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Preference on proven technology over cost

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The Indian mining industry is going through a slow momentum, but there is a lot of scope for improvement, says SUBHAJIT CHAUDHURI, Vice-President-Sales & Projects of MMD Heavy Machinery (India) Private Limited.
India?s next mining boom is on its way as the present government is determined to revive the sector. A few emerging mining equipment technologies to watch out for in 2017.

In-Pit Sizing and Conveying (IPSC) is the emerging mining technology and the twin shaft mineral sizer is the emerging equipment to watch in 2017 and onwards. IPSC systems are a cost-effective and safer alternative to discontinuous material haulage by dump trucks; reducing operating costs, improving safety, and reducing CO2 emissions, dust, and noise pollution. Employing either fully mobile, semi-mobile or static sizer units in conjunction with conveyors, IPSC efficiently processes and transports material out of the mine.

The Indian mining industry is going through a slow momentum in the present scenario, but there is a lot of scope. Many minerals are yet to be exploited and I believe that the Government of India is working actively on this part. One big example is coal block allocation. The Ministry of Coal has very aggressive plans to achieve 1 billion tonnes of coal production by 2020 and thus new technologies such as IPSC solutions need to be adapted to achieve higher throughput. From my perspective, the mining industry has a very positive future. And of course, to increase the throughput capacity and reducing cost, adaptation of the best technology is very much needed. The implementation of fully mobile & semi-mobile IPSC system certainly will help in reducing the greenhouse emissions, saving the high cost of diesel, and maintaining safety during mining operations, all together. Mining can become more environmentally sustainable by developing and implementing the right technologies that reduce the environmental impact of mining operations.

The latest technology breakthrough in this domain.
Global mining is changing rapidly: rising costs, environmental pressures and health and safety have called time on traditional truck and shovel methods. As the industry becomes increasingly aware of the need for "Sustainable Mining", the ecological benefits derived from the elimination of dust and reduction of harmful greenhouse emissions caused by truck and shovel methods are self-evident. MMD?s innovative technology is at the forefront of this revolution.

For the ultimate in cost savings, environmental mining and portability, fully mobile Sizer units (fully mobile IPSC) enable the use of efficient conveyor haulage directly from the mine face. They move frequently to work directly with the excavator, whilst sizing and delivering conveyable material onto the conveyor haulage system, eliminating trucks and their associated costs, safety risks and environmental impact. MMD has, throughout its existence, developed purpose designed mobile units to suit any mining method and material. The whole range of Sizers can be incorporated into a wide range of transport options available to suit the duties and throughput required. Through the use of the well established components such as the twin shaft Sizer and heavy duty apron plate feeder, MMD Fully Mobile units deliver the reliability and robustness required for IPSC operations. Further Features / Benefits includes the followings,

  • Throughput capacities up to and over 10,000 TPH
  • Automated material handling
  • Low carbon emissions and environmental impact by using all electrical power
  • Operates in extreme weather conditions
  • Maintenance friendly.

MMD has been producing semi-mobile IPSC units since the early 1980?s. It?s generally fed by a small fleet of trucks transporting material over short distances from the mine face. The Sizer unit reduces material in preparation for efficient conveyor haulage out of the mine. As the mining face progresses these units are relocated occasionally to minimise the truck haulage distance. Semi mobile sizer units leverage the flexibility of truck haulage together with the efficiency of conveyor haulage. This provides the ideal efficient solution for many mining scenarios where mining flexibility is vital, such as selective mining (blending), heavily faulted seams or irregular shaped ore bodies. Semi-Mobile units are constructed in easy-to-assemble modules that can be relocated closer to the mine face by the MMD Atlas Transporter. Through the use of the well established components such as the twin shaft Sizer and heavy duty apron plate feeder, MMD Semi Mobile units deliver the reliability and robustness required for IPSC operations.

MMD has, throughout its existence developed purpose designed units to suit any mining method and material as required. The whole range of Sizers can be incorporated into a wide range of transport options available to suit the duties required. MMD are the innovators of the product, which allows the flexibility of a mining shovel to be matched with the cost effectiveness of long distance conveyor haulage.

The 10,000 TPH Fully Mobile Sizer Station is a cost-effective engineering solution, which enables excavating, sizing and conveyor haulage process to take place in unison, along the mine face, advancing as it progresses. An obvious advantage of this system is the elimination of haul trucks in a truck and shovel operation. The Fully Mobile Sizer Station has many attributes and features to enable consistent efficient operation of the complete system.

