Economy & Market

Regional mix helps Ambuja post strong results

Published

8 years ago

July 31, 2017

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Ambuja Cements’ exposure to west, north and east India drove strong growth in realisations, which were much better than the forecasts. Cement volume growth of 5 per cent was also a positive in the current context, driving market share gains. The company managed to post the highest unit EBITDA in nearly 19 quarters, as was the case with its 50 per cent-sub, ACC. Net earnings still fell 13 per cent YoY to Rs 3.9 billion, which was 22 per cent ahead of the estimate.

Ambuja’s 2Q standalone EBITDA rose 6 per cent YoY to Rs 6.1 billion, 19 per cent ahead of our estimate. Depreciation was a bit lower and so was other income; the tax rate of 28.2 per cent too came in a bit lower. Net earnings declined 13 per cent YoY to Rs 3.9 billion, which was 22 per cent ahead of our estimate. Consolidated EBITDA (including ACC) was up 21 per cent YoY to Rs 12.9 billion while net earnings rose 7 per cent YoY to Rs 5.6 billion.

Ambuja reported 5 per cent YoY growth in cement volume with overall volume up 4 per cent; this was a tad lower than our forecast. Cement realisation, however, rose at a strong 11 per cent QoQ to Rs 233 per bag. Ambuja benefitted from its strong presence, as all its regions had strong pricing trends. We believe that prices rose the most in west India followed by north and then the east. Overall costs were also under check with unit cost up just 1 per cent QoQ. The cost of manufacturing (materials+energy) rose 2 per cent QoQ while freight was marginally down. Unit EBITDA increased to a 19-quarter high of Rs 1,010 per tonne (+67 per cent QoQ). Ambuja’s 50 per cent-held subsidiary, ACC, reported better results than we had expected led by higher volume and lower costs. Overall 2Q EBITDA rose 20 per cent YoY to Rs 5 billion, 12 per cent ahead, and a saw strong beat at the net earnings level too. Volume growth of 10 per cent was also strong led by new capacity in the east with a 5 per cent QoQ rise in net realisations. Unit EBITDA at ACC was also at a 19-quarter high of Rs 735 per tonne.

JSW IPO to hit market in 2019
JSW Cement, a subsidiary of JSW Steel, announced that it is looking at a valuation of around Rs 25,000 crore to Rs 30,000 crore when it issues its initial public offer (IPO) in 2019.

The company is eyeing at raising Rs 2,500-Rs 3,000 crore from a 10 per cent dilution in the first phase. It plans to propose for an IPO after 2019 general elections as the company want to be a 20 MT cement company with limestone reserves in two to three states.

Govt nod for Cement Corp revival
The Government has approved revival of the three operating units of state-owned Cement Corporation of India and will shut down the non-operating units of the company. In a written reply in the Rajya Sabha, Minister of State for Heavy Industries and Public Enterprises Babul Supriyo said that the Government has approved ‘revival (of Cement Corporation of India) as a public sector enterprise’through closure of non-operating units and revival of three operating units.

The Board for Reconstruction of Public Sector Enterprises had recommended closure and sale of non-operating units and revival of operating units as a public sector enterprise. However, in its reply, the Government was silent on the sale of the non-operating units and said it has approved their closure.

PWD to use green tech for laying roads
The Public Works Department (PWD) will go in for Cold In-Place Recycling (CIR) of bituminous pavement, an environment-friendly green technology for laying roads. The National Highway wing of the PWD is adopting the new technology close on the heels of using shredded plastic, rubber, application of geosynthetics, coir geotextiles and pavement recycling to enhance the life of road corridors.

The National Highway 66 corridor between Pathirappally and Purakkad in Alappuzha district has been subjected for the first time in the State the CIR, a rehabilitation technique of pavement in which the existing materials are reused. Of the 28-km stretch identified, 16 had been relaid using green technology with Indian Road Congress (IRC) specifications and is offering cozy ride to motorists, Chief Engineer, PWD, NH KP Prabhakaran told. The remaining stretch in Alappuzha will be taken up after the rain and has plans to use it to more NH corridors.

The Reclaimed Asphalt Pavement (RAP) material is obtained by milling, planning or crushing the existing pavement. RAP material along with fresh aggregate are mixed, laid and then compacted. The CIR can restore old pavement to the desired profile, eliminate ruts, restore the crown and cross slope and eliminate potholes, unevenness and rough areas.

In Alappuzha, the pavement condition warranted for almost a full depth reclamation as the damages extended up to the sub-base at many locations. The pavement was milled for a thickness of 160 mm and relaid using cold process.

