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The Indian cement industry is paying sub-optimum attention to brand management, despite two-thirds of its volumes being in the consumer market, says YOGI VASHISHTA.

Today, most successful businesses are valued far more than the value of their tangible assets by the market. Globally, brands as assets are estimated to account for approximately one-third of all corporate wealth. In this context, it is important to interrogate how brands are being paid attention by the Indian cement industry.

One quick way to judge the importance of branding by an industry is to peer into its M&As and see how much have the brands been valued in those transactions. It is informative indeed to see what assets have been prioritised as sources of value in arriving at fair valuation in some of the recent M&As in the cement industry in India. Brands as assets have hardly featured in arriving at the enterprise value. Most mid- and small-size cement companies have had their enterprise value lower than even the current replacement cost of the tangible assets. An enterprise value even marginally higher than the replacement cost is considered admirable for a cement company – such is the pre-eminence of the tangible assets in valuing a business in this industry! Even those assets that have had their enterprise value higher than their replacement value were so valued because of their operational efficiencies and higher productivity. Brands didn’t feature much for what value they brought to the business.

Every industry has its unique complexities that inform its valuation perspective. The cement industry has its own reasons to prioritise the quality and strategic fit of the tangible operating assets, but does it have to be at almost a complete exclusion of the value of brand as an asset?

Granted, it doesn’t help that most cement brands are actually the corporate names, which, in an acquisition scenario, present their own unique use/ownership issues. However, the corporate history world over is replete with examples when a corporate brand name has been bought over for the consumer goodwill and equity of the brand, and the new owners have carefully transferred the said equity to another brand. Obviously the concerned brands presented significant equity to have commanded premium valuation despite the effort involved in transferring the equity to another brand. Closer home, L&T Cement name changeover to UltraTech is one such example.

Value proposition
It is beyond any debate that out of all that a corporation owns, the brand is the most important and the most sustainable asset. Even at operational levels, companies driven by strong brands have delivered significantly superior financial performance compared to their peers not driven by strong brands. In sum, strong brands mean better returns, period. And the Indian cement industry is certainly paying sub-optimum attention to brand management, despite two-thirds of its volume being in the consumer market.

Brand creation is not a priority
For FY 2015-16, the Indian cement industry collectively spent about Rs 220 crore on advertising across TV, print and radio – the above the line (ATL) media. Arguably, the industry does spend a significant part of its advertising budget on media like billboards and wall painting. Though it is hard to estimate these spends, we may not be too off the mark if we were to assume the total advertising spend at double the amount spent in ATL. At Rs 440 crore, the spend makes it a miniscule 0.28 per cent of revenue of this mammoth Rs 153,000 crore industry! Clearly the industry doesn’t consider advertising an important business tool. And what is even more revealing is what this much-less-than-optimum budget gets spent on – very generic, mere salience building advertising. Most advertising discourse is focused on the core expectation from the category – strength/durability or even more general things like quality, trust etc. The quality of advertising betrays the fact that neither deep consumer insights nor rigorous competitive product analysis to drive differentiation is being deployed.

A large study owned by Young and Rubicam that tracks hundreds of brands across a large spectrum of categories, shows that ‘differentiation’ is a large prerequisite for a brand to start getting created, a meaningful differentiation of course. But the cement brands, as revealed from their advertising, are hardly making efforts to create differentiation.

And yet, advertising is not even the core of genuine brand building. It is at best one of the tools, only one of the ingredients in brand creation.

Not just about advertising
Before it gains ground, it is critical to perish the thought quickly and early on in this article, that brand is all about advertising. In fact the cement industry’s skin-deep engagement with brand creation and management suggests it might be afflicted with this notion. Being brand driven is much deeper than being mere advertising driven. It is a strategic shift in the way an organisation conducts its business.

Closely related to advertising, but a very basic and fundamental brand prerequisite is to be consumer driven. Brand-driven organisations will be strongly consumer-knowledge and understanding driven. In the cement industry, even the most basic exercises like segmentation and differentiation, the building blocks of basic brand management and marketing construct, are missing – something that one would expect from an industry with such a large number of players as an approach to competitive engagement.

Branding is a commitment at the business strategy level. Who will the brand serve most, what will the brand promise, and how will it back that promise up in each and every act, where will it spend most of its R&D efforts, which aspects of its operations will it seek to excel in, what kind of internal business review matrices will it deploy, what kind of talents it will hire, etc., are the kind of alignment being branding driven demands.

