industry, transitioning from simple manual techniques to highly sophisticated automated systems. Today, the focus is on providing eco-friendly and durable solutions that meet the demands of customers while adhering to environmental standards. Traditional woven polypropylene (WPP) bags have been the industry standard for years, offering a balance between cost and functionality. However, the global shift towards sustainability has driven the adoption of biodegradable and recyclable alternatives.
Riddhish Pandey, Associate General Manager (Packing Plant), Wonder Cement, says, “The adoption of multi-layered packaging materials, such as woven polypropylene (WPP) bags, has significantly improved the durability and strength of cement packaging. WPP bags offer enhanced resistance to moisture, tearing, and wear and tear, which is crucial during handling, transportation, and storage. These bags are particularly effective in protecting the cement from environmental factors that could compromise its quality. In addition to WPP bags, some companies are exploring the use of biodegradable or recycled materials as a sustainable alternative. These materials provide a balance between durability and environmental responsibility, helping to reduce the overall environmental impact of cement packaging without sacrificing product integrity.”
“Moreover, adding protective coatings and lamination to packaging has further strengthened the cement bags’ ability to withstand external pressures. These additional layers help maintain the integrity of the cement by providing an extra shield against moisture, dust, and other contaminants, ensuring the product remains in optimal condition during both storage and transit. This combination of advanced materials and protective measures enhances the overall quality of cement distribution, benefiting both the environment and customers” he adds.
In India, UltraTech Cement has been at the forefront of this change. The company introduced recyclable packaging for select products, showcasing its commitment to reducing its environmental footprint. This initiative has set a benchmark for other manufacturers, encouraging them to explore sustainable packaging options. Automated packaging lines, which ensure precision and consistency, are also becoming increasingly popular, allowing companies to reduce wastage and enhance efficiency.

Automation in bagging and packaging
Automation has revolutionised bagging and packaging processes in the cement industry, offering unparalleled benefits in terms of speed, accuracy, and reliability. Automated bagging machines are capable of handling large volumes with minimal human intervention, ensuring consistent bag weight, precise sealing, and reduced spillage.
Companies such as Wonder Cement have adopted state-of-the-art automated bagging systems that integrate features like real-time monitoring and self-calibration. These systems not only minimise downtime but also enable operators to monitor performance remotely, ensuring that the packaging process aligns seamlessly with production schedules. The result is an optimised workflow that enhances overall plant efficiency and meets customer demands promptly.
Gaurav Gautam, Business Unit Head, Beumer Group, says, “The bagging, packaging, and palletising area is crucial in cement plants as this is where revenue generation happens for our customers. Unfortunately, this area often lacks the same efficiency focus as other sections and continues to employ significant manpower. It is also less human-friendly, as workers still handle 50 kg bags under challenging conditions. We are committed to automating these processes and working alongside our customers to identify and resolve challenges. However, introducing automation requires a supportive ecosystem. Innovative equipment alone isn’t enough if the ecosystem isn’t prepared.”
“We approach this as a partnership with our customers, where we understand their problems—whether it’s space issues or challenges with manual loading. While full automation will take time, we have made significant progress. Several of our customers, such as UltraTech, Holcim and Wonder Cement, have already adopted automation, particularly on the loading side of bagging lines,” he adds.
Additionally, automation reduces the reliance on manual labour, addressing challenges such as worker fatigue, errors, and safety concerns. This shift is particularly significant in India, where labour intensive practices have long dominated the industry. By investing in automated solutions, manufacturers can improve productivity while creating safer working environments for their employees.

Importance of bag quality
The quality of bags used in packaging plays a vital role in ensuring the smooth operation of bagging lines and the durability of the product during transportation and storage. Substandard bags can lead to issues such as spillage, breakage, and moisture infiltration, resulting in financial losses and reduced customer satisfaction.
In the Indian cement industry, woven SDP bags are still widely used. While cost-effective, these bags often lack the durability and sealing capabilities required for optimal performance. High-density polyethylene (HDPE) bags, which offer superior strength and moisture resistance, are emerging as a preferred alternative.
To exemplify, Shree Cement has been experimenting with advanced bag designs that enhance sealing and durability. These improvements not only reduce product loss during transportation but also ensure that the cement reaches customers in pristine condition. By prioritising bag quality, manufacturers can enhance their brand image and build long-term customer loyalty.