A wearing course of 50 mm BC was given over recycled layer. The CIR involves reuse of existing pavement materials without application of heat. Foam bitumen was used as recycling agent in the cold milling equipment. Almost 15 per cent fresh aggregate was added along with cement.

The existing road would be cleaned by air compressor and the around 15 per cent aggregates and 1.5 per cent cement would be pre-spread on the asphalt road. The road would be rehabilitated by in-situ pulverising (milling) the top 160 mm of the existing pavement. At the time of pulverizing, the pre-spread aggregates, cement and hot bitumen is injected into milled surface. The recycled mix is then compacted and graded to profile using roller and grader and eventually sealed by BC.

Bank of Baroda moves NCLT to recover money from Binani
Bank of Baroda has filed a petition against Binani Cement Ltd with the National Company Law Tribunal’s (NCLT) Kolkata bench, seeking to recover Rs 97 crore in an outstanding loan under the new Insolvency and Bankruptcy Code after the firm failed to come up with a restructuring plan to clear its dues.

Lawyers for Binani Cement, a privately held firm of the Braj Binani Group, claimed that the application from Bank of Baroda had several technical flaws, and that its claim was minuscule compared with the total value of the group’s assets, which, according to its lawyers, is Rs 14,000 crore.

Binani Cement, which is a unit of Binani Industries Ltd, had assets worth Rs 5,074 crore at the end of March, according to the holding firm’s auditor, MZSK & Associates. NCLT’s Kolkata bench reserved its order on whether or not it would admit the lender’s application under the new insolvency code. If the application is admitted, the company’s board will be superseded and an interim resolution professional appointed to take control of its assets and operations. Bank of Baroda wants management consulting firm Deloitte to be appointed as interim resolution professional.

Pratap Chatterjee, counsel for Binani Cement, said Bank of Baroda was not the lead lender to the cement maker and that it had not taken the approval of the joint forum of lenders before moving NCLT. Citing Reserve Bank of India rules, Chatterjee said Bank of Baroda was required to write to the joint forum and wait for at least 30 days before unilaterally moving NCLT.

Chatterjee asked why Bank of Baroda was seeking the appointment of an administrator to recover a small loan of Rs 97 crore when the lead banker, Central Bank of India, was not seeking dispute resolution in this manner.

Gujarat HC notice to govt, Ambuja over mining safety
The Gujarat High Court has issued notice to concerned authorities and the cement factory in Gir-Somnath district over a PIL complaining that safety measures are not taken in mining activity and that the mining is illegally carried out in reserve forest areas.

Petitioner RTI Activist Sangathan has sought direction from the high court to direct the authorities to make Gujarat Ambuja Cement Ltd compel to erect fence around its mining areas. The petitioner has complained that at least 15 persons have lost their lives in Gir-Somnath district where the company is undertaking its mining operations. This has happened due to deliberate neglect on part of the company and the authorities that fencing is a must safety measure.

The petitioner alleged that the company also undertakes mining in private land, grazing land as well as in the forest areas also. Upon hearing the case, the HC issued notice to the Centre, the cement company, Director of Mining Safety, DySP of Gir-Somnath and the Jamwala Range Forest Officer of Gir sancturary. Further hearing is on September 6.

LafargeHolcim lowers growth forecast
Swiss-French cement group LafargeHolcim has lowered its forecast for growth in global cement markets this year after second quarter sales fell short of expectations. Based on developments in the first half 2017, it expected growth in its markets this year of between 1 and 3 per cent in 2017, the world’s largest cement company by sales said. That compared with the 2 to 4 per cent it had expected in May.

However, Beat Hess, Chairman, said that the group still expected to meet its 2017 and 2018 targets, ‘with key countries such as the US, India, Nigeria and, notably this quarter, Mexico making significant contributions to earnings, more than offsetting headwinds in some of our markets.’

LafargeHolcim reported net sales had risen by 3.6 per cent to SFr 6.85 billion on a like-for-like basis in the three months to June. That compared with the almost SFr 7 billion expected on average by analysts. Adjusted pre-tax operating profits of SFr 1.74 billion were 10 per cent higher than a year earlier on a like-for-like basis – and slightly higher than expected by analysts.

LafargeHolcim was formed by the ?41 billion merger in 2015 of Lafarge of France and Holcim of Switzerland. Over the past year, the group has been dogged by a scandal over a plant it operated in Syria until September 2014. In April, Eric Olsen resigned as chief executive to help restore calm at the company – although the company said he was not involved in or aware of any wrongdoing.