Branding-driven organisations are constantly chasing deeper and deeper consumer understanding, seeking product and service innovations, and seeking points of meaningful differentiation and departure. They are essentially seeking sustainable competitive advantages that are harder to beat or compete with.

Isn’t cement a commodity?
So what?

It might be the best news, from a branding point of view.
Cement being a commodity is an often-heard refrain in the industry. And, just like its belief that mere advertising equals branding, even this could count as a self-defeating belief. It is not that it is a commodity, but the fact is that this over-arching belief might be making us put fewer efforts in creating deeper brand assets. Is salt any less of a commodity? What about flour, cooking oil? And drinking water, coffee, tea, sugar, milk, hair oil? It is a secret that not many are in the know of; biggest brands have indeed been created and built in commodity categories! Only the last 20-odd years have been somewhat of an exception where technology products might have taken the centre-stage in brand creation and investment. Otherwise the biggest brand battles have been fought in the commodity space, and some of the biggest brand values too have been created in the commodity or near commodity space.

If one were to ask what, between a coffee and a cement, might feature as carrying higher stakes to the customer, we might discover an even happier news that not only is cement just like many commodities that are best amenable to brand creation, it is one of the most important commodities in terms of the stakes it carries. Even a cursory interrogation of the category makes one wonder why some of the most obvious unique customer needs haven’t been used to create market segmentation and brand positioning, e.g., cements best suited for structures in coastal areas or high rain areas or for areas of extreme temperatures, cements best suited for different parts of a structure like foundation and slabs, cements for those who seek quicker construction time, cements that need less water for regions that are water deficit, etc. Why are there no attempts at SKU (stock keeping unit) sizes? Yes, it does call for a significant disruption in the entire supply chain, but that exactly is the difference between an industry that is consumer driven and the one that is inside out.

Consumer-driven organisations will make all efforts to overcome the current constraints to fulfil customer expectations while the inside-out organisations will make compromises with their existing constraints and in the process miss out on creating customer delight by finding solutions they want. If fresh cement is a big deal, it may make sense to for a player to think of a logistics innovation that minimises time taken for the cement to travel from manufacturing to the site, something that allows the cement to arrive ‘hot and fresh’ on the construction site.v Admittedly, there have been attempts, but so feeble that they seem to have lacked conviction and served to only reiterate the existing self-limiting belief that cement is a commodity that is best treated as a commodity.

Hurdles
Hard to tell, but mostly it is about an industry’s belief system that the industry defines itself with. What you consider as a belief to live with and perpetuate, and what you challenge makes all the difference.

Even the way an organisation structures itself gives higher or lower emphasis to various aspects of business. Branding in cement companies is largely relegated to some marcom teams, seen as fiddling around with logos and colours etc. The brand spends are mostly seen as those painful line item expenditures that, unfortunately, can’t be avoided. For want of robust brand strength matrices and their proven co-relationship with business impact, the finance guys, and rightfully so, remain ambivalent about it. The industry, driven mostly by those who have come up at the leadership positions from the manufacturing side, possibly sees itself as a hard, masculine industry and, seeing branding only as cosmetic advertising, views it as a rather soft subject that some designers are left to deal with.

The stage at which branding kicks in is another key determinant of what stops an organisation from making the best use of branding. If it is at the fag end of an organisation’s core work – ‘product is ready, now let us create some advertising’, the branding will be superficial, cosmetic and sub-impactful. For it to be effective, branding has to be the starting point of an organisation’s business and competitive strategy. It is what should be driving what kind of product differentiation to work towards, what quality standards to chase, what kind of packaging, how many SKUs, what kind of logistics and time to delivery, what kind of distribution strategy, what kind of stock keeping both at the warehouses and at the retail counters etc., to have. The organization as a whole must align itself to deliver on the brand strategy and not just the brand or marketing head. After all, a brand represents the entire organization’s commitment and efforts to get the all-important competitive advantage. It is a promise that the entire organization has to fulfil in all its functions.

Branding benefits
If managed well, brands bring immense operational and strategic benefits. They prompt business re-thinks from what product one is selling to what benefits one delivers and stands for. This in turn, in the cement industry for example, could lead to questions like what other product category could one extend a brand to. It is shocking to realise that most of what goes into building a house is unbranded material from the unorganised sector. Cement represents only about 10-15 per cent. Why should a cement organisation not consider extending itself into some of the other materials needed for construction – like sand and bricks?