Why should the MMD Sizer be considered?
The operating principles of MMD Twin Shaft Mineral Sizer provide various unique advantages which is inevitable for green mining solutions.

MMD Sizing Technology:
The basic concept of the MMD Sizer is the use of two rotors with large teeth, on small diameter shafts, driven at a low speed by a direct high torque drive system. This design produces three major principles which all interact when breaking materials using Sizer Technology. The unique principles are; The Three Stage Breaking Action, the Rotating Screen Effect, and the Deep Scroll Tooth Pattern.

Accurate Sizing: Three-Stage Breaking Action

The Rotating Screen effects
The interlaced toothed rotor design allows free flowing undersize material to pass through the continuously changing gaps generated by the relatively slow moving shafts.

The Deep Scroll Tooth Pattern
The deep scroll conveys the larger material to one end of the machine and helps to spread the feed across the full length of the rotors. This feature can be used to reject oversize material from the machine.

With large teeth and small shaft diameters the material is gripped and broken in shear rather than compression force resulting in much lower energy consumption. Absorbed power is 55 per cent on installed power.

The deep scroll tooth pattern acts as a rotating screen allowing already undersize material to pass without any further size degradation or power usage. MMD Sizer technology produces the minimum fines.

MMD Sizer is also the only solution to handle wet & sticky situations with high moisture content in the material.

Minimum Space requirement
Sizer was invented the company?s founder, Alan Potts to facilitate British underground coal mine where space was a constraint. The machine is very compact and requires minimum space to install.

Minimum downtime MMD Sizer requires minimum downtime; the complete single set of worn-out components can be replaced within one to two shifts in the same day. This minimum downtime increases productivity significantly.

Steel structural support
All gearboxes are mounted on the Sizer itself, resulting in correct alignment at all times and does not require a support frame or separate structure. The MMD Heavy Duty Gearbox is specially designed to facilitate the MMD Sizer only. On a twin-drive machine, the gearboxes are mounted on the same end of the Sizer, allowing inline or perpendicular installation without restricting maintenance access to drives.

The robust MMD Heavy Duty Gearbox has been in operation for decades. MMD has more than 4,500 successful global installations worldwide with over 80 different minerals worldwide. The company has more than 350 customers with repeat orders.

Lesser Installation Cost

  • Only levelled & compacted civil bed is required depending on the arrangement;
  • Due to lesser height & compact size, minimum headroom is required for maintenance;
  • Minimum chute work and no heavy structural steel support is required; hence, minimum manpower is required to install the machine;
  • Machine Installation time is less (within a day) subject to availability of adequate resources;
  • No special tools & tackles required during erection & commissioning; Operational expenditure is very less:
  • Electrical consumption is very low.
  • Very less spares consumption.
  • Consumables requirement is very low.

About the author
Subhajit Chaudhur
i, a Mechanical Engineer, is Vice-President-Sales & Projects of MMD Heavy Machinery (India) Private Limited, a part of the MMD Group of Companies, UK. He has worked in different business segments including auto-ancillaries, distillation & brewery and water management, material handling, mineral processing & mining.

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Economy & Market

RAHSTA Roundtable Sets Agenda for Smarter, Safer Highways

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Roundtable discussions focus on innovation for safer highways.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the RAHSTA Roundtable brought together stakeholders from across the highways and infrastructure ecosystem to shape the agenda for the 16th RAHSTA 2026, scheduled for 8–9 July 2026 at the Jio Convention Centre, Mumbai. The session focused on key industry themes including road construction, technology, safety and long-term sustainability.

Opening the discussion, Pratap Padode, Founder, FIRST Construction Council, said the roundtable marked the beginning of a broader consultative process leading up to the July event. The aim, he noted, is to bring together industry stakeholders to refine the agenda for discussions on the future of roads, bridges, tunnels and allied infrastructure.

Padode noted that while central road project awards have slowed in recent years, states are increasingly driving the next phase of infrastructure growth. Maharashtra, with its long-term road development plans and agencies such as MSRDC and MSIDC, is expected to play a significant role in this expansion.

RAHSTA Expo 2026 as a specialised platform dedicated to road infrastructure, covering highways, tunnels, bridges and flyovers along with construction technologies, safety systems and maintenance solutions. He also highlighted the growing importance of rural connectivity and said the organisers are engaging with government bodies to highlight rural road development initiatives.

Tanveer Padode, CIO, ASAPP Info Group, presented insights from IMPACCT, the group’s infrastructure intelligence platform. He pointed to a strong project pipeline despite slower highway awards earlier in the year, noting that states such as Maharashtra, Odisha and Arunachal Pradesh are emerging as key drivers of new projects. The data also revealed that only a small group of contractors participates in large-value infrastructure bids.