Global pension funds keen on highway projects
International pension funds with an appetite for staying invested for several years are expected to be primary suitors for the highway contracts to be auctioned by the National Highways Authority of India (NHAI). Experts say the Government wants to generate cash to support its next tranche of investment in the highways sector. They are of the view that foreign pension funds would be keen to bid for such projects because they typically invest in those with a longer duration, unlike private companies, which look for quick results.

‘Since most of the construction-related risk is taken care of by the Government, the private sector would be interested in these contracts because the traffic is already established and the Government is hopeful of getting surplus cash post auctions,’said Adil Zaidi, partner-economic development and infrastructure advisory, EY. He said the Government should plan the highways and alignments it intended to auction.

Global pension funds might be attracted by the certainty of the return on investment, an analyst said. Last year, the Cabinet Committee on Economic Affairs authorised the NHAI to monetise 111 publicly-funded requiring reduced NHAI involvement in projects.

Further, the corpus generated from the proceeds of such project monetisation could be utilised by the Government to meet its requirements on development and O&M of highways in the country NH projects that were operational and were generating toll for at least two years after the Commercial Operations Date (COD) through the toll-operate-transfer (TOT) model. Around 75 operational NH projects completed under public funding have been preliminarily identified for potential monetisation using the TOT model. This model would provide an operation and maintenance (O&M) framework, requiring the NHAI’s reduced involvement in projects after construction completion.

Further, the corpus generated from the proceeds of such project monetisation could be utilised by the government to meet its fund requirements regarding development and O&M of highways in the country. This could help the development and strengthening of highways in unviable geographies. The Government aims to cater for that category of investors which is averse to taking construction risks but is adequately equipped for making long-term investments in road infrastructure, e.g. institutional investors including pension and insurance funds, and sovereign funds. In the past Macquarie, Brookfield, Cube Highways, and other such global funds took equity in NH projects worth about 4,150 crore, from which private promoters had exited. The auction can also be seen as a move to allow the entry of sovereign funds from Abu Dhabi and Qatar into such projects.

Orient posts Rs 39 cr net profit
CK Birla group firm Orient Cement Ltd reported a net profit of Rs 38.92 crore in the first quarter ended on June 30, 2017. The company had posted a net loss of Rs 7.56 crore in the same period last fiscal, Orient Cement Ltd said.

Revenue from operations during the period under review was at Rs 656.73 crore as against Rs 505.21 crore in the year-ago period, up 30 per cent. During the quarter, the company signed definitive agreement for acquisition of 74 per cent shares of Bhilai Jaypee Cement from Jaiprakash Associates and its nominees for an enterprise value of Rs 1,450 crore.

The company also inked similar pact for the business transfer of Nigrie Cement Grinding unit of Jayprakash Power Ventures Ltd at an enterprise value Rs 496 crore.

Govt to assist Assam for repair of highways
The Minister of Road Transport & Highways and Shipping Nitin Gadkari has announced a financial assistance of Rs 200 crore as the first installment for the immediate repairs of National Highways damaged due to heavy rains in Assam. The announcement was made after the Assam Chief Minister Sarbananda Sonowal called on Gadkari for a review of the situation in Assam where heavy rains have led to National Highways being damaged.

Meanwhile, an expert team of the National Highways Authority of India (NHAI) officials has been dispatched for on the spot assessment of the damage. If needed, further financial assistance will be provided based on the NHAI team’s report. Another Rs 400 crore has been sanctioned for dredging work in Brahmaputra river. The work will start from September using six dredgers. Dredging will increase the depth of the river and prevent it from flooding. A total of seven bridges are to be built on Brahmaputra river during the next five years for better road connectivity with the NE region. Work on two bridges is underway. DPR for three more bridges is to be prepared by the State Government.

Gadkari has also asked the State Government to submit the DPR for the proposed Bhramaputra National Highways to be built along the banks of the river at a cost of Rs 40,000 crore.

Govt may lease out infra projects to private operators: NITI CEO
The Government needs to exit infrastructure projects and even look at handing over jails, schools and colleges to the private sector as happens to be the case in countries like Canada and Australia, NITI Aayog CEO Amitabh Kant said. At the same time, he was highly critical of India’s private sector, terming it as ‘most irrational’and ‘insensitive’. Kant said it messed up projects by aggressive bidding and creating current crisis in the public private partnership (PPP) model.

