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Maximising Efficiency

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Kiln along with refractories constitute important areas of higher productivity of the cement plants. Refractories (though unseen) play a critical role in both the rotary kiln lining, and the lining of the high volume static equipment areas that comprise a modern precalciner kiln system. ICR provides an in-depth review on the importance of refractories in the cement industry.

The refractory though unseen from outside, plays a crucial role during plant operation, since the materials that are used to line different vessels from inside are generally not visible. There are two different areas of application: one used during moving the equipment, and the other used in static equipment. Rotary kiln and coolers are a part of moving/rotating equipment, while preheaters and precalciner are static hardware. However lining of a kiln still remains a challenging job – both with respect to materials and application.

The availability of a rotary kiln is highly dependent on the state of the refractory lining. Depletion of the refractory lining can lead to significant failures with fallout of bricks or castable that may require shutdown of the production. Unplanned shutdowns can cause very high production losses. Refractory products are often used in harsh service environment and therefore are prone to degradation. Tolerance to temperature, mechanical loads, thermal cycling, wear and chemical resistance are some of the common causes of degradation. Generally, the lining of kiln lasts for a period of minimum 10-11 months but there can be a few exceptions, subject to the operating conditions and other effects.

It has been experienced that however good the material may be but if not applied correctly will not give satisfactory results. This is more so in case of castable and other type of monoliths. The application of refractory is more of a civil engineering job, and therefore many plants employ civil engineers as refractory engineers. Over a period of time, many changes have happened in the materials of linings. Multi-location large plants have standardised the shapes so as to have minimum inventory. Earlier the use of alumina bricks was common because of easy availability. Later it was changed to mag-chrome bricks, which were found environmentally hazardous. Therefore slowly the mag-chrome bricks have been phased out and have been replaced with magnesite bricks. Though in Europe and the US these have been banned long ago.

Today in the industry, the trend is to source magnesite bricks from 3-4 worldwide suppliers. These bricks mainly go in the burning zone of a kiln. Alumina bricks still find their use in other part of the kiln and also in the coolers and preheaters and precalciner zone. Talking about the lining job itself, as stated in the article of Bricking Solutions, there have been a lot of improvement in the technique including that of the safety measures. It is very much appreciable that a number of accidents during lining jobs have gone down considerably because of availability of suitable devices and safety gadgets.

Apart from bricks, monolithic refractories like castable and plastic materials are also used at different locations. Generally, plastic refractory materials are used in repairing jobs, where without stopping the equipment, a job can be carried out, whereas in case of castable there has been a wide range of materials that available depending on the location of application. The important aspect of castable is the application technique, which is very important to follow. Here the role of the application engineer plays a significant role for the success of material. In case of low cement or cement-less castable, the water addition beyond a limit can create havoc and will never give the desired results. It is better to hire an expert agency to carryout the job.

In case of lining job also, there are mechanised ways of doing the job through brick laying machines. These machines are also used for removal of old lining from the kiln, which saves a considerable time. There are safety cages and movable platforms for use which makes the job a lot easier.

Actually the performance of lining depends on several factors. Assuming that the correct materials are used and right procedure is still followed, the performance can be way below the expectations.

A large number of kiln now use alternative fuels. Many of them substitute these alternative fuels through the main kiln burner as well as in the preheater/precalciner. The chemical reactions caused by fluctuations in the fuel(s) mix has a major influence on the coating and atmospheric conditions existing through the rotary kiln into the precalciner. The other factor that needs attention is the chemistry of raw meal and that of coal as fuel. Certain ingredients present in coal or in raw meal can be deleterious to the refractory lining.

The kiln lining over a period of time developes a coating on the brick lining and reduces its damage. When the lining is new, efforts are taken by plant personnel to form good uniform coating on the new lining so as to enhance its life. Premature failure of refractory lining has always been a subject of research. In situ testing and some laboratory tests can be the useful to find the root cause. The durability of the rotary kiln lining generally determines the time length of kiln operation. Whilst great efforts are made to ensure appropriate refractory material selection, installation, deployment (zoning) and the optimisation of the kiln light-up, etc., it is primarily the nature and stability of the subsequent kiln operation that influences rotary kiln lining life. Today the consumption of refractory materials is around 300-400 gm per tonne of cement produced, which is quite comparable to the world?s best figures. In deed the performance of men and materials is appreciable.

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Economy & Market

Power Build’s Core Gear Series

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A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

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Economy & Market

Conveyor belts are a vital link in the supply chain

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Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.

In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.

Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.

How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.

How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.

What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.

How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.

What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.

How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.

What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.

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Economy & Market

Impactful Branding

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Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.

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