Lt Gen Rajeev Chaudhary, former Director General, Border Roads Organisation and Chairman of the RAHSTA Expo Committee, emphasised the need for stronger collaboration across the ecosystem, including policymakers, contractors, technology providers and financiers. He also called for addressing systemic issues within the sector and encouraged greater participation of women in infrastructure leadership.

The discussion also explored the evolving economics of road development. Phani Prasad Mandalaparthy, Associate Director, CRISIL Intelligence, noted that the slowdown in project awards reflects a shift towards higher-value logistics corridors rather than simple road widening projects. However, private participation through BOT and TOT models remains limited.

From the contractors’ perspective, Sudhir Hoshing, Whole-Time Director, Ceigall, said companies are becoming more selective in bidding, favouring projects with clearer payment mechanisms and efficient processes. While NHAI continues to offer greater operational clarity, states such as Uttar Pradesh and Bihar were cited as relatively supportive environments for project execution.

Durability and sustainability also emerged as key themes. Himanshu Agarwal, COO – Road & Infrastructure, Zydex Group India, highlighted the need to prioritise lifecycle performance and resilient pavements, while participants discussed the potential of alternative materials such as plastic waste, steel slag and industrial by-products in road construction.

Dr LR Manjunatha, Vice President, JSW Cement, emphasised that India has abundant fly ash, slag and other industrial materials that can improve durability and sustainability if integrated into specifications and policy frameworks.

Technology and equipment challenges were also discussed. Dr Lakshmana Rao Mantri, Dy General Manager, Afcons Infrastructure, highlighted the shortage of tunnel boring machines (TBMs), which is delaying several underground infrastructure projects. Participants agreed that developing domestic TBM manufacturing capabilities will be critical for future infrastructure expansion.

The future of concrete pavements was another area of discussion. Dr V Ramachandra, President, Indian Concrete Institute, stressed that the debate should focus on lifecycle performance rather than material choice alone, noting that evolving design standards are improving the feasibility of concrete roads.

Prof Dharamveer Singh of IIT Bombay added that while India has made significant progress in infrastructure development, stronger capacity building and better execution practices are essential to ensure consistent road quality.

The discussion also touched upon technology adoption in the sector. Rushabh Mamania, Partner & CBO, Roadvision, highlighted the growing role of AI in road infrastructure, noting that AI-driven monitoring systems are already being deployed across large stretches of national highways.

Overall, the roundtable underscored that the future of highway infrastructure will depend not only on the pace of construction but also on durability, safety, technology integration and sustainable materials. The discussions offered valuable insights that will help shape the agenda for RAHSTA 2026 and guide future collaboration within the industry.

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Economy & Market

CTS Roundtable Charts Tech-Led Roadmap for Construction

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CTS Roundtable Maps Technology Roadmap for Construction

Ahead of the Construction Technology Show (Con Tech Show) 2026, industry leaders, technology innovators and academia came together in Mumbai to deliberate on how digitalisation, automation and industrialised construction can reshape the sector. The discussion made one thing clear: construction can no longer afford to treat technology as optional.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the CTS Roundtable served as a precursor to the Construction Technology Show 2026, scheduled for 19–20 August 2026 at NESCO, Mumbai.

A platform to move from discussion to deployment

Opening the session, Pratap Padode, Founder and Editor-in-Chief, ASAPP Info Global Group, said construction technology has long remained close to his heart, especially given the sector’s traditionally slow pace of technology adoption. He noted that over the years, the Construction Technology Summit had steadily built interest, and the next step was now to expand it into a larger, more meaningful platform that could bring together technology providers, users, startups and innovators under one roof.

Padode said the vision for CTS is not limited to software alone. The platform aims to embrace all forms of technology that can improve construction efficiency, quality and execution—from digital tools and project management systems to lean construction, off-site fabrication and startup-led innovation. He also highlighted plans to deepen startup participation and create space for young companies to showcase emerging construction solutions.

Industry at a turning point

Moderating the roundtable, Naushad Panjwani, Chairman, Mandarus Partners, set the context by pointing out that the global construction industry, despite being a multi-trillion-dollar sector, continues to lag in productivity. He noted that while manufacturing has consistently improved efficiency, construction has remained slow to modernise.

Referring to both global and Indian trends, Panjwani underlined that the industry is now at a decisive moment. India, he said, is entering a major build cycle, and delivering the next phase of infrastructure and real estate growth through traditional methods alone is no longer viable. The goal of the roundtable, therefore, was not to debate technology in isolation, but to identify the most critical conversations that would bridge the gap between innovation and implementation.

