Raju Ramchandran, SVP and Head Manufacturing – Eastern Region, Nuvoco Vistas, on how the company is setting new benchmarks in industrial safety and operational resilience, with smart technologies and a proactive approach.

In the high-risk environment of cement manufacturing, safety is more than a compliance requirement—it is a strategic imperative. Raju Ramchandran, SVP and Head – Manufacturing, Eastern Region, Nuvoco Vistas, shares how the company is redefining workplace safety through technology, accountability and next-generation systems. In this in-depth conversation, he outlines the evolving risks, robust safety frameworks and the future of digital-first safety culture.

How has the approach to safety evolved in cement manufacturing over the past decade?
Over the past decade, safety in cement manufacturing has evolved from being a regulatory checkbox to becoming an intrinsic part of organisational culture. At Nuvoco, safety is not just a priority, it is a core value, deeply woven into the way we operate every single day. Guided by our ‘Zero Harm’ philosophy, we strive to ensure that every individual stepping into our premises returns home safely.
We have moved towards a more proactive and preventive approach and building strong behavioural safety practices. Specialised training programmes, regular incident reviews and active Safety Committee engagements have strengthened accountability and vigilance across all units. Initiatives such as Cross-Unit Safety Audits, improved workplace hygiene standards, and the successful rollout of the ‘Safety Buddy’ programme reflect our emphasis on collaboration and shared responsibility for safety.
Additionally, best-in-class measures from mandatory safety nets and harnesses to advanced risk assessments for high-hazard tasks are now standard practice across our sites. Supported by leadership commitment, digital monitoring tools and real-time feedback mechanisms, these efforts have transformed safety from a procedural obligation into a shared mindset.
At Nuvoco, safety is a non-negotiable tenet—it is a way of life, and we are constantly raising the bar to protect every member of our workforce.

What are biggest safety risks unique to cements plant today?
Cement manufacturing is an intense, high-temperature and operation-heavy process, where safety is paramount at every stage. The environment presents several unique risks that require constant vigilance and robust preventive measures.
Mining operations within the industry bring their own set of hazards, with strict adherence to Directorate General of Mines Safety (DGMS) guidelines being essential. Exposure to dust is another area of concern, necessitating advanced dust suppression systems and protective equipment to safeguard workers’ health.
Electrical safety and proper energy isolation are also crucial, given the complexity of the equipment involved. Confined space entries, conveyor belt operations and machine guarding present additional risks that call for specialised procedures and continuous monitoring to prevent accidents. Preheaters and precalciners also pose challenges during maintenance activities, such as cleaning cyclone jams, while fire hazards remain present in areas with flammable materials. Additionally, working at heights continues to be one of the major risk activities, making stringent fall protection protocols a non-negotiable.
At Nuvoco, we tackle these risks with a layered approach combining engineering controls, digital monitoring and rigorous safety protocols backed by continuous training and regular mock drills to ensure preparedness for any eventuality. Safety is an unwavering commitment to safeguarding everyone who works in and around our plants.

What role does technology play in enhancing plant safety?
Digital technologies are transforming safety management in cement manufacturing, enabling a shift from reactive measures to a predictive and preventive approach. At Nuvoco, we leverage cutting-edge tools and systems to minimise risk, strengthen hazard management and create safer workplaces for everyone.
Our advanced energy isolation systems such as Lock Out, Tag Out, Try Out (LOTOTO) processes are in place to safeguard electrical operations, while machines are fitted with Visual Cutoff Switches (VCS) for enhanced local control. GPS and Vehicle Tracking Systems (VTS) ensure the safe movement of commuting vehicles across sites.
Real-time monitoring through IoT sensors allows us to track critical parameters like, temperature fluctuations, harmful gases in coal mills and machinery vibrations. These early alerts help prevent potential fires, explosions, and equipment failures. To limit human exposure to hazardous environments, drones are used for inspecting kilns, chimneys and high structures during shutdowns, while robots perform cleaning tasks in preheaters and confined spaces, keeping people out of high-risk areas.
We have also introduced devices such as gas detectors and real-time location trackers that enables faster emergency responses.
Complementing these efforts, our STARS (SHE [Safety, Health & Environment], Tracking, Analysis and Reporting System) software ensures comprehensive tracking of leading and lagging indicators, while mobile apps enable instant reporting of near misses, safety observations and audits. These tools ensure quick corrective actions and strengthen our safety culture across all operations.
By embedding technology into every layer of safety management, Nuvoco has built a digitally enabled, proactive safety framework—one that not only mitigates risks but empowers employees to work confidently, knowing their well-being is protected at every step.