‘The Government has done a lot of big projects but the government is not good at operation and maintenance. Therefore, the government must start the process of reverse BOT (build, operate and transfer), must sell out projects and let the private sector handle it,’he said addressing India PPP Summit 2017, organised by industry body FICCI.

Citing the example of dirty bathrooms at airports, which fall under the Airport Authority of India, he said: ‘We must bring in the private sector. That is, the fastest way to bring in private sector and bring private sector money back in infrastructure. These projects are fully de-risked.’

Kant also said that there were huge opportunities for the private sector in India like station re-development projects, Port construction and Sagarmala projects. There is no shortage of money in the market and India can use the opportunity by de listing its projects, he said.

Dangote records sales volume rise across Africa
Dangote Cement, Africa’s largest cement producer, has announced its unaudited results for the six months ended June 30, 2017, posting a 12.6 percent increase in sales volume across Africa. Financials released indicated that the increase in sales volume showed a growing capture of Pan-African market as Dangote Cement continues to gain grounds.

Revenues from operations in Nigeria increased by 34.5 per cent while Pan-Africa revenue increased by 63.7 per cent mainly as a result of increased volumes and foreign exchange gains when converting the sales from country local currency into Naira. Analysis of the half year result revealed that sales volumes of African operations increased by 12.6 per cent to 4.7 million metric tonne with Sierra Leone making a 53 kt maiden contribution.

Record of sales from its operations scattered around the African continent revealed that a total of 1.1 million metric tonnes of cement was sold in Ethiopia, almost 0.7 million metric tonne sold in Senegal, 0.6 million metric tonne sold in Cameroon, and 0.5 million tonne in Ghana.

Also, 0.4 million metric tonnes of cement was sold in Tanzania and 0.3 million tonne in Zambia. Sales volumes from Nigerian operations fell from 8.8 mt to 6.9 mt, occasioned by the onset of rains which stalled many construction projects.

East proves best for Shree Cement
Shree Cement’s Street-beating Q1 performance was led by its cement business. Though the company’s power segment reported a loss at the operating level, cement was the show-stopper, enabling Shree Cement post an EBITDA (earnings before interest, tax, depreciation and amortisation) of Rs 680 crore, which was reasonably ahead of Bloomberg consensus estimates of Rs 646 crore. A better-than-expected recovery in cement realisations, led by price hikes since the start of April, helped the company beat cost pressures too.

Birla to invest Rs 2.4k cr in new cement plant Birla Corporation Limited, the MP Birla Group flagship company, would invest around Rs 2,400 crore for its proposed new cement plant at Mukutbandh near Nagpur. ‘We are planning to invest around Rs 2,400 crore for 4 MTPA greenfield cement plant at Mukutbandh. We will now go to the board for approval’, Chairman of Birla Corporation Harsh V Lodha told at the company’s AGM. Lodha said after the completion of the new plant, the total cement production capacity of the company would touch 20 MTPA from the present 15.5 MTPA after acquisition of Reliance Cement. Funding of the project would be a mixture of debt and internal accruals, he said.

Birla Corporation had acquired the cement plants of Reliance at a consideration of Rs 4,800 crore. To fund this acquisition, Birla Corporation had taken a loan of Rs 1,000 crore on its books. Lodha said that the company was making some capital expenditure at the acquired plants to make it more efficient.

‘Reliance’s plants did not have a captive power plant. So we are in the process of setting up a waste heat recovery system at a cost Rs 125 crore’, he said. This would provide us power to meet a portion of the total demand, 45 MW, free of cost. ‘We are studying the feasibility of a captive thermal power plant there’, he said.

Lodha said as the demand for cement was rising in central India and no new capacity was coming up in the region, the company was well-poised to take advantage of this. On GST, he said it would not have any major impact.

Concrete

The primary high-power applications are fans and mills

Published

2 weeks ago

October 10, 2025

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Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.

As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.

How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.

What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.

Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.

Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.

How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.

What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.

Concrete

We conduct regular internal energy audits

Published

2 weeks ago

October 10, 2025

admin

Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.

In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.

How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.

What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.

How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.

Concrete

Digitalisation is pivotal in driving energy efficiency

Published

2 weeks ago

October 10, 2025

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As energy costs continue to dominate the cement industry, efficiency and sustainability are proving to be vital components. MM Rathi, Joint President, Power Management, Shree Cement, explains the company’s long-term strategy is focused on cutting emissions while powering growth with renewable energy solutions.

