Technology

Low carbon technology roadmap of the Indian cement industry

Published

10 years ago

July 4, 2016

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Reducing the clinker factor in the final cement reduces CO2 both from the calcination of carbonates and from combustion of coal, but the fuel substitution rate has to go up. Facilitation is required to allow cement kilns to utilise large quantum of wastes as AFRs. Ulhas Parlikar of Geocycle India elaborates on what can happen with appropriate policy framework.

India is the second largest producer of cement next to China. The Indian cement industry is consolidated, organised and mature. The top 20 cement companies account for almost 70 per cent of the total cement production of the country (IBEF, 2014). Actual production of 250 Mt cement in 2013, meant that the industry consumed approximately 300 Mt of virgin raw material, 24 Mt of coal (MoC, 2015), 20 billion kWh electricity and emitted nearly 175 MtCO2. Due to reducing coal linkages over the years, the Indian cement industry imports over 30% of its total coal requirement, adding to the cost of producing cement.

The Indian industry?s average thermal energy consumption is estimated to be about 725 kcal/kg clinker and the average electrical energy use is about 80 kWh/t cement, much lower than the global average of 934 kcal/kg clinker and 107 kWh/t cement. The best levels achieved by the Indian cement industry, at about 680 kcal/kg clinker and 66 kWh/t cement, are comparable with the best achieved levels in the world (WBCSD CSI, 2013). The cement industry is currently using 45 Mt of fly ash from coal-based power stations and around 10 Mt of blast furnace slag from the production of pig iron (WBCSD, 2013).

The mineral waste fractions are substituting the Portland cement clinker by grinding it together in the cement mill (or separate pulverisation prior to blending). Reducing the clinker factor in the final cement reduces the CO2 both from the calcination of carbonates and from combustion of coal.

However, the Thermal Substitution Rate (TSR) or Fuel Substitution of the Indian cement industry with the utilisation of wastes from agricultural, industrial and municipal sources as alternative fuels and raw materials (AFRs) is only in the range of 1 – 2 per cent.

Waste generation scenario and cement kiln option for its gainful disposal
India generates large quantum of wastes from agricultural, Industrial and municipal sources and currently the entire waste is disposed without any recovery process. Several countries globally have utilised cement kilns as an effective option for their country?s industrial, municipal and hazardous waste disposal. This creates a win-win situation for both the local administration and the cement plants: the administration utilises the infrastructure already available at cement kilns, thereby spending less on waste management, and the cement kilns are paid by the polluter for safe waste disposal, as well as having their fuel requirements partly met.

The Cement Vision of India 2025 prepared by AT Kearney/CII has projected that the TSR of the Indian cement industry would be about 12% by 2025 and the study of the Low-Carbon Technology Roadmap for the Indian cement industry prepared by the International Energy Association, in collaboration with WBCSD, has projected the same to be 19% in 2030 and 25% in 2050.

Opportunity for resource conservation and GHG mitigation through co-processing
If the Indian cement industry is also able to move towards large-scale use of AFRs and is able to achieve the TSR as envisaged in the low carbon technology roadmap, there will be a substantial contribution that the cement industry will be able to make towards resource conservation and GHG mitigation.

The projected output of this exercise is presented in the Table-1
It can be observed that if wastes are utilised as AFRs, there is potential to conserve coal of about 11 to 16 Mio TPA in the year 2030 and about 17 to 30 Mio TPA of coal in the year 2050. In 2020 and 2030, for every Mt of cement produced, 7 000 tonnes and 25 000 tonnes of AFs need to be co-processed, respectively. This means that we will be saving an amount of coal that we are consuming at present. This also helps in mitigating an amount of GHG emissions that we are letting into the environment. India?s industrial waste is growing in volume. Out of current generation of 4 Mt of landfillable and incinerable wastes, 2.5 Mt (60%) is awaiting disposal. Studies conducted by the Ministry of New and Renewable Energy (MNRE) have estimated surplus biomass availability at about 120-150 Mt per annum covering agricultural and forestry residues. As per the Planning Commission task force report on waste to energy, of the 62 Mt of MSW generated in urban India, 12 Mt is a combustible fraction, which can be potentially converted to RDF, thereby replacing 8 Mt of coal.