How do you ensure contractor and third-party compliance with your safety standards?
Ensuring contractor and third-party compliance with safety standards in the building material industry involves a comprehensive process that spans prequalification, onboarding, active supervision and post-contract evaluation. It begins at the selection stage, where contractors are assessed not only for their technical competence but also for their safety track record, relevant certifications, availability of personal protective equipment, and the preparedness of their personnel. These expectations are formalised through contractual agreements that clearly outline health and safety responsibilities, legal obligations and consequences in case of non-compliance.
Prior to starting work, contractors undergo mandatory onboarding and training, which cover site-specific hazards, protocols and emergency procedures often communicated in local languages to ensure clarity. For high-risk activities such as hot work, working at heights or confined space entry, a permit-to-work system is in place, supported by detailed risk assessments jointly signed by contractor representatives and plant personnel to reinforce
shared accountability.
During execution, trained supervisors are deployed to monitor compliance on the ground through daily toolbox talks, spot checks and documented audits. Safety performance is closely tracked using both leading and lagging indicators, such as participation in safety initiatives, near-miss and injury reporting. In the event of repeated violations, appropriate enforcement actions are taken, ranging from temporary work stoppage and financial penalties to permanent disqualification while contractors demonstrating consistent adherence are recognised through structured reward and recognition programmes.
Towards the end of the contract period, each contractor’s safety performance is formally reviewed, with the insights feeding into future selection processes. This continuous cycle of evaluation and improvement ensures that safety expectations remain consistent across all stakeholders working within the plant environment.

How are you investing in next-generation safety equipment or systems?
We are investing in next-generation safety systems that not only reduce risks but also transform the way hazards are detected, monitored and controlled across our operations.
We have invested in IoT-enabled sensors provide real-time insights into high temperatures, carbon monoxide levels in coal mills, oxygen levels in pyro processes, and vibrations in heavy machinery, while flame detection via CCTV ensures early alerts for potential fire incidents.
Robotic descalers are used for refractory de-bricking inside preheaters, while drone surveillance is deployed to inspect tall structures such as stacks and silos. This helps identify structural hazards, material build-up and assess the condition of coatings in silos and preheater cyclones. These technologies significantly reduce human exposure to high-risk areas while improving inspection accuracy and efficiency.
Furthermore, we have strengthened fire and explosion protection with advanced suppression systems in coal mills and dust collectors, supported by thermal imaging, we are also exploring the use of AI-enabled cameras for instant detection and response. In hauling operations, driver fatigue detection cameras provide real-time alerts to prevent accidents, while environmental safety is reinforced through live dust monitoring systems with alarms and visual displays at plant gates for corrective action. By embracing these next-generation technologies, we are building a safer, smarter and sustainable world.

Frank Ormeloh, Business Unit Manager for Cement, HAVER & BOECKER, discusses how packing equipment manufacturers enhance efficiency and sustainability.

When we hear the word ‘sustainability,’ many people jump to a definition that focuses solely on environmental impacts. However, in the truest sense of the word, sustainability encompasses three factors — social, economic and, of course, environmental.
As with all businesses, cement plants have been drawn into the sustainability conversation. As pressure mounts to save resources and reduce carbon footprints and energy consumption, cement plants are developing smart and efficient practices to meet strict environmental standards. To reach sustainability objectives, facilities need to scrutinise the entire plant to identify the most effective solutions. Yet many operations overlook packing and loading lines, writing them off as insignificant to sustainability. However, plants can reduce resource consumption and improve product protection by optimising every system and that includes the packing process.
Some key areas to focus on while optimising a plant for sustainability include choosing the right equipment and components that can be customised to the plant as well as considering machine designs that allow for upgrades and enhancements. These options increase the longevity of the packing line while improving filling accuracy and reducing lost product.

Cleanliness, health and safety
Many producers believe dust is an inevitable byproduct of cement production. This is a myth. It is true that packing powdered material, for example, requires the addition of air to move the material, inevitably creating dust. However, dust suppression technology available today can offer nearly dust-free working conditions. By reducing dust, minimising product loss and promoting the careful use of resources, the employee, the environment and the bottom line all benefit. Maintaining cleanliness also enhances employee health and provides a safer working environment. Reducing dust is just one way to enhance sustainability in a packing plant, though. Adjustments at nearly every stage of the filling process — from feeding and dosing to packing and loading — can have a positive impact.