Good brand management cultures would also make organisations ask questions like licensing and franchising as possible low cost/low capital ways to business growth. Though hard work, brands bring disproportionate operational and strategic rewards. They not only have influence on the consumer, they even influence talent attraction and attrition. Beyond the organisation’s immediate concerns, brands even have significant social influence and serve as buffers of goodwill in moments of rare organisational failures or crisis.

Brands certainly drive customer loyalty and advocacy and fetch higher market shares and price premium. They even drive significant operational efficiencies and eventually, stakeholder value. What the brand thinking delivers beyond the financial parameters is even more precious – like organisational alignment and clarity; it unleashes collective energy and blesses the practicing organisation with the most sustainable competitive advantage called a ‘brand’ and a most prized culture of being ‘consumer driven’. So it not whether or when, but how should the cement industry start creating mega brands out of their huge businesses. Branding is a critical business enabler that key stakeholders of the cement industry should start demanding without any further loss of time, and that too in a fundamental, comprehensive and scientific approach. It will only surprise the industry by its impact and value creation. And we may soon see valuations in the sector that gladden the hearts of shareholders even more.

Yogi Vashishta is a brand strategy consultant. He is presently CEO, Minority Brand Creation and Management LLP. Yogi has worked in leadership roles across ad agencies, market research, manufacturing, and marketing organisations, India and abroad. He has experience across diverse categories and brands like VIP Skybags, Orient Fans, Levers, Cadbury’s, McDonald’s, Reliance Cement, Servo and Kinetic Honda.

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Concrete

Refractory demands in our kiln have changed

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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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Concrete

Digital supply chain visibility is critical

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MSR Kali Prasad, Chief Digital and Information Officer, Shree Cement, discusses how data, discipline and scale are turning Industry 4.0 into everyday business reality.

Over the past five years, digitalisation in Indian cement manufacturing has moved decisively beyond experimentation. Today, it is a strategic lever for cost control, operational resilience and sustainability. In this interview, MSR Kali Prasad, Chief Digital and Information Officer, Shree Cement, explains how integrated digital foundations, advanced analytics and real-time visibility are helping deliver measurable business outcomes.

How has digitalisation moved from pilot projects to core strategy in Indian cement manufacturing over the past five years?
Digitalisation in Indian cement has evolved from isolated pilot initiatives into a core business strategy because outcomes are now measurable, repeatable and scalable. The key shift has been the move away from standalone solutions toward an integrated digital foundation built on standardised processes, governed data and enterprise platforms that can be deployed consistently across plants and functions.
At Shree Cement, this transition has been very pragmatic. The early phase focused on visibility through dashboards, reporting, and digitisation of critical workflows. Over time, this has progressed into enterprise-level analytics and decision support across manufacturing and the supply chain,
with clear outcomes in cost optimisation, margin protection and revenue improvement through enhanced customer experience.
Equally important, digital is no longer the responsibility of a single function. It is embedded into day-to-day operations across planning, production, maintenance, despatch and customer servicing, supported by enterprise systems, Industrial Internet of Things (IIoT) data platforms, and a structured approach to change management.

Which digital interventions are delivering the highest ROI across mining, production and logistics today?
In a capital- and cost-intensive sector like cement, the highest returns come from digital interventions that directly reduce unit costs or unlock latent capacity without significant capex.
Supply chain and planning (advanced analytics): Tools for demand forecasting, S&OP, network optimisation and scheduling deliver strong returns by lowering logistics costs, improving service levels, and aligning production with demand in a fragmented and regionally diverse market.
Mining (fleet and productivity analytics): Data-led mine planning, fleet analytics, despatch discipline, and idle-time reduction improve fuel efficiency and equipment utilisation, generating meaningful savings in a cost-heavy operation.
Manufacturing (APC and process analytics): Advanced Process Control, mill optimisation, and variability reduction improve thermal and electrical efficiency, stabilise quality and reduce rework and unplanned stoppages.
Customer experience and revenue enablement (digital platforms): Dealer and retailer apps, order visibility and digitally enabled technical services improve ease of doing business and responsiveness. We are also empowering channel partners with transparent, real-time information on schemes, including eligibility, utilisation status and actionable recommendations, which improves channel satisfaction and market execution while supporting revenue growth.
Overall, while Artificial Intelligence (AI) and IIoT are powerful enablers, it is advanced analytics anchored in strong processes that typically delivers the fastest and most reliable ROI.

