Concrete

Building Concrete Dialogue & Partnerships for Future

Published

8 years ago

January 12, 2018

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The first edition of Cement Manufacturers Association (CMA) CONCREATECH conference successfully culminated in New Delhi. The event saw the industry make a concerted attempt to not only remove misapprehensions around it but also stake a rightful claim as one of the key drivers in the India growth story.

There is 0 per cent tax on salt, cement is 28 per cent, steel is 18 per cent, paint is 18 per cent and Surf is 18 per cent. We often say that India is still a base economy of roti, kapda aur makaan (food, clothing and shelter). On roti that I am taking as sugar and salt, the price is high the tax is low. On kapda, I am taking it as Surf, the price is very high but the tax is still low. But on makaan, which is cement and meant for the poor, the price is the lowest while the tax is the highest!" This statement made by Ajay Kapur, Managing Director & CEO, Ambuja Cement during a panel discussion at the Cement Manufacturers Association organised CONCREATECH 2018 amply captured the prevailing sentiment within the Indian cement industry. No wonder then that it drew a prolonged round of applause from the assembled audience.

The captains of what is now the world’s second-largest cement industry after China assembled in late November for CMA’s first CONCREATECH conference, in New Delhi. The event was supported by the federal government’s Ministry of Environment, Forest and Climate Change. Leading policymakers, economists and industry leaders shared insights on the cement industry’s achievements and anxieties as well as its commitment to the UN General Assembly’s Sustainable Development Goals (SDG) for 2030.