His central message was clear: CTS 2026 must be shaped around themes that make CEOs, CIOs and CTOs feel they cannot afford to miss the event.

From BIM to AI, data to governance

A major theme that emerged through the discussion was the need for better data, better visibility and better decision-making. Dr Venkata Santosh Kumar of IIT Bombay echoed this, saying that the underlying data infrastructure itself needs attention. Construction projects, particularly remote ones, often face issues around connectivity, data collection and data use. Without this foundation, more advanced technologies cannot deliver their full value.

Chandra Vasireddy, CEO & Co-founder, Inncircles, expanded the discussion to governance, arguing that technology must help connect the many moving parts of a construction business. For him, the real value of digital transformation lies in creating better governance, clearer visibility and stronger business outcomes.

Tejas Vara of Inncircles stressed the importance of timely site data for leadership teams, especially in large and remote projects where decisions on materials, machinery and manpower often get delayed because information does not reach headquarters in time.

The role of AI also featured prominently. Rushabh Mamania, Partner and CBO, Roadvision said that while AI and machine learning are now common terms, vision intelligence and language intelligence have still not deeply penetrated the construction sector. He emphasised that startups in India are building relevant AI-led solutions and are already attracting international interest, showing that innovation need not be imported—it can be built locally and scaled globally.

Industrialised construction gains ground

The roundtable also placed strong emphasis on industrialised construction methods. Kalyan Vaidyanathan, CTO – Construction & R&D, Tvasta, called for greater focus on off-site fabrication and the broader industrialisation of construction. Bhargav Jog, General Manager, Dextra, highlighted precast technology and alternative sustainable materials as areas with immediate relevance.

Several participants agreed that modular, precast and pre-engineered approaches are no longer niche ideas. They are increasingly becoming practical responses to the sector’s challenges around labour shortage, timelines, quality control and predictability.

Anup Mathew, Sr VP & Business Head, Godrej, argued that the industry needs a fully integrated approach—from design and procurement to execution and asset management. Unless these are connected, technology adoption will remain fragmented and sub-optimal. He pointed to pre-engineered and modular systems as examples of how industrial thinking can compress timelines, improve quality and reduce dependence on difficult on-site conditions.

Adoption remains the biggest hurdle

While there was broad agreement on the promise of technology, the discussion repeatedly returned to one fundamental challenge: adoption.

Abhishek Kumar, COO, LivSYT, observed that the market is crowded with solutions, but many buyers still struggle to evaluate which technology suits which use case. According to him, the industry needs clearer frameworks to help users select, compare and adopt solutions, rather than expecting a single platform to solve every problem.

Dr Tenepalli JaiSai, Associate Professor, School of Construction(SoC), NICMAR University, noted that isolated technologies will not solve the productivity problem by themselves. What is required is an integrated Construction 4.0 approach, where digital, physical and cyber-physical systems work together rather than in silos.

That concern around silos was reinforced by Subodh Dixit, former Director, Shapoorji Pallonji, who said the issue is not just that technologies are disconnected, but that stakeholders are as well. Clients, consultants, contractors and partners often operate with different priorities. Unless these silos are broken, technology will struggle to percolate across the full project value chain.

Harleen Oberoi, Project Management, Tata Realty shared a practical perspective from the client side, saying that successful BIM implementation requires investment across the ecosystem, not just within one organisation. Trade partners, vendors and other stakeholders must also be trained and aligned if the technology is to deliver its intended results.

Beyond buzzwords

A notable takeaway from the session was that the industry is moving past the phase of treating technology as a buzzword. Participants repeatedly stressed that the real question is not whether technology should be used, but where it creates measurable value and how that value can be scaled.

The conversation also expanded beyond mainstream themes to include repairs and rehabilitation, construction and demolition waste, sustainability, circular economy, green sourcing, carbon measurement, design interoperability, generative design, robotics, and the role of horticulture and greener built environments.

Setting the agenda for CTS 2026

By the close of the session, the roundtable had surfaced a strong set of themes for the upcoming show: BIM and digital twins, AI and data platforms, industrialised construction, startup innovation, governance-led technology adoption, robotics, sustainable materials, and integrated project delivery.

More importantly, the session established CTS 2026 as more than an exhibition. It is shaping up to be a serious industry platform where users, technology providers, researchers and policymakers can collectively define the future of construction.

