Technology

Innovation at work

Published

7 years ago

January 31, 2018

admin

Innovation is driving advancement of technologies and growth of the cement packaging segment globally. India must be able to take part and reap benefits from them.
While innovation is changing the way every work is done in every field of activity, cement packaging cannot be too different. Though there is hardly any change in the material consumed for manufacturing cement packaging, the new technologies and processes are making them high on productivity, safer, quicker to fill, load and re-load, leak-proof and amenable to automation, when compared to yester years when it was dangerous, hazardous and labour-intensive.
Bags are a common way of distribution in the industry, accounting for about 60 per cent of the product shipped to consumers/users. This also holds true for other developing countries, according to industry sources, which put the figure at 45 per cent on an average. Bulk packaging though is yet to catch up on a large scale in India, it is being patronised by some major cement manufacturers and bulk consumers.
Though there are several manufacturers of cement packaging bags in the country, most of the highly advanced automated machinery and systems are being imported from countries like Germany, Italy, Switzerland, the US, Taiwan, etc.
Innovation has been the key for sustained growth of global players like Windm?ller & H?lscher during the recent years, particularly when it has introduced hot air to seal the moisture-proof sacks that used to be closed with adhesives earlier, thereby reducing production costs and technical process limitations. Another global player, FLSmidth offers complete automation solutions by integrating various product types with that of fully automated packing plants, automating even loading and unloading activities.
Packing plants have not only become part of cement production lines, but also grinding stations or cement terminals. A single packing line produces up to 15 to 50 million bags per year based on the material used and the process adopted. That way, packing plants have evolved into complex, fully automated operations, driven by innovation in the recent years.Options
There are three options for cements sacks: Paper, woven and film. "Paper sacks are a comparatively cost-effective form of packaging made from a renewable source," says spokesperson of Windm?ller & H?lscher, which claims to be the market leader in the field of paper sack systems, with over 90 per cent share globally.
Woven polypropylene (PP)/plastic sacks are very lightweight and tear-resistant, which is particularly useful if the sacks are to be used in tougher environments. So, many Indian companies have embraced the option till the regulatory intervention, citing higher loss of cement in wrong handling. But they face a challenge – necessary deaeration of product.
A natural side effect of packing cementitious material into a polypropylene bag is trapped air. In order to make PP packaging a viable option for cement, this air needed to be managed back out of the process to achieve a uniform and stable
pack, which is a crucial ingredient for efficient palletisation. Achieving this, while maintaining the intended waterproof credentials of polypropylene and maintaining process speed is no mean task. However, this has been enabled by the latest technologies.
Film valve sacks, on the other hand, provide excellent moisture protection, and advertising on them is more effective as they hold print well, a factor which is key, particularly in the field of premium packaging.
"Valve sacks have the important benefit of being able to be filled on nozzle packers, which ensure a high filling output. Valve sack concepts are available in all three major materials (paper, pp-woven, PE-film). Important factors regarding filling speed and automated handling are deaeration performance and form stability," says W&H.
Packaging in cement production has to fulfil multiple needs like moisture protection, extended shelf-life, clean appearance and good handling, says W&H, while explaining the prerequisites for a cement bag. "Better stackability, pilfer-resistance, anti-counterfeit solution and better aesthetics are some of the reasons why the hot air sealed woven sacks have been preferred in the Indian market," added the W&H spokesperson. Besides, less flying of packaged product also helps cement users save cost. These benefits also help cement companies create a better brand image in the market-domestic or export.Store appearance
Look and feel of packaging, which was till recently confined to consumer goods packaging, is becoming an important parameter while selecting the medium of packaging even for the cement industry. Their importance is gaining prominence when it comes to product placement and communication to the end-customer, particularly about the sustainability angle of the product and/or its special strengths and features. As such, sacks need to present all marketing messages in an attractive way.
"Currently additional packaging features like carrying handle or easy opening feel an increasing market demand as those features present an added value regarding sack handling for the end-user," says W&H.