Energy efficiency has always been a cost-saving lever for the cement industry. Today, it is the backbone of sustainability and competitiveness. Cement manufacturers are under growing pressure to optimise consumption, diversify power sources and align with decarbonisation targets. Shree Cement has been at the forefront of this transformation, significantly scaling up its green power capacity and embedding advanced technologies across operations. In this exclusive conversation, MM Rathi, Joint President – Power Management, Shree Cement, shares insights on the company’s approach to energy efficiency, challenges in brownfield modernisation and long-term strategies for achieving net zero alignment.

What percentage of your total operational cost is attributed to energy consumption?
At Shree Cement, energy is one of the most significant components of production cost, accounting for nearly 30 per cent to 40 per cent of total operational expenses. Within this, thermal energy typically contributes around 20 per cent to 25 per cent, while electrical energy forms about 10 per cent to 15 per cent. The exact share varies depending on factors such as the fuel mix (coal, pet coke or alternative fuels and raw materials), the power source (grid-based or captive like solar, wind or thermal), raw mix quality, and regional fuel and electricity price variations. This makes energy efficiency and the adoption of sustainable power sources a key focus area, both from a cost and sustainability perspective.

How has your company improved energy efficiency over the past five years?
Over the past five years, Shree Cement has consistently invested in enhancing energy efficiency across operations. Our green power capacity, covering wind, solar and Waste Heat Recovery (WHR), has more than doubled from 245 MW in 2020 to 592 MW in 2025. All grinding units are now equipped with biomass firing facilities, reducing dependence on conventional fuels. From the project stage itself, we prioritise efficiency by selecting advanced technologies such as six-stage kilns with integrated WHR, CFD-designed plants, and equipment fitted with VFDs, centrifugal compressors and high-efficiency fans. We also review and upgrade equipment systematically, replacing fans, compressors, blowers, pumps, boilers and turbines with more efficient options. This continuous approach has reduced costs while significantly advancing our sustainability journey.
What technologies or practices have shown the highest energy-saving potential in cement production?
WHR stands out as one of the most effective solutions, offsetting a significant portion of electricity required for clinker production. Hot air recirculation has also proven highly beneficial in reducing heat losses. Additionally, regular energy audits help us identify opportunities for improvement and implement corrective measures in daily operations. Together, these practices play a critical role in optimising energy efficiency and driving sustainable operations.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
The biggest challenge is the significant upfront investment required for upgradation. Retrofitting existing facilities often involves complex civil and structural modifications, which add costs and extend downtime. Integration is another hurdle, as new high-efficiency equipment may not align seamlessly with older kiln systems, fans, mills or automation setups. These factors make the transition in brownfield plants more resource-intensive and time-consuming compared to greenfield projects.

How do you measure and benchmark energy performance across different plants?
We track key performance indicators such as specific heat consumption and specific power consumption for each unit, benchmarking them against internal and external standards. Thermal Substitution Rate (TSR percentage) is another critical metric, measuring the share of alternative fuels in the thermal energy mix. Internally, we benchmark performance across plants to encourage best practice sharing. Externally, we compare against national averages and align with the Bureau of Energy Efficiency’s PAT (Perform, Achieve, Trade) scheme, which sets Specific Energy Consumption (SEC) baselines and targets for cement plants. This multi-layered approach ensures continuous monitoring, improvement, and industry leadership in energy efficiency.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation is pivotal in driving energy efficiency at Shree Cement. IoT sensors integrated with SCADA and DCS systems allow real-time monitoring of parameters like heat consumption and energy use, moving beyond periodic reports. Our digital platforms consolidate plant data, enabling management to compare metrics such as SPC, SHC, kWh per tonne and kcal per kg across units in real time. This visibility supports data-driven decisions, faster corrective actions, and higher operational efficiency.

How do government policies and incentives influence your energy-saving decisions?
Government policies and incentives strongly shape our energy-saving decisions. The Perform, Achieve, Trade (PAT) scheme sets plant-specific SEC targets. Non-compliance incurs penalties, while compliance earns tradable energy-saving certificates. This ensures energy efficiency is both cost-driven and regulatory. Additionally, subsidies and viability gap funding for renewable energy projects in wind, solar and AFR co-processing help reduce payback periods and make energy-saving investments more viable.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
Our long-term strategy aligns energy efficiency with India’s net zero 2070 goals. Key levers include improving efficiency, expanding green electricity, producing more blended cement, and increasing alternative fuel use. Today, more than 60 per cent of our electricity comes from green sources such as solar, wind, and WHR, the highest in India’s cement industry. Our blended cement products, which reduce limestone and fuel consumption, further lower emissions. These products are certified under the GreenPro ecolabel by CII, validating our sustainability practices and environmental standards.