Feeding and dosing
The first step in the packing process is when material is fed into the packer silo. The material is then moved through a rotary feeder and a dosing system. In this initial step, many machines feature a slide gate dosing unit, which leaves a gap of several millimeters where dust and spillage can escape. To reduce dust production and protect against spillage, operations should consider a fully enclosed, metal shaft-sealed system featuring a rubber interface between the gates. This simple changeout makes the process at least 70 per cent cleaner and up to eight per cent faster compared to traditional slide gate systems. The only dust and spillage that can escape using this system comes from the way the filling spout and the bag valve interact — a challenge that some manufacturers are prepared to address with services such as updated bag sealing technology.

Sealing technology
Advanced sealing technology goes a long way in addressing material loss during bag filling and sealing. Standard rigid filling spouts require the unsealed valve bag to adhere to the tube, leaving room for product to escape. Once packed, unsealed valve bags rely on the inner pressure of the bag to close, which results in the bag being only 70 per cent closed and leaves a 30 per cent opening for spillage.
To solve this challenge, premium manufacturers offer specialized inflatable filling tubes that hermetically seals the gap between the bag and the filling spout during the filling process. This translates to no dust escaping through the valve and, when filling is complete, the bag is removed from the spout and the valve is welded shut by an ultrasonic sealing unit. This creates a cleaner working environment with less product loss, cleanup and energy consumption and better weight accuracy. During palletizing, transportation and storage, these completely sealed bags can make producers stand out with custom designs and a clean packing solution.

FFS technology
Another factor that should be considered for reducing product loss is the type of bag, and its compatibility with the packing equipment. Specialised manufacturers analyse the material being packed and the bags used before making recommendations. These customised recommendations increase the harmony between the bags, packing machines and product. For example, tubular film bags are ideal as a completely sealed, weatherproof and leakproof solution for a wide range of industries, spanning from cement to building and chemical products.
Tubular film is fed into a packing machine where it is cut and sealed, ensuring it is 100 per cent closed. This sealing method creates a permanent, tamper-resistant closure that holds up reliably during transport and storage — a key advantage over other methods that may weaken under shifting conditions. These tubular film bags are also completely emptiable, eliminating product loss for the consumer. Plus, they are recyclable, providing an additional sustainability benefit.
If making the switch to a Form-Fill-Seal (FFS) or tubular film machine, consider the manufacturer and the machine itself. Some FFS machines use vacuum methods to compact material as it’s filled into the bag. On the other hand, some machines are equipped with vibration technology to accomplish this task, which is much more effective and allows for the same amount of product to be packed into a smaller bag, meaning less film used per bag.
Over time, this translates to significant environmental and economic advantages. The fully sealed bags remain clean and uniform, which can draw in more customers. The weatherproof qualities of these bags make handling and storage easier.

Automation at play
Once equipment and bag material choices have been made, it’s time to look at automation, which helps significantly impact efficiency and sustainability. A fully automated packing line allows for more flexible line layouts and negates the inefficiencies caused by human error or manual limitations. Though both may seem like small matters, the effects add up over time. Automation also allows skilled labor to focus on higher-value tasks, improving overall workforce utilisation.
Manual processes, such as bag placement, leave room for lost productivity and errors from tired or distracted workers, who may be late placing a bag on the filling spout or miss a bag entirely. If a bag is not placed at the correct time in the correct way, facilities see major product loss of material per missed bag.
To replace the manual process, a robotic depalletiser can transfer bags — even loose, unstrapped bundles — from the pallet to the automatic bag placer. Automated bag application systems eliminate provide steady packing by ensuring continuous and accurate bag placement. Then, the bag placer securely places the bags onto the filling spout at a rate that matches the packing machine, with an output of up to 6,000 bags per hour with some models. An automated bag application system allows for a consistent, sustained pace for bag placement that is simply impossible to achieve with manual labour.
Some plants are limited by space, making it difficult or seemingly impossible to accommodate the footprint needed for production-boosting automation. This requirement previously inhibited automation, forcing manual placement and increasing safety risks by putting operators near the packing machine. However, innovative new products developed by leading manufacturers provide systems to transfer empty bags from the bag applicator to the packing machine, eliminating the need to place the bulky applicator right next to the packing machine. With the new and innovative systems, bag applicators can be positioned away from the packing machine — even in a different room. Not only does this protect the bag applicator from the immediate surroundings of the packing machine, but it also allows the plant to position it in a way that makes maintenance easier and allows users to completely rethink their empty bag logistics process.
Properly maintained equipment works more efficiently for longer, increasing sustainability and allowing operations to get the most out of their packing line. In addition to these options, palletisers — either robotic or traditional layer palletisers — can be incorporated to completely automate lines from empty to full bag.