W&H is also seeing acceptance in India of high-end Biaxially-Oriented Polypropylene (BOPP) laminated hot air sealed block bottom bags, which are much more expensive than the conventional sewn bags, and are amenable for printing very high quality photographic images. New automatic range
Automation is catching up with packaging processes of cement industry, of late. The technique of making an apparatus, a process, or a system operate automatically as it is described is being opted for by the industry for taking advantage of its well-known attributes – increased productivity, more efficient use of materials, better product quality, improved safety and reduced factory lead times. The packaging automation has extended to loading of closed top and open top trucks or containers by now.
"In India, hot air sealed block bottom bags are the most used for high automation production. The benefit for bag producers is lower manpower requirement for producing as these bags are produced with high speeds and advance automation," says the W&H spokesperson.
AD PROTEX valve bags produced on CONVERTEX platform by W&H ideally combine minimum raw material usage, adhesive-free sack production and unequalled functionality of their box-shaped design. As a result, they are made in a particularly economical way, but can also be filled and palletized similarly as the conventional pasted valve bags. "Our new production line for cement valve packaging ensures the production of paper sacks which fulfil the requirements for automated high speed filling," the company said.
Packaging for dry powdered materials like cement has changed little in the last 40 years leaving the end user to cope with the problems associated with the industry standard paper valve sack. As a result problems such as dust, spillage and a relatively high wastage return rate caused by the ingress of water brought about by poor storage conditions have largely remained unchallenged.
However, domestic packaging manufacturer, Arodo has introduced it brand of vacuum bagging system that produces fully deaerated plastic packs that don’t feature perforations of any kind, addressing the concerns of cement manufacturers and their customers. It is projected as a waterproof and tamper-proof cement pack.
"The absence of perforations allows each individual pack to be stored or placed in the most arduous of weather conditions without risk of spoiling the product through water ingress," says Vikas Marwaha, Director, Arodo India Pvt Ltd. These packs have been placed outside and completely underwater for weeks before retrieving and using the product as if it had been freshly packed, Marwaha claims.
Windm?ller & H?lscher has developed CONVERTEX, which heat seals woven PP cross bottom bags and thus eliminates the need of glue for this type of bags. "During the last 10 years the output of the bottomer was more than doubled: from 60 bags per minute to 140 in the last model. This speed represents the technological leadership in this type of equipment," W&H said, stating that today, CONVERTEX forms the backbone of its extensive portfolio of the woven PP business.
High-quality PP tapes with tenacity up to 7 g/den and indexed micro-perforation provide the technological tools to be able to produce e.g. cement bags with a weight of 65 grams instead of the current global market standard of 80 grams. Drop tests with the LS Bags are done – with the result that LS bags easily excel conventional bags, W&H claims.
The AD proFilm MP sack, launched in 2015, is unusual in the sense that it uses hot air to seal the sacks. This means that it does not require adhesives, which can be the source of significant production costs and technical process limitations. It is manufactured on the AD PLASTIC 2 valve bottomer.
When the company was developing the new AD proFilm MP film valve sack, it chose to focus on two key factors: high moisture protection (MP = moisture-proof), and extending the product’s shelf life. It achieved these through the use of its innovative Breathing Chamber Technology – a ventilation chamber along the longitudinal seam of the sack. "This technology means that effective ventilation and high moisture protection are no longer mutually exclusive", explains Uwe K?hn, Head of Processing Products at W&H.
In a presentation made on June 21, 2017, Francesco Ferrandico, President-FLSmidth Ventomatic Cement Packaging said that the company’s automation systems range extends beyond filling of sacks to loading into trucks – open or closed. "FLSmidth Ventomatic provides the key product types and integrates them for fully automated packing plants," Ferrandico said while explaining about different packaging processes that include electronic rotary and inline packers; empty bag applicators; palletizing systems; loaders for closed trucks/containers; and loaders for open top trucks.
FLSmidth claims that its loaders for closed trucks/containers were the first full automatic pallet loading system in the market. Truck/container loaders significantly increase safety level and productivity and they do not use forklifts and relevant operators, it said. Its electronic rotary and inline packer’s equipment for filling bulk cement from silos into bags have an output from 60 tons/h up to 250 tons/h.