Current regulatory processes are not aligned to tap this opportunity
The cement industry prefers uniform emission standards for co-processing rather than case-by-case permits. In India, it normally takes more than a year for a waste stream to get regular permits for co-processing. This is because the law and guideline mandates trial runs to be conducted for each new waste streams, requiring approvals for trial and regular usage from both state and central pollution control boards. For some special and difficult to treat hazardous wastes (pesticides, PCB, CFC, etc.), however, it is important and necessary to carry out trial burns to ensure compliance to environment and occupational health and safety.

In India itself, co-processing technology has also been used to destroy hazardous chemicals. A trial conducted at ACC-Kymore cement works, in SINTEF?s and CPCB?s supervision, demonstrated destruction and removal efficiency (DRE) of 99.9999% for concentrated CFC (chlorofluorocarbons) gases at high feeding rate in an Indian cement kiln. This shows the potential of the technology with regard to safe and sound destruction of hazardous chemicals in existing infrastructure.

The major categories of wastes that can be used by the cement industry as alternative fuels and raw materials are hazardous wastes, non-hazardous wastes, Refuse Derived Fuel (RDF), Municipal Solid Waste (MSW), shredded tyres and biomass. The major constraints in implementing large-scale co-processing of these kinds of wastes in the Indian cement industry along with the support required are elaborated in detail in the low carbon technology roadmap document.

The major constraint is the current regulatory framework that is built on the principle of disposal rather than the principle of sustainability. A permitting system resembling international best practice will probably stimulate broader interest. A revision and update of the existing guidelines and permitting requirements (addressing issues such as interstate transportation, emission limits, standard approach for utilisation of alternative sources of de-carbonated materials and mineralizers, etc.,) is regarded to be of crucial importance in order to stimulate increased co-processing practice.

Desired changes in the Indian regulatory framework
The desired changes are provided below.
I.Hazardous wastes
1)Amendment in Hazardous Waste (Management, Handling & Transboundary Movement) Rules, 2008 to:
1.Recognise co-processing in cement kiln as a preferred technology for disposal because it is a resource recovery option over landfill and incineration operation. (By this provision, the wastes that can be co-processed will not get disposed through landfill and incineration process. In fact, restrictions or limits on landfill (or inclusion of externality charges or future liability costs to landfill charges) will give impetus to co-processing initiative in India).

2.Authorise cement plants to receive, store, pre-process and co-process wastes based on the availability of required infrastructure to handle and store hazardous wastes as specified in the HWM Rules and based on prescribed emission standards.

The current waste by waste permitting process through co-processing trial is not a relevant process of approval for co-processing for following reasons: (a)The concern of the impact of the chemical constituents present in the waste on the emissions/ product quality.

(b)There are more than 20,000 waste streams that are co-processed globally. In the past 10 years, we have been able to complete trial of less than 100 waste streams. By the waste by waste trial approval process, we will never be able to move ahead.

(c)Even if a waste stream is approved for co-processing through trial, its waste characteristics are never constant. They vary from batch to batch and from time to time.

(d)While undertaking the co-processing of approved waste streams, they get blended to a new chemical composition which is completely different from all individual ones.

(e)The very purpose of implementing waste stream approval based on trial gets completely defeated.

Hence, the trial based waste by waste permitting process is not relevant at all.

Based on experience gained in India and international best practices, the desired regulatory process of approval needs to be based on (i) emission standards for cement kilns conducting co-processing, (ii) adequate infrastructure to safely handle and store wastes, (iii) appropriate laboratory facility to achieve desired input control, (iv) proper systems to monitor & control the input rates and (v) well established operational procedures for health and safety. These processes will secure the same level of environmental protection at Indian cement plants as the current EU and US regulations.

3.Allow interstate movement of hazardous wastes for cement kiln co-processing with letter of intimation to concerned SPCBs.

With this provision, waste can be moved at economically attractive distances across the states.

The pricing of waste management services is a key factor, both to ensure waste minimisation at source (to reduce disposal costs for waste generators) as well as to ensure low cost to cement manufacturers (encouraging them to install the infrastructure needed for proper handling, storage and firing at their premises) for increased TSR. The ?polluter-pays? principle should be the basis for the economic and financial analysis of waste utilisation.

II.Non-hazardous waste
To allow cement kilns, that are complying with the prescribed emission standards for co-processing, to co-process of all kinds of non-hazardous wastes in cement kilns through intimation to SPCBs.