Digitalisation and lifetime of equipment
The integration of equipment monitoring technology across all machines is an excellent way to achieve easier equipment optimisation and preventative maintenance tailored to the needs of the plant. Maintenance warnings or optimisation adjustments are displayed on the HMI, which is integrated into the control and weighing units of the machine, allowing service personnel to address concerns before they become critical and preventing unexpected downtime and lost production.
Systems with a centralised digital solution connect multiple machines together to translate data from the machine control and weighing system, making updating the entire packing line easier and resulting in more versatility. These systems require relatively low investments and result in fast return on investment. One of the easiest ways to start a sustainability journey is to invest in digitalisation.
Beyond digitalisation, some manufacturers offer rebuilds and upgrades kits to expand the flexibility, longevity and return on investment of packing lines. These kits also help the plant adapt as changes are made to the composition of materials. Many kits come preconfigured, making connecting them much easier than other upgrade options. As businesses continue to grow, some plants will need to expand, whether that means diversifying into other materials or adding new locations.

ETO approach
While many quality assemble-to-order systems enhance key sustainability metrics, operations that want to take things one step farther often look to packing plants that are truly engineered to order. For facilities seeking even more tailored solutions, engineer-to-order (ETO) systems offer long-term benefits by allowing companies to customise with all the features that continue to save money and boost profitability for years to come. Consider working with a manufacturer that offers a truly consultative approach to determine the best options for not only the packing machine but the entire plant.
All together, these systems make packing powdered material safer, cleaner and more efficient, allowing for greater operational sustainability. Choosing the right technology is an essential step to maximise the sustainability process when it comes to preventing product loss and saving resources like energy.

Diversification and expansion
In the cement industry, circumstances change quickly, and operations need options to meet demand wherever in the world that might be. Look for a manufacturer who offers prefabricated, modular packing systems for quick installation in situations with short timelines between when a purchasing decision needs to be made and entry into a new market. These specialised systems can be disassembled and reassembled in different areas, making it a sustainable option for production facilities.
It has also become increasingly important for operations to look for ways to diversify their product output. One way cement plants can do this is by using cement byproducts to create new materials. For example, instead of burning limestone, plants can use it as a component of fertiliser, which allows for an additional source of revenue in new
markets and effectively reduces the amount of CO2 the plant produces. To accomplish this, consider working with a manufacturer that offers a depth of expertise in a wide range of industries and process engineering capabilities.

Our blue planet
No matter what the future of packing brings, when experienced cement producers and equipment manufacturers partner, it results in more sustainable, efficient plants. The future of sustainability does not just rely solely on reducing power usage, dust suppression or even minimising product loss. Instead, the truly sustainable operations will be those that account for the big-picture view of all factors — from environmental to social and economic.

About the author:
Frank Ormeloh, Business Unit Manager for Cement, HAVER & BOECKER, is a mechanical engineer with over 30 years of industry expertise.

Dijam Panigrahi, Co-founder and COO, GridRaster, discusses how AI, digital twins and cobots are reshaping cement manufacturing.

The modern industrial landscape in cement production is changing, driven by the convergence of artificial intelligence (AI), digital twins and collaborative robots (cobots). This trifecta is not only enhancing existing operations but fundamentally reimagining how cement manufacturing functions, creating a synergistic environment where human and machine capabilities are maximised.
The International Federation of Robotics (IFR) notes that the global operational stock of industrial robots reached 4.2 million units in 2023, with cobots accounting for a considerable share. Furthermore, the global collaborative robot (Cobot) sales market, valued at $1,020 million in 2024, is projected to reach $2,199 million by 2031, growing at a compound annual growth rate of 11.8 per cent during the forecast period of 2025-2031.
At the heart of this evolution is AI, serving as the intelligent core that orchestrates a multitude of processes in cement production. Its capabilities span from optimising cobot control and predictive maintenance for kilns and grinding mills to ensuring stringent quality control of cement mixtures and streamlining complex supply chain management of raw materials like limestone, clay and gypsum.
AI empowers machines and robots with the ability to learn, adapt, and make real-time decisions, leading to significant improvements in operational efficiency and responsiveness across the board in cement plants. This intelligent automation is enabling the cement industry to achieve levels of precision and speed previously unattainable.