Depending on level of automation, packing plants consist of 2 – 8 packing lines, and at full automation, reduces required manpower per shift from 12 to 2 when going from complete manual to automation packing, but with the same output, FLSmidth added.Cementing growth
W&H has seen a huge growth in consumption of hot air sealed woven sacks in Indian market with several plants running already and more on order. It has also seen a trend in the market of use of high-end Biaxially-Oriented Polypropylene (BOPP) laminated hot air sealed Block Bottom bags. "These bags are much more expensive than the conventional sewn bags, but are finding good acceptance in the Indian market. These bags can be printed with very high quality photographic images," W&H spokesperson said. We also expect increase in consumption of multiwall paper bags in the Indian market. The reasons are very interesting, innovations like high strength paper and water soluble paper done by paper industries.
As packaging industry’s growth is tied to the Indian economy and demand for cement and cement products, growth in these two elements are of critical importance for sustainability and growth of packaging industry in the country. Though the current trends in cement demand do not augur well for the packaging industry, the Union Budget released recently have some good news to bask under.
During the first eight months of FY2018 (2017-18), cement production witnessed a marginal growth of 0.6 per cent at 190.0 million MT compared to 188.8 million MT during the same period the previous year, leading rating agency ICRA said, citing various factors like weak real-estate activity, sand shortage and issues related to implementation of GST as reasons. Based on the current trend, it projected that cement demand is likely to report a modest demand growth of around 2 percent in FY2018.
In a pre-budget (January 31, 2018) analysis, Sabyasachi Majumdar, Senior Vice President & Group Head, ICRA Ratings, said "Going forward, the demand growth is likely to be driven by a pick-up in the housing segment – primarily affordable and rural housing, and infrastructure segment – primarily road and irrigation projects. However, new project announcements from the private sector continue to remain weak and revival of public-private partnership is crucial to improve the pace of infrastructure development."
"ICRA expects the capacity overhang and moderate demand growth to continue to keep the industry’s capacity utilisation level between 60-65 per cent over the medium term," Majumdar added.
However, the Union Budget 2018-19 released on February 1, 2018, has some good news for the cement industry. The move to boost the capital outlay of Pradhan Mantri Awas Yojana (housing scheme) -Urban (PMAY-U) five-fold to Rs 31,500 crore, will aid some recovery in the otherwise muted urban-housing demand, which accounts for 30 per cent of cement demand, said leading rating firm, CRISIL in a post-budget report. Besides, increase in outlays for the Ministry of Road Transport and Highways (MoRTH) and Railways by 11 per and 22 per cent respectively are expected to impact cement demand positively.
However, CRISIL had added a word of caution, when it said, "Healthy budget outlay for cement-intensive infrastructure segments like roadways, irrigation and railways should cement growth (infrastructure share estimated at 20 per cent). However, achievement of budgeted outlay to be key monitorable as some shortfall was observed in the previous fiscal."
There is a marginal negative stroke for the sector from the budget in the form of social welfare surcharge of 10 per cent on customs duty, which replaces the earlier 3 per cent education cess on custom duty of all imports. This will particularly affect the advanced packaging equipment imports.Looking ahead
Innovations are driving advancement of technologies and growth of the cement packaging segment globally over the recent years. India being one of the major producers of cement has to make inroads into the top echelons of the sector by increasing spending on research and development and entering into joint ventures with major global manufacturers to lower our import dependency in the long run.
Major cement manufacturers like UltraTech Cement, ACC, India Cement and Ambuja have to take the lead in this initiative. This is an imperative when all the major manufacturers have to take advantage of latest technologies and improve their global competitiveness. Full automation may come in handy in this regard by boosting productivity and quality. Reduction of manpower may not be as important for India as it is for many other countries. Labour being cheaper in the country, the companies have to weigh the social impact of full automation in comparison with social benefit of utilising the cheap manpower, if other parameters like quality and productivity are not affected.
Adoption of advanced technologies also means guarding against health hazards for employees and stakeholders, which will lead to attraction and retention of talent, a critical resource for success of any business. It will also lead to optimisation of costs and leads to higher competitiveness, which are essential for the prosperity of companies and the country.– BS SRINIVASALU REDDY
Factors to be considered for best packaging
The factors one should consider while searching for the best packaging production are:

Sack geometry
Sack converting
Sack design
Appearance
Stack design

Each aspect can be more or less important depending on the region and market the customer is looking for. Furthermore, different applications, availability of the respective materials, or even regional differences, sometimes with historical root causes may influence the decision. The supplier must be able to provide machines for the production of each sack type and after installation service.
Windm?ller & H?lscherCritical success factors in India
The following are the critical success factors (CSFs) that determine the future of a company or business, particularly for a player in the packaging equipment industry in India:

Technology
Price
Delivery
Performance standards
Cost of equipment, and
Low running cost
Possible upgrades to the product and
Aftersales/installation service
Compiled from different sources

Growth through productivity: FLSmidth CARICATECHTM automatic truck loader

Innovative development for loading all type of bags on all kind of trucks
Bag layers are picked up by a fork with a special roller way (no vacuum system required) while maintaining the traditional loading from the top Addresses trend of productivity improvements through automation in developing markets
CARICATECHTM replaces existing loading equipment without major process changes or rebuilds – targeting upgrades of existing packing lines

Concrete

We consistently push the boundaries of technology

Published

2 months ago

April 18, 2025

admin

Swapnil Jadhav, Director, SIDSA Environmental, discusses transforming waste into valuable resources through cutting-edge technology and innovative process solutions.

SIDSA Environmental brings decades of experience and expertise to the important niche of waste treatment and process technologies. As a global leader that is at the forefront of sustainable waste management, the company excels in recycling, waste-to-energy solutions and alternative fuel production. In this conversation, Swapnil Jadhav, Director, SIDSA Environmental, shares insights into their advanced shredding technology, its role in RDF production for the cement industry and emerging trends in waste-to-energy solutions.

Can you give us an overview of SIDSA Environmental’s role in waste treatment and process technologies?
SIDSA is a leading innovator in the field of waste treatment and process technologies, dedicated to delivering sustainable solutions that address the growing challenges of waste management.
SIDSA is a more than 52-year-old organisation with worldwide presence and has successfully realised over 1100 projects.
Our expertise is in the engineering and development of cutting-edge systems that enable the conversion of waste materials into valuable resources. This includes recycling technologies, waste-to-energy (W2E) systems, and advanced methods for producing alternative fuels such as refuse derived fuel (RDF). The organisation prioritises environmental stewardship by integrating energy-efficient processes and technologies, supporting industrial sectors—including the cement industry—in reducing their carbon footprint. Through our comprehensive approach, we aim to promote a circular economy where waste is no longer a burden but a resource to be harnessed.

How does SIDSA Environmental’s shredding technology contribute to the cement industry, especially in the production of RDF?
SIDSA’s shredding technology is pivotal in transforming diverse waste streams into high-quality RDF. Cement kilns require fuel with specific calorific values and uniform composition to ensure efficient combustion and operational stability, and this is where our shredding systems excel. In India, we are segment leaders with more than 30 projects including over 50 equipment of varied capacity successfully realised. Some of the solutions were supplied as complete turnkey plants for high capacity AFR processing. Our esteemed client list comprises reputed cement manufacturers and chemical industries. Our technology processes various types of waste—such as plastics, textiles and industrial residues—breaking them down into consistent particles suitable for energy recovery.

Key features include:

High efficiency: Ensures optimal throughput for large volumes of waste.
Adaptability: Handles mixed and heterogeneous waste streams, including contaminated or complex materials.
Reliability: Reduces the likelihood of operational disruptions in RDF production. By standardising RDF properties, our shredding technology enables cement plants to achieve greater energy efficiency while adhering to environmental regulations.

What are the key benefits of using alternative fuels like RDF in cement kilns?
The adoption of RDF and other alternative fuels offers significant advantages across environmental, economic and social dimensions:

Environmental benefits: Cement kilns using RDF emit fewer greenhouse gases compared to those reliant on fossil fuels like coal or petroleum coke. RDF also helps mitigate the issue of overflowing landfills by diverting waste toward energy recovery.
Economic savings: Alternative fuels are often more cost-effective than traditional energy sources, allowing cement plants to reduce operational expenses.
Sustainability and resource efficiency: RDF facilitates the circular economy by repurposing waste materials into energy, conserving finite natural resources.
Operational flexibility: Cement kilns designed to use RDF can seamlessly switch between different fuel types, enhancing adaptability to market conditions.