How is real-time data helping plants shift from reactive maintenance to predictive and prescriptive operations?
Real-time and near real-time data is driving a more proactive and disciplined maintenance culture, beginning with visibility and progressively moving toward prediction and prescription.
At Shree Cement, we have implemented a robust SAP Plant Maintenance framework to standardise maintenance workflows. This is complemented by IIoT-driven condition monitoring, ensuring consistent capture of equipment health indicators such as vibration, temperature, load, operating patterns and alarms.
Real-time visibility enables early detection of abnormal conditions, allowing teams to intervene before failures occur. As data quality improves and failure histories become structured, predictive models can anticipate likely failure modes and recommend timely interventions, improving MTBF and reducing downtime. Over time, these insights will evolve into prescriptive actions, including spares readiness, maintenance scheduling, and operating parameter adjustments, enabling reliability optimisation with minimal disruption.
A critical success factor is adoption. Predictive insights deliver value only when they are embedded into daily workflows, roles and accountability structures. Without this, they remain insights without action.

In a cost-sensitive market like India, how do cement companies balance digital investment with price competitiveness?
In India’s intensely competitive cement market, digital investments must be tightly linked to tangible business outcomes, particularly cost reduction, service improvement, and faster decision-making.
This balance is achieved by prioritising high-impact use cases such as planning efficiency, logistics optimisation, asset reliability, and process stability, all of which typically deliver quick payback. Equally important is building scalable and governed digital foundations that reduce the marginal cost of rolling out new use cases across plants.
Digitally enabled order management, live despatch visibility, and channel partner platforms also improve customer centricity while controlling cost-to-serve, allowing service levels to improve without proportionate increases in headcount or overheads.
In essence, the most effective digital investments do not add cost. They protect margins by reducing variability, improving planning accuracy, and strengthening execution discipline.

How is digitalisation enabling measurable reductions in energy consumption, emissions, and overall carbon footprint?
Digitalisation plays a pivotal role in improving energy efficiency, reducing emissions and lowering overall carbon intensity.
Real-time monitoring and analytics enable near real-time tracking of energy consumption and critical operating parameters, allowing inefficiencies to be identified quickly and corrective actions to be implemented. Centralised data consolidation across plants enables benchmarking, accelerates best-practice adoption, and drives consistent improvements in energy performance.
Improved asset reliability through predictive maintenance reduces unplanned downtime and process instability, directly lowering energy losses. Digital platforms also support more effective planning and control of renewable energy sources and waste heat recovery systems, reducing dependence on fossil fuels.
Most importantly, digitalisation enables sustainability progress to be tracked with greater accuracy and consistency, supporting long-term ESG commitments.

What role does digital supply chain visibility play in managing demand volatility and regional market dynamics in India?
Digital supply chain visibility is critical in India, where demand is highly regional, seasonality is pronounced, and logistics constraints can shift rapidly.
At Shree Cement, planning operates across multiple horizons. Annual planning focuses on capacity, network footprint and medium-term demand. Monthly S&OP aligns demand, production and logistics, while daily scheduling drives execution-level decisions on despatch, sourcing and prioritisation.
As digital maturity increases, this structure is being augmented by central command-and-control capabilities that manage exceptions such as plant constraints, demand spikes, route disruptions and order prioritisation. Planning is also shifting from aggregated averages to granular, cost-to-serve and exception-based decision-making, improving responsiveness, lowering logistics costs and strengthening service reliability.

How prepared is the current workforce for Industry 4.0, and what reskilling strategies are proving most effective?
Workforce preparedness for Industry 4.0 is improving, though the primary challenge lies in scaling capabilities consistently across diverse roles.
The most effective approach is to define capability requirements by role and tailor enablement accordingly. Senior leadership focuses on digital literacy for governance, investment prioritisation, and value tracking. Middle management is enabled to use analytics for execution discipline and adoption. Frontline sales and service teams benefit from
mobile-first tools and KPI-driven workflows, while shop-floor and plant teams focus on data-driven operations, APC usage, maintenance discipline, safety and quality routines.
Personalised, role-based learning paths, supported by on-ground champions and a clear articulation of practical benefits, drive adoption far more effectively than generic training programmes.