As Padode noted in his closing remarks, the conversation will continue through further consultations and possibly webinars in the run-up to the show. If the roundtable is any indication, CTS 2026 will aim not merely to showcase technology, but to push the industry towards meaningful adoption at scale.

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Concrete

Human Factor in Grinding Optimisation

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Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, discusses the role of skilled operators as the decisive link between advanced additives, digital control and world-class mill performance.

The industry always tries to reduce the number of operators in the Centre Control Room. (CCR) Though the concept was succeeded to certain extent, still we need a skilled person in the CCR.
In an era where artificial intelligence (AI) grinding aids, performance enhancers, and digital optimisation tools are becoming increasingly sophisticated, it’s tempting to believe that chemistry alone can solve the challenges of mill efficiency. Yet plants that consistently outperform their peers share one common trait: highly skilled operators who understand the mill as a living system, not just a machine.
Additives can improve flowability, reduce agglomeration, and enhance separator efficiency, but they cannot replace the nuanced judgement that comes from experience. Grinding is a dynamic process influenced by raw material variability, moisture, liner wear, ball charge distribution, ventilation, and separator loading. No additive can fully compensate for poor control of these fundamentals.

Operators see what additives cannot
When I joined the cement industry in 1981, not much modernisation was available then. Mostly the equipment was run from the local panel. Once I was visiting the cement mills section. The cement mills were water sprayed over the shell to reduce the temperature to avoid the gypsum disintegration.
The operator stopped the feeding for one of the mills. When I asked the reason, he replied that mill was getting jammed, and he added that he could understand the mill condition by its sound. I also learned that and it was useful throughout my career. In another plant I saw the ‘Electronic Ear,’ which checked the sound of the mill and the signal was looped with feed control!
Whatever modernisation we achieve, it is from the human factor that the development starts.
Additives respond to conditions; operators interpret them.
A skilled operator can detect subtle shifts, like a change in mill sound, a slight variation in circulating load, or a drift in separator cut point. It’s long before instrumentation flags a problem. These micro-observations often prevent major efficiency losses.
Additives work best when the process is stable
I would like to share one real time incident. The mill was running on auto mode looped with the mill outlet bucket elevator kilowatt. (KW)There was a decrease in the KW, and the mill feed was increased by the auto control (PID). After a while, the operator stopped both the feed and the mill. He asked the local operator to check the airslide between mill outlet and the elevator. They found the airslide was jammed and no material flow to the elevator!
The operator deduced the abnormality by his experience by seeing the conditions and the rate of increase of the feed by the auto control.
It’s always the human factor that adds value to the optimisation.

Grinding aids are multipliers,
not magicians.
They deliver maximum benefit only when:
• Mill ventilation is correct
• Ball charge is balanced
• Feed moisture is controlled
• Separator speed and loading are improved
• Blaine targets are realistic
Without these fundamentals, even advanced additives may become costly investments. The operator is responsible for ensuring process stability, whether using a ball mill or a vertical mill. After ensuring the system is stable, the operator observes it briefly before transitioning to automatic control. If there is any anomaly in the system the operator at once takes control of the system, stabilises and bring back to auto control.

Skilled operators adapt in real time
It will be interesting to note that the operators who operate from local panel start to operate from DCS also. They have the experience and the ability to adapt the changes. Operator checks each parameter deeply. Any meagre change in the parameters is also visible to him.
Raw materials change. Weather changes. Wear patterns change.
A skilled operator adjusts:
• Feed rate
• Water injection
• Separator speed
• Grinding pressure (in VRMs)
• Mill load distribution.
These adjustments require intuition built from years of experience, something no additive can replicate.

Human insight prevents over reliance on additives
Plants sometimes increase additive dosage to mask deeper issues like:
• Poor clinker quality
• Inadequate drying capacity
• Incorrect ball gradation
• High residue due to worn separator internals.


A knowledgeable operator finds root causes instead of chasing temporary chemical fixes.
The real optimisation sweet spot is reached when:
• Operators understand how additives interact with their specific mill.
• Additive suppliers collaborate with plant teams.
• Process data is interpreted by humans who know the mill’s behaviour.
This constructive collaboration consistently delivers:
• Lower kWh/t
• Higher throughput
• Better product consistency
• Optimum standard deviation.

Advanced additives are powerful tools, but they are not substitutes for human ability. Grinding optimisation is ultimately a human driven discipline, where skilled operators make the difference between average performance and world class efficiency. Additives enhance the process but operators
control it.

About the author:
Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, is a seasoned cement process consultant with 43+ years of global experience in plant operations, process optimisation, refractory management, safety systems and training multicultural teams across international cement plants.

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