What innovations have been introduced in waste-to-energy (W2E) and recycling solutions?
SIDSA’s machinery is meticulously engineered to handle the complex requirements of processing hazardous and bulky waste.

This includes:

Robust construction: Our equipment is designed to manage heavy loads and challenging waste streams, such as industrial debris, tires and large furniture.
Advanced safety features: Intelligent sensors and automated controls ensure safe operation when dealing with potentially harmful materials, such as chemical waste.
Compliance with standards: Machinery is built to adhere to international environmental and safety regulations, guaranteeing reliability under stringent conditions.
Modular design: Allows for customisation and scalability to meet the unique needs of various waste management facilities.

How does your organisation customised solutions help cement plants improve sustainability and efficiency?
We consistently push the boundaries of technology to enhance waste management outcomes.
General innovations and new product development focus on:

Energy-efficient shredders: These machines consume less power while maintaining high throughput, contributing to lower operational costs.
AI-powered sorting systems: Utilise advanced algorithms to automate waste classification, increasing material recovery rates and minimising errors.
Advanced gasification technologies: Convert waste into syngas (a clean energy source) while minimising emissions and residue.
Closed-loop recycling solutions: Enable the extraction and repurposing of materials from waste streams, maximising resource use while reducing environmental impact.

What future trends do you foresee in waste management and alternative fuel usage in the cement sector?
Looking ahead, several trends are likely to shape the future of waste management and alternative fuels in the cement industry:

AI integration: AI-driven technologies will enhance waste sorting and optimise RDF production, enabling greater efficiency.
Bio-based fuels: Increased use of biofuels derived from organic waste as a renewable and low-carbon energy source.
Collaborative approaches: Strengthened partnerships between governments, private industries and technology providers will facilitate large-scale implementation of sustainable practices.
Circular economy expansion: The cement sector will increasingly adopt closed-loop systems, reducing waste and maximising resource reuse.
Regulatory evolution: More stringent environmental laws and incentives for using alternative fuels will accelerate the transition toward sustainable energy solutions.

(Communication by the management of the company)

Concrete

FORNNAX Technology lays foundation for a 23-acre facility in Gujarat

Published

3 months ago

March 17, 2025

admin

FORNNAX Technology, a leading manufacturer of recycling equipment in India, has marked a major milestone with the Groundbreaking (Bhoomi Pujan) ceremony for its expansive 23-acre manufacturing facility in Gujarat. Specialising in high-capacity shredders and granulators, FORNNAX is strategically positioning itself as a global leader in the recycling industry. The new plant aims to produce 250 machinery units annually by 2030, making it one of the largest manufacturing facilities in the world.
The foundation stone for this ambitious project was laid by Jignesh Kundaria, CEO and Director, alongside Kaushik Kundaria, Director. The ceremony was attended by key leadership members and company staff, signifying a new chapter for FORNNAX as it meets the growing demand for reliable recycling solutions. Speaking on the occasion, Jignesh Kundaria stated, “This marks a historic moment for the recycling sector. Our high-quality equipment will address various waste categories, including tyre, municipal solid waste (msw), cables, e-waste, aluminium, and ferrous metals. this facility will strengthen our global presence while contributing to India’s Net Zero emissions goal by 2070.”
FORNNAX is actively expanding its footprint in critical markets such as Australia, Europe and the GCC, forging stronger sales and service partnerships. The facility will house an advanced Production Department to ensure seamless manufacturing.

Concrete

Decarbonisation is a focus for our R&D effort

Published

4 months ago

February 12, 2025

admin

Dyanesh Wanjale, Managing Director, Gebr. Pfeiffer discusses the need to innovate grinding technologies to make the manufacturing process more efficient and less fuel consuming.

Gebr. Pfeiffer stands at the forefront of grinding technology, delivering energy-efficient and customised solutions for cement manufacturers worldwide. From pioneering vertical roller mills to integrating AI-driven optimisation, the company is committed to enhancing efficiency and sustainability. In this interview, we explore how their cutting-edge technology is shaping the future of cement production.