III.RDF from MSW
To implement amendment in draft Municipal Solid Wastes (Management and Handling) Rules, 2015 to ensure that the segregated combustible fraction is not allowed to be landfilled but is converted into Refused Derived Fuel (RDF) that is suitable for use as alternate fuel in cement plants and other suitable thermal processes. Also, to institute fiscal measures that will facilitate building large number of pre-processing facilities to convert wastes into AFRs and MSW into RDF.

IV.Shredded Tyres
Shredded tyres are used extensively in the cement industry as a supplementary fuel and MoEFFCC/CPCB may want to consider ways to increase the availability in India.

V.Biomass
Co-processing of biomass leads to complete energy recovery and this process is much more energy efficient, even compared to biomass-based power plants. Incentives should be given for biomass utilisation in cement kilns akin to that given for biomass-based power plants.

International co-operation for assimilating Technology, Skills and Policy (TSP) framework to leap-frog
Co-processing in cement kilns is a widely practiced activity in many countries for management of wastes. The technological infrastructure required for implementing large scale co-processing is well established and operated. The skills are well developed with the operating teams to operate the kilns with large quantum of wastes and produce the right quality cement product. In these countries, the legislative processes are also designed and practiced with preference to recovery technologies such as co-processing. The TSR in these countries is therefore very high.

Our experience in the country of the past 10 years suggests to us that AFR co-processing growth takes place with a reasonable learning curve and support available from the international co-operation helps a lot. The Indian cement industry is already collaborating with several knowledge partners in utilising this lever for using large amount of wastes as AFRs in the cement kilns. Several international cement players that are implementing large scale co-processing in their plants in different countries, such as LafargeHolcim, Hiedelberg, CRH, VICAT, Italicement, etc are already operating in India and several Indian cement players such as Ultratech, Dalmia, etc., are also sourcing international co-operation in bridging the technical and skill gap in implementing large scale utilisation of AFRs.

CPCB has been closely working with the Norwegian research organisation SINTEF for the last few years and has been able to contribute towards building capacity and confidence among various stakeholders on the viability of safe and sound co-processing. We consider that co-operation of Indian policy-making bodies with agencies like SINTEF, who have been working closely with the authorities and industries in such countries, can facilitate quicker assessment of the policy level hurdles encountered in implementing large scale management of wastes as AFRs through co-processing and implementing fitting solutions to deal with them from the policy and operational considerations.

Low carbon technology roadmap
Table-1

Parameter	Unit	Base case	Low demand			High Demand
		2010	2020	2030	2050	2020	2030	2050
Cement Production	Mio TPA	217	416	598	780	492	848	1361
Clinker to Cement Ratio		0.74	0.7	0.64	0.58	0.7	0.64	0.58
Thermal Intensity of clinker production	Kcal / Kg Clinker	725	709	694	680	703	690	678
Alternative Fuel share in total energy used	%	0.6	5	19	25	5	19	25
Coal conserved having CV of 4,500 Kcal/Kg	Mio TPA	0.16	2.3	11.2	17.1	2.7	15.8	29.7
CO₂ emission reduced	Mio TPA	0.19	2.8	13.8	21.0	3.3	19.4	36.5

Economy & Market

Precision in Motion

Published

2 weeks ago

June 17, 2026

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A deep dive into Power Build’s core gear series products – M, C, F, K

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 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.

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

Economy & Market

TSR Will Define Which Cement Companies Win India’s Net-Zero Race

Published

2 months ago

April 27, 2026

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Jignesh Kundaria, Director and CEO, Fornnax Technology

India is simultaneously grappling with two crises: a mounting waste emergency and an urgent need to decarbonise its most carbon-intensive industries. The cement sector, the second-largest in the world and the backbone of the nation’s infrastructure ambitions, sits at the centre of both. It consumes enormous quantities of fossil fuel, and it has the technical capacity to consume something else entirely: the waste our cities cannot get rid of.

According to CPCB and NITI Aayog projections, India generates approximately 62.4 million tonnes of municipal solid waste annually, with that figure expected to reach 165 million tonnes by 2030. Much of this waste is energy-rich and non-recyclable. At the same time, cement kilns operate at material temperatures of approximately 1,450 degrees Celsius, with gas temperatures reaching 2,000 degrees. This high-temperature environment is ideal for co-processing, ensuring the complete thermal destruction of organic compounds without generating toxic residues. The physics are in our favour. The infrastructure is not.

Pre-processing is not the support act for co-processing. It is the main event. Get the particle size wrong, get the moisture wrong, get the calorific value wrong and your kiln thermal stability will suffer the consequences.