Digital twins: Virtual replicas for real-world optimisation
Complementing AI’s computational prowess are digital twins, which offer virtual replicas of physical assets and processes within a cement plant. These digital models provide an invaluable sandbox for businesses, allowing them to simulate and rigorously test new systems and workflows in a virtual environment before committing to costly physical implementation, such as optimising a new production line or a material handling system.
This capability is particularly crucial for optimising human-robot collaboration, as it allows for the fine-tuning of interactions and processes to ensure seamless integration and maximum output in potentially hazardous areas of a cement facility. The real-time monitoring capabilities of digital twins further enhance their utility, enabling continuous optimisation and proactive problem-solving, for example, by predicting equipment failure in a kiln. The synergy between AI and digital twins significantly reduces risks associated with new deployments and accelerates their time to market.

Empowering the human workforce: Upskilling and collaboration
While the focus on advanced automation might suggest a diminishing role for human workers, the reality is quite the opposite in cement manufacturing. Workforce enablement technologies are designed to empower and elevate the human element within this increasingly automated ecosystem.
These innovative tools facilitate comprehensive upskilling through immersive augmented reality (AR) and virtual reality (VR) training programmes, preparing the workforce for the demands of new technologies and roles, such as operating and maintaining cobots or analysing digital twin data. User-friendly interfaces are simplifying human-robot interaction, making it more intuitive and accessible for workers to collaborate directly with cobots in areas like quality control or material handling.
Furthermore, remote assistance capabilities provide on-demand expert support, ensuring that human workers have the resources they need to troubleshoot and optimise operations effectively in a cement plant.

A synergistic future: Boosting productivity, flexibility and safety
One of the most significant advantages of integrating cobots in cement manufacturing is their ability to offload repetitive, dangerous or physically demanding tasks from human workers, such as bagging cement, loading trucks, or operating in dusty environments. This frees up the human workforce to concentrate on higher-value activities that
demand critical thinking, problem-solving, and creativity – uniquely human attributes that machines cannot replicate.
This integrated approach not only drives remarkable gains in productivity, flexibility and safety but also cultivates a truly synergistic relationship between cutting-edge technology and a skilled, adaptable human workforce.
The implications of this integrated approach extend across various facets of cement manufacturing. The precision and speed offered by AI-powered cobots, validated through digital twin simulations, lead to reduced errors in mixing, faster production cycles, and greater customisation capabilities for different cement types. This translates into higher quality products and the ability to respond more rapidly to market demands.
The optimisation of supply chains through AI and the efficient handling of raw materials and finished goods by cobots result in faster delivery times, reduced operational costs and enhanced inventory management in cement plants. The ability to simulate and optimise complex logistical networks with digital twins means that potential bottlenecks in material flow can be identified and resolved before they impact real-world operations, leading to a more resilient and responsive supply chain for cement.
Moreover, the emphasis on workforce enablement ensures that as technology advances, human workers are not left behind but rather become integral components of the new industrial paradigm in cement production. Upskilling initiatives, facilitated by AR/VR, allow for continuous learning and adaptation, creating a dynamic workforce capable of navigating technological shifts.
The simplified human-robot interfaces remove barriers to entry, making collaborative robotics accessible to a broader range of workers in
cement facilities. This human-centric approach to automation fosters a more engaged and empowered workforce, leading to increased job satisfaction and reduced turnover.
The combination of AI, digital twins and cobots today represents a fundamental modernisation of the cement manufacturing landscape. AI provides the intelligence, digital twins offer the foresight and cobots provide the physical execution, all while workforce enablement technologies ensure that humans remain at the center of innovation and decision-making in cement plants. This integrated approach promises a future where operations are more efficient, resilient and adaptive, ultimately leading to unprecedented levels of productivity and a more fulfilling work environment for all in the cement industry.

About the author:
Dijam Panigrahi is Co-Founder and COO of Gridraster with over 21 years of international experience in market development, business growth, and product management.