Can you tell us about the grinding technology your company offers and its role in the cement industry?
We are pioneers in grinding technology, with our company being based in Germany and having a rich history of over 160 years, a milestone we will celebrate in 2024. We are widely recognised as one of the most efficient grinding technology suppliers globally. Our MBR mills are designed with energy efficiency at their core, and for the past five years, we have been focused on continuous improvements in power consumption and reducing the CO2 footprint. Innovation is an ongoing process for us, as we strive to enhance efficiency while supporting the cement industry’s sustainability goals. Our technology plays a critical role in helping manufacturers reduce their environmental impact while improving productivity.

The use of alternative fuels and raw materials (AFR) is an ever-evolving area in cement production. How does your technology adapt to these changes?
Our vertical roller mills are specifically designed to adapt to the use of alternative fuels and raw materials. These mills are energy-efficient, which is a key advantage when working with AFR since alternative fuels often generate less energy. By consuming less power, our technology helps bridge this gap effectively. Our solutions ensure that the use of AFR does not compromise the operational efficiency or productivity of cement plants. This adaptability positions our technology as a vital asset in the industry’s journey toward sustainability.

What are some of the challenges your company faces, both in the Indian and global cement industries?
One of the major challenges we face is the demand for expedited deliveries. While customers often take time to decide on placing orders, once the decision is made, they expect quick deliveries. However, our industry deals with heavy and highly customised machinery that cannot be produced off the shelf. Each piece of equipment is made-to-order based on the client’s unique requirements, which inherently requires time for manufacturing.
Another significant challenge comes from competition with Chinese suppliers. While the Indian cement industry traditionally favoured our technology over Chinese alternatives, a few customers have started exploring Chinese vertical roller mills. This is concerning because our German technology offers unmatched quality and longevity. For example, our mills are designed to last over 30 years, providing a long-term solution for customers. In contrast, Chinese equipment often does not offer the same durability or reliability. Despite the cost pressures, we firmly believe that our technology provides superior value in the long run.

You mentioned that your machinery is made-to-order. Can you elaborate on how you customise equipment to meet the specific requirements of different cement plants?
Absolutely. Every piece of machinery we produce is tailored to the specific needs of the customer. While we have standard mill sizes to cater to different capacity requirements, the components and configurations are customised based on the client’s operational parameters and budget. This process ensures that our solutions deliver optimal performance and cost efficiency. Since these are heavy and expensive items, maintaining an inventory of pre-made equipment is neither practical nor economical. By adopting a made-to-order approach, we ensure that our customers receive machinery that precisely meets their needs.

The cement industry is focusing not only on increasing production but also on decarbonising operations. How does your company contribute to this dual objective, and how do you see this evolving in the future?
Decarbonisation is a key focus for our research and development efforts. We are continuously working on innovative solutions to reduce CO2 emissions and improve overall sustainability. For example, we have significantly reduced water consumption in our processes, which was previously used extensively for stabilisation. Additionally, we are leveraging artificial intelligence to optimise mill operations. AI enables us to monitor the process in real-time, analyse feedback, and make adjustments to achieve optimal results within the given parameters.
Our commitment to innovation ensures that we are not only helping the industry decarbonise but also making operations more efficient. As the cement industry moves toward stricter sustainability goals, we are confident that our technology will play a pivotal role in achieving them.

Can you provide more details about the use of digitalisation and artificial intelligence in your processes? How does this improve your operations and benefit your customers?
Digitalisation and AI are integral to our operations, enabling us to offer advanced monitoring and optimisation solutions. We have developed three distinct models that allow customers to monitor mill performance through their computer systems. Additionally, our technology enables real-time feedback from our German headquarters to the customer. This feedback highlights any inefficiencies, such as when a parameter is outside the optimal range,
and provides actionable recommendations to address them.
By continuously monitoring every parameter in real time, our AI-driven systems ensure that mills operate at peak efficiency. This not only enhances production but also minimises downtime. I am proud to say that our mills have the lowest shutdown rates compared to other manufacturers. This reliability, combined with the insights provided by our digital solutions, ensures that customers achieve consistent and efficient operations. It’s a game-changer for reducing costs and enhancing overall productivity.