Palletising: The shift towards hydbrid models
Palletising represents a significant step forward in the packaging and distribution process. Unlike traditional live operations, where bags are filled and dispatched simultaneously, palletising involves buffering bags onto pallets before loading them onto transport vehicles. This method decouples filling and loading operations, allowing for greater flexibility, reduced bottlenecks, and improved efficiency.
While many Indian cement plants are still in the early stages of adopting palletising, pioneers like Ambuja Cement are leading the way. The company has introduced hybrid models that combine manual and automated processes, ensuring a smoother transition from traditional methods to fully automated systems. These palletising solutions not only improve loading efficiency but also enhance safety by minimising manual handling of heavy bags.
In global markets, palletising has become the norm, with European and American manufacturers leveraging advanced robotics and software to optimise operations. As the Indian cement industry continues to modernise, the adoption of palletising is expected to gain momentum, bringing significant benefits in terms of speed, accuracy, and safety.

Dust-free and moisture-controlled packaging environments
Creating a dust-free and moisture-controlled environment is essential for preserving cement quality and ensuring the health and safety of workers. Dust generated during the packaging process can lead to product loss, environmental pollution, and respiratory issues for employees. Similarly, exposure to moisture can cause cement to harden prematurely, rendering it unusable.
To address these challenges, modern cement plants are investing in advanced dust collection systems, moisture barriers, and air-tight packaging technologies. Automated loading machines, for example, are designed to operate close to truck beds, minimising fugitive dust and ensuring precise bag placement.

Digital transformation in bagging and packaging
The integration of digital tools into bagging and packaging processes is revolutionising the cement industry. From predictive maintenance to real-time monitoring, digital technologies enable manufacturers to optimise operations, reduce downtime, and enhance overall equipment effectiveness.
IoT-based solutions are particularly transformative, allowing plant managers to collect and analyse data on machine performance, production rates, and maintenance needs. For instance, Dalmia Cement has introduced digital tools that provide actionable insights into its bagging and packaging operations. These systems help identify potential issues before they escalate, ensuring that equipment remains operational and production schedules
are maintained.

Sustainability quotient
Sustainability has become a critical focus area for the cement industry, with packaging practices playing a key role in achieving environmental goals. By transitioning to biodegradable materials, reducing plastic use, and adopting energy-efficient machinery, manufacturers can minimise their environmental impact while meeting regulatory requirements.
Dalmia Cement’s exploration of biodegradable packaging is a notable example of this commitment. By aligning packaging practices with sustainability objectives, the company not only reduces its carbon footprint but also strengthens its reputation as an environmentally responsible organisation.

Challenges and opportunities in India
Despite significant advancements, the Indian cement industry continues to face challenges in bagging, packaging, and palletising. Infrastructure limitations, workforce training gaps, and the high cost of adopting advanced technologies are major barriers. Additionally, the reliance on traditional bags and manual operations in many plants limits efficiency and increases operational risks.
However, these challenges also present opportunities for innovation and growth. By investing in automation, embracing digital tools, and prioritising sustainability, Indian cement manufacturers can enhance their competitive edge and contribute to the industry’s overall development.

Conclusion
Bagging, packaging, and palletising are not just operational processes—they are strategic enablers that shape the future of the cement industry. By adopting advanced technologies, improving bag quality, and transitioning to hybrid and automated models, Indian cement manufacturers can overcome existing challenges and unlock new opportunities. As the industry embraces innovation, sustainability, and ecosystem readiness, it is well-positioned to achieve long-term success in an increasingly competitive global market.