The Regulatory Push Is Real

The Solid Waste Management (SWM) Rules 2026 mandate that cement plants progressively replace solid fossil fuels with Refuse-Derived Fuel (RDF), starting at a 5 per cent baseline and scaling to 15 per cent within six years. NITI Aayog’s 2026 Roadmap for Cement Sector Decarbonisation targets 20 to 25 per cent Thermal Substitution Rate (TSR) by 2030. Beyond compliance, every tonne of coal replaced by RDF generates measurable carbon reductions which is monetisable under India’s emerging Carbon Credit Trading Scheme (CCTS). TSR is no longer a sustainability metric. It is a financial lever.

Yet our own field assessments across multiple Indian cement plants reveal a sobering reality: the primary barrier to scaling AFR adoption is not waste availability. It is the fragmented and under-engineered pre-processing ecosystem that sits between the waste and the kiln.

Why Indian Waste Is a Different Engineering Problem

Indian municipal solid waste is not the material that imported shredding equipment was designed for. Our waste streams frequently exceed 40 per cent to 50 per cent moisture content, particularly during monsoon cycles, saturated with abrasive inerts including sand, glass, and stone. Plants relying on imported OEM equipment face months of downtime awaiting proprietary spare parts. Machines built for segregated, low-moisture waste fail quickly and disrupt the entire pre-processing operation in Indian conditions.

The two most common failures we observe are what I call the biting teeth problem and the chewing teeth problem. Plants relying solely on a primary shredder reduce bulk waste to large fractions, but the output remains too coarse for stable kiln combustion. Others attempt to use a secondary shredder as a standalone unit without a primary stage to pre-size the feed, leading to catastrophic mechanical failure. When both stages are present but mismatched in throughput capacity, the system becomes a bottleneck. Achieving the 40 to 70 tonnes per hour required for meaningful coal displacement demands a precisely coordinated two-stage process.

Engineering a Made-in-India Answer

At Fornnax, our response to these challenges is grounded in one principle: Indian waste demands Indian engineering. Our systems are built around feedstock homogeneity, the holy grail of kiln stability. Consistent particle size and predictable calorific value are the foundation of stable kiln combustion. Without them, no TSR target is achievable at scale.

Our SR-MAX2500 Dual Shaft Primary Shredder (Hydraulic Drive) processes raw, baled, or loosely mixed MSW, C&I waste, bulky waste, and plastics, reducing them to approximately 150 mm fractions at throughputs of up to 40 tonnes per hour. The R-MAX 3300 Single Shaft Secondary Shredder (Hydraulic Drive), introduced in 2025, takes that primary output and produces RDF fractions in the 30 to 80 mm range at up to 30 tonnes per hour, specifically optimised for consistent kiln feeding. We have also introduced electric drive configurations under the SR-100 HD series, with capacities between 5 and 40 tonnes per hour, already operational at a leading Indian waste-processing facility.

Looking ahead, Fornnax is expanding its portfolio with the upcoming SR-MAX3600 Hydraulic Drive primary shredder at up to 70 tonnes per hour and the R-MAX2100 Hydraulic drive secondary shredder at up to 20 tonnes per hour, designed specifically for the large-scale throughput that higher TSR ambitions require.

The Investment Case Is Now

The 2070 Net-Zero target is not a distant goal for India’s cement sector. It starts today, with decisions being made on the plant floor.

The SWM Rules 2026 are already in effect, requiring cement plants to replace coal with RDF. Carbon credit markets are opening up, and coal prices are not going to get cheaper. Every tonne of coal a cement plant replaces with waste-derived fuel saves money on one side and generates carbon credit revenue on the other. Pre-processing infrastructure is no longer just a compliance requirement. It is a business investment with a measurable return.

The good news is that nothing is missing. The technology works. The waste is available in every Indian city. The government has provided the policy direction. The only thing standing between where the industry is today and where it needs to be is the commitment to build the right infrastructure.

The cement companies that move now will not just meet the regulations. They will be ahead of every competitor that waits.

About The Author

Jignesh Kundaria is the Director and CEO of Fornnax Technology. Over an experience spanning more than two decades in the recycling industry, he has established himself as one of India’s foremost voices on waste-to-fuel technology and alternative fuel infrastructure.

Concrete

Reimagining Logistics: Spatial AI and Digital Twins

Published

3 months ago

April 13, 2026

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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.