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Lower capacity utilisation has impacted overall efficiency
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8 years agoon
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Ashutosh Saxena,Director General (Actg.), National Council for Cement and Building Materials (NCB)
In an exclusive interaction with ICR, Ashutosh Saxena, Director General (Actg.), National Council for Cement and Building Materials (NCB) is optimistic that with various infrastructure projects picking up traction, the Indian cement sector is well be on its way to recovery in the near future.
How open is the Indian industry to innovation?
Indian cement industry has been innovative and has adopted state-of-the-art technologies in areas such as resource conservation, environmental protection, energy conservation, waste utilisation, low carbon technologies, and so on. These have been witnessed in the form of increased production of Blended Cement, meeting the stringent norms of NOx, SO2 and particulate matter emissions, increased usage of alternate fuels and raw materials, formulation of code for new cements like composite cement, and a large number of other measures taken by cement plants at local levels. All these, stand testimony to the commitment of cement industry towards adopting innovative technologies and measures to meet the challenges nationally as well as globally. Cement industry itself is propagating the idea of holding seminars and conferences for dealers as well as users. A lot of knowledge is being proactively disseminated by the cement industry with the ultimate objective of promoting durable construction as also resource conservation. These two things go side by side.
What are the some of the new developments in technology that may get implemented in the near future?
We need to reduce the carbon footprint in cement manufacturing. We need to increase the utilisation of fly ash and slag in Portland Pozzolana and composite cements. That is one area. Another area is the thermal substitution of coal for its conservation. We need to use all types of alternate fuels, especially municipal solid waste (MSW) and hazardous wastes, available. Also, the ongoing research in cement seeks to minimise the clinker content. Then there are concepts of geo polymer cement and limestone calcined clay cement or LC3. In addition, concrete is in itself a very large area of R&D.
What would you regard as the most significant development in your segment?
The industry is very proactive in waste utilisation. Of late, there is a demand for banning the use of petcoke. Refineries within Indian and world over generate huge quantities of petcoke and other waste materials. The cement industry has upgraded technology and its operational skills to utilise even the low volatile content petcoke with several benefits. There is a substantial saving in coal consumption as it is directly substituted by petcoke. Moreover, because of the low ash content in petcoke, the cement industry can utilise low grade limestone even while conserving the high-grade limestone. There is a concern that that petcoke burnt in boilers releases lot of sulphur into the atmosphere. However, the intrinsic chemistry of the process is such that over 99 per cent of the sulphur present in petcoke reacts with the calcium carbonate content of the limestone to convert it into calcium sulfate. It is nothing but gypsum.
Since 4 to 6 per cent gypsum is anyway added to cement, the requirement for the mineral gypsum also comes down with the utilisation of petcoke. So, from a technical point of view, petcoke utilisation is good for resource conservation. As for the release of sulphur dioxide, there are wet scrubber and other technologies available to take care of the emission.
What are some of the other challenges before the cement industry?
The Indian cement industry’s present installed capacity is over 400 million tonnes per year. But the production in the 2016-17 financial year was only around 280 million tonnes. As a result, capacity utilisation hovers around 65 per cent. Low capacity utilisation leads to overall inefficiency in every area of production. The present government is trying to do a lot for development of the housing sector and infrastructure. Therefore, I am very optimistic that within the next six months to one year, the industry will get back on course.
As India goes about vigorously building infrastructure projects quality management becomes a challenge. What is your own take on that?
As far as cement coming out of plants is concerned, there is no issue with quality because the system of quality control in India has matured over the years. We have various Bureau of Indian Standards (BIS) benchmarks that have been developed based on vigorous research in institutions like ours as well as taking inputs from the European industry. Almost all cement plants in India are ISO 9001 as well as ISO 14001 compliant. In fact, some manufacturers are now going for ISO 50001 certification. The BIS has a very stringent and fool-proof system of quality inspection. It randomly collects samples to test them at our as well as other ISO 17025 accredited labs. But one concern that is lately arising pertains to mixing of fly ash at construction sites by builders. During production of slag or fly ash based Portland Pozzolana cement within the cement industry, proper care is taken about mixing and quality control. But the same slag and fly ash procured directly by the builder and mixed with Ordinary Portland Cement (OPC) grade 43 and 53 may not be as fail-proof in terms of quality. Concerned statutory authorities must take some regulatory action on controlling the quality of cement used by builders. We cannot afford to have substandard building materials to be used in infrastructure projects.
In the recent past, the very mention of the word cement implied cheap Chinese imports. Since, going forward, this might no longer be the case, what are the technologies that India can excel in and export to other parts of the world?
We are now part of a global economy. For example, FLSmidth’s research centre in Chennai is its largest in the world. Similarly, there are lot of efforts for ‘Make in India’ in the cement industry. Several machinery manufacturers have got very large set ups in various parts of India. Designs for machines produced there are jointly developed through research carried out both within and outside India. The fabrication is mostly done by Indian companies, with specialised laboratory and quality control equipment being imported from other countries. I am sure that once the market picks up and our research and manufacturing set-up get further strengthened, we will also have facilities for world-class manufacturing of state-of-the-art laboratory and quality control equipment.