Which emerging digital technologies will fundamentally reshape cement manufacturing in the next decade?
AI and GenAI are expected to have the most significant impact, particularly when combined with connected operations and disciplined processes.
Key technologies likely to reshape the sector include GenAI and agentic AI for faster root-cause analysis, knowledge access, and standardisation of best practices; industrial foundation models that learn patterns across large sensor datasets; digital twins that allow simulation of process changes before implementation; and increasingly autonomous control systems that integrate sensors, AI, and APC to maintain stability with minimal manual intervention.
Over time, this will enable more centralised monitoring and management of plant operations, supported by strong processes, training and capability-building.

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Concrete

Cement Additives for Improved Grinding Efficiency

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Shreesh A Khadilkar discusses how advanced additive formulations allow customised, high-performance and niche cements—offering benefits while supporting blended cements and long-term cost and carbon reduction.

Cement additives are chemicals (inorganic and organic) added in small amounts (0.01 per cent to 0.2 per cent by weight) during cement grinding. Their main job? Reduce agglomeration, prevent pack-set, and keep the mill running smoother. Thus, these additions primarily improve, mill thru-puts, achieve lower clinker factor in blended cements PPC/PSC/PCC. Additionally, these additives improve concrete performance of cements or even for specific special premium cements with special USPs like lower setting times or for reduced water permeability in the resultant cement mortars and concrete (water repellent /permeation resistant cements), corrosion resistance etc.
The cement additives are materials which could be further differentiated as:

Grinding aids:
• Bottlenecks in cement grinding capacity, such materials can enhance throughputs
• Low specific electrical energy consumption during cement grinding
• Reduce “Pack set” problem and improve powder flowability

Quality improvers:
• Opportunity for further clinker factor reduction
• Solution for delayed cement setting or strength development issues at early or later ages.

Others: materials which are used for specific special cements with niche properties as discussed in the subsequent pages.
When cement additives are used as grinding aids or quality improvers, in general the additives reduce the inter-particle forces; reduce coating over grinding media and mill internals. Due to creation of like charges on cement particles, there is decreased agglomeration, much improved flowability, higher generation of fines better dispersion of particles in separator feed and reduction of mill filling level (decrease of residence time). However, in VRM grinding; actions need to be taken to have stable bed formation on the table.
It has been reported in literature and also substantiated by a number of detailed evaluations of different cement additive formulations in market, that the cement additive formulations are a combination of different chemical compounds, typically composed of:

  1. Accelerator/s for the hydration reaction of cements which are dependent on the acceleration effect desired in mortar compressive strengths at early or later ages, the choice of the materials is also dependent on clinker quality and blending components (flyash / slag) or a mix of both.
  2. Water reducer / workability / wet-ability enhancer, which would show impact on the resultant cement mortars and concrete. Some of the compounds (retarders) like polysaccharide derivatives, gluconates etc., show an initial retarding action towards hydration which result in reducing the water requirements for the cements thus act as water reducers, or it could be some appropriate polymeric molecules which show improved wet-ability and reduce water demand. These are selected based on the mineral component and type of cements (PPC/PSC /PCC).
  3. Grinding aids: Compounds that work as Grinding Aid i.e. which would enhance Mill thru-put on one hand as well as would increase the early strengths due to the higher fines generation/ or activation of cement components. These compounds could be like alkanol-amines such as TIPA, DEIPA, TEA etc. or could be compounds like glycols and other poly-ols, depending on whether it is OPC or PPC or PSC or PCC manufacture.

Mechanism of action — Step By Step—

  1. Reduce Agglomeration, Cement particles get electrostatically charged during grinding, stick together, form “flocs”, block mill efficiency, waste energy. Grinding aid molecules adsorb onto particle surfaces, neutralise charge, prevent re-agglomeration.
  2. Improve Powder Flowability, Adsorbed molecules create a lubricating layer, particles slide past each other easier, better mill throughput, less “dead zone” buildup.
    Also reduces caking on mill liners, diaphragms, and separator screens, less downtime for cleaning.
  3. Enhance Grinding Efficiency (Finer Product Faster), By preventing agglomeration, particles stay dispersed more surface area exposed to grinding media, finer grind achieved with same energy input, Or: same fineness achieved with less energy, huge savings.
    Example:
    • Without aid ? 3500 cm²/g Blaine needs 40 kWh/ton
    • With use of optimum grinding aid same fineness at 32 kWh/ton 20 per cent energy savings
  4. Reduce Pack Set and Silo Caking Grinding aids (GA) inhibit hydration of free lime (CaO) during storage prevents premature hardening or “pack set” in silos. especially critical in humid climates or with high free lime clinker.
    It may be stated here that Overdosing of GA can cause: – Foaming in mill (especially with glycols) reduces grinding efficiency, retardation of cement setting (especially with amines/acids), odor issues (in indoor mills) – Corrosion of mill components (if acidic aids used improperly)
    The best practice to optimise use of GA is Start with 0.02 per cent to 0.05 per cent dosage test fineness, flow, and set time adjust up/down. Due to static charge of particles, the sample may stick to the sides of sampler pipe and so sampling need to be properly done.
    Depending on type of cements i.e. OPC, PPC, PSC, PCC, the grinding aids combinations need to be optimised, a typical Poly carboxylate ether also could be a part of the combo grinding aids

Cement additives for niche properties of the cement in concrete.
The cement additives can also be tailor made to create specific niche properties in cements, OPC, PPC, PSC and PCC to create premium or special brands. The special niche properties of the cement being its additional USP of such cement products, and are useful for customers to build a durable concrete structure with increased service life.


Such properties could be:
• Additives for improved concrete performance of cements, high early strength in PPC/PSC/PCC, much reduced water demand in cement, cements with improved slump retentivity in concrete, self-compacting, self levelling in concrete, cements with improved adhesion property of the cement mortar
• Water repellence / water proofing, permeability resistance in mortars and concrete.
• Biocidal cement
• Photo catalytic cements
• Cements with negligible ASR reactions etc.

Additives for cements for improved concrete performance
High early strengths: Use of accelerators. These are chemical compounds which enhance the degree of hydration of cement. These can include setting or hardening accelerators depending on whether their action occurs in the plastic or hardened state respectively. Thus, the setting accelerators reduce the setting time, whereas the hardening accelerators increase the early age strengths. The setting accelerators act during the initial minutes of the cement hydration, whereas the hardening accelerators act mainly during the initial days of hydration.
Chloride salts are the best in class. However, use of chloride salts as hardening accelerators are strongly discouraged for their action in promoting the corrosion of rebar, thus, chloride-free accelerators are preferred. The hardening accelerators could be combinations of compounds like nitrate, nitrite and thiocyanate salts of alkali or alkaline earth metals or thiosulphate, formate, and alkanol amines depending on the cement types.
However, especially in blended cements (PPC/PSC/PCC the increased early strengths invariably decrease the 28 day strengths. These aspects lead to creating combo additives along with organic polymers to achieve improved early strengths as well as either same or marginally improved 28 days strengths with reduced clinker factor in the blended cement, special OPC with reduced admixture requirements. With use of appropriate combination of inorganic and organic additives we could create an OPC with substantially reduced water demand or improved slump retentivity. Use of such an OPC would show exceptional concrete performance in high grade concretes as it would exhibit lower admixture requirements in High Grade Concretes.
PPC with OPC like properties: With the above concept we could have a PPC, having higher percentage flyash, with a combo cement additive which would have with concrete performance similar to OPC in say M40/M50 concrete. Such a PPC would produce a high-strength PPC concrete (= 60 MPa @ 28d) + improved workability, durability and sustainability.
Another interesting aspect could also be of using ultrafine fine flyash /ultrafine slags as additions in OPC/PPC/PSC for achieving lower clinker factor as well as to achieve improved later age strengths with or without a combo cement additive.
The initial adhesion property at sites of especially PPC/PSC/PCC based mortars can be improved through use of appropriate organic polymers addition during the manufacture of these cements. Such cements would have a better adhesion property for plastering/brick bonding etc., as it has much lower rebound loss of their mortars in such applications.
It is needless to mention here that with use of additives, we could also have cement with viscosity modifying cement additives, for self-compaction and self-leveling concrete performance.
Use of Phosphogypsum retards the setting time of cements, we can use additive different additive combos to overcome retardation and improve the 1 day strengths of the cements and concretes.

About the author:
Shreesh Khadilkar, Consultant & Advisor, Former Director Quality & Product Development, ACC, a seasoned consultant and advisor, brings over 37 years of experience in cement manufacturing, having held leadership roles in R&D and product development at ACC Ltd. With deep expertise in innovative cement concepts, he is dedicated to sharing his knowledge and improving the performance of cement plants globally.

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