In Africa, we have line-of-credit schemes and the Indian government is doing lot of work for development of the continent. There is lot of export of cement machinery to African countries. We are also trying to expand the utilisation of cement manufacturing technology from India.
Is skilled manpower easily available for the purpose?
This is a very pertinent question. In fact, there was a trend for over a decade where the best talent would go to the IT sector. As a result, core engineering sectors like mechanical, civil, electrical, chemical and cement were deprived of best graduates or post graduates. This was a cause for concern. The government is well aware of the problem and that is why you find that some of the main missions taken up by it are in the area of skill development such as ‘Skill India’ and ‘Make in India’. In fact, more the manufacturing sector grows, more will be the number of meritorious students taking up core engineering as a subject at India’s top colleges. This will also benefit the cement industry. NCB is doing its bit in the area. We have a training centre for skill development called Centre for Continuing Education that conducts training courses for various levels of engineers in all areas of cement manufacturing as well as cement utilisation for concrete.
MANISH PANT
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Price hikes, drop in input costs help cement industry to post positive margins: Care Ratings
Published
4 years agoon
October 21, 2021By
admin
Region-wise,the southern region comprises 35% of the total cement capacity, followed by thenorthern, eastern, western and central region comprising 20%, 18%, 14% and 13%of the capacity, respectively.
The cement industry is expected to post positive margins on decent price hikes over the months, falling raw material prices and marked drop in overall production costs, said an analysis of Care Ratings.
Wholesale and retail prices of cement have increased 11.9% and 12.4%, respectively, in the current financial year. As whole prices have remained elevated in most of the markets in the months of FY20, against the corresponding period of the previous year.
Similarly, electricity and fuel cost have declined 11.9% during 9M FY20 due to drop in crude oil prices. Logistics costs, the biggest cost for cement industry, has also dropped 7.7% (selling and distribution) as the Railways extended the benefit of exemption from busy season surcharge. Moreover, the cost of raw materials, too, declined 5.1% given the price of limestone had fallen 11.3% in the same aforementioned period, the analysis said.
According to Care Ratings, though the overall sales revenue has increased only 1.3%, against 16% growth in the year-ago period, the overall expenditure has declined 3.2% which has benefited the industry largely given the moderation in sales.
Even though FY20 has been subdued in terms of production and demand, the fall in cost of production has still supported the cement industry by clocking in positive margins, the rating agency said.
Cement demand is closely linked to the overall economic growth, particularly the housing and infrastructure sector. The cement sector will be seeing a sharp growth in volumes mainly due to increasing demand from affordable housing and other government infrastructure projects like roads, metros, airports, irrigation.
The government’s newly introduced National Infrastructure Pipeline (NIP), with its target of becoming a $5-trillion economy by 2025, is a detailed road map focused on economic revival through infrastructure development.
The NIP covers a gamut of sectors; rural and urban infrastructure and entails investments of Rs.102 lakh crore to be undertaken by the central government, state governments and the private sector. Of the total projects of the NIP, 42% are under implementation while 19% are under development, 31% are at the conceptual stage and 8% are yet to be classified.
The sectors that will be of focus will be roads, railways, power (renewable and conventional), irrigation and urban infrastructure. These sectors together account for 79% of the proposed investments in six years to 2025. Given the government’s thrust on infrastructure creation, it is likely to benefit the cement industry going forward.
Similarly, the Pradhan Mantri Awaas Yojana, aimed at providing affordable housing, will be a strong driver to lift cement demand. Prices have started correcting Q4 FY20 onwards due to revival in demand of the commodity, the agency said in its analysis.
Industry’s sales revenue has grown at a CAGR of 7.3% during FY15-19 but has grown only 1.3% in the current financial year. Tepid demand throughout the country in the first half of the year has led to the contraction of sales revenue. Fall in the total expenditure of cement firms had aided in improving the operating profit and net profit margins of the industry (OPM was 15.2 during 9M FY19 and NPM was 3.1 during 9M FY19). Interest coverage ratio, too, has improved on an overall basis (ICR was 3.3 during 9M FY19).
According to Cement Manufacturers Association, India accounts for over 8% of the overall global installed capacity. Region-wise, the southern region comprises 35% of the total cement capacity, followed by the northern, eastern, western and central region comprising 20%, 18%, 14% and 13% of the capacity, respectively.
Installed capacity of domestic cement makers has increased at a CAGR of 4.9% during FY16-20. Manufacturers have been able to maintain a capacity utilisation rate above 65% in the past quinquennium. In the current financial year due to the prolonged rains in many parts of the country, the capacity utilisation rate has fallen from 70% during FY19 to 66% currently (YTD).
Source:moneycontrol.com
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Wonder Cement shows journey of cement with new campaign
Published
4 years agoon
October 21, 2021By
admin
The campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV…
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Cement manufacturing company Wonder Cement, has announced the launch of a digital campaign ‘Har Raah Mein Wonder Hai’. The campaign has been designed specifically to run on platforms such as Instagram, Facebook and YouTube.
#HarRaahMeinWonderHai is a one-minute video, designed and conceptualised by its digital media partner Triature Digital Marketing and Technologies Pvt Ltd. The entire journey of the cement brand from leaving the factory, going through various weather conditions and witnessing the beauty of nature and wonders through the way until it reaches the destination i.e., to the consumer is very intriguing and the brand has tried to showcase the same with the film.
Sanjay Joshi, executive director, Wonder Cement, said, "Cement as a product poses a unique marketing challenge. Most consumers will build their homes once and therefore buy cement once in a lifetime. It is critical for a cement company to connect with their consumers emotionally. As a part of our communication strategy, it is our endeavor to reach out to a large audience of this country through digital. Wonder Cement always a pioneer in digital, with the launch of our IGTV campaign #HarRahMeinWonderHai, is the first brand in the cement category to venture into this space. Through this campaign, we have captured the emotional journey of a cement bag through its own perspective and depicted what it takes to lay the foundation of one’s dreams and turn them into reality."
The story begins with a family performing the bhoomi poojan of their new plot. It is the place where they are investing their life-long earnings; and planning to build a dream house for the family and children. The family believes in the tradition of having a ‘perfect shuruaat’ (perfect beginning) for their future dream house. The video later highlights the process of construction and in sequence it is emphasising the value of ‘Perfect Shuruaat’ through the eyes of a cement bag.
Tarun Singh Chauhan, management advisor and brand consultant, Wonder Cement, said, "Our objective with this campaign was to show that the cement produced at the Wonder Cement plant speaks for itself, its quality, trust and most of all perfection. The only way this was possible was to take the perspective of a cement bag and showing its journey of perfection from beginning till the end."
According to the company, the campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV. No other brand in this category has created content specific to the platform.
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In spite of company’s optimism, demand weakness in cement is seen in the 4% y-o-y drop in sales volume. (Reuters)
Published
4 years agoon
October 21, 2021By
admin
Cost cuts and better realizations save? the ?day ?for ?UltraTech Cement, Updated: 27 Jan 2020, Vatsala Kamat from Live Mint
Lower cost of energy and logistics helped Ebitda per tonne rise by about 29% in Q3
Premiumization of acquired brands, synergistic?operations hold promise for future profit growth Topics
UltraTech Cement
India’s largest cement producer UltraTech Cement Ltd turned out a bittersweet show in the December quarter. A sharp drop in fuel costs and higher realizations helped drive profit growth. But the inherent demand weakness was evident in the sales volumes drop during the quarter.
Better realizations during the December quarter, in spite of the 4% year-on-year volume decline, minimized the pain. Net stand-alone revenue fell by 2.6% to ?9,981.8 crore.
But as pointed out earlier, lower costs on most fronts helped profitability. The chart alongside shows the sharp drop in energy costs led by lower petcoke prices, lower fuel consumption and higher use of green power. Logistics costs, too, fell due to lower railway freight charges and synergies from the acquired assets. These savings helped offset the increase in raw material costs.
The upshot: Q3 Ebitda (earnings before interest, tax, depreciation and amortization) of about ?990 per tonne was 29% higher from a year ago. The jump in profit on a per tonne basis was more or less along expected lines, given the increase in realizations. "Besides, the reduction in net debt by about ?2,000 crore is a key positive," said Binod Modi, analyst at Reliance Securities Ltd.
Graphic by Santosh Sharma/Mint
What also impressed analysts is the nimble-footed integration of the recently merged cement assets of Nathdwara and Century, which was a concern on the Street.
Kunal Shah, analyst (institutional equities) at Yes Securities (India) Ltd, said: "The company has proved its ability of asset integration. Century’s cement assets were ramped up to 79% capacity utilization in December, even as they operated Nathdwara generating an Ebitda of ?1,500 per tonne."
Looks like the demand weakness mirrored in weak sales during the quarter was masked by the deft integration and synergies derived from these acquired assets. This drove UltraTech’s stock up by 2.6% to ?4,643 after the Q3 results were declared on Friday.
Brand transition from Century to UltraTech, which is 55% complete, is likely to touch 80% by September 2020. A report by Jefferies India Pvt. Ltd highlights that the Ebitda per tonne for premium brands is about ?5-10 higher per bag than the average (A cement bag weighs 50kg). Of course, with competition increasing in the arena, it remains to be seen how brand premiumization in the cement industry will pan out. UltraTech Cement scores well among peers here.
However, there are road bumps ahead for the cement sector and for UltraTech. Falling gross domestic product growth, fiscal slippages and lower budgetary allocation to infrastructure sector are making industry houses jittery on growth. Although UltraTech’s management is confident that cement demand is looking up, sustainability and pricing power remains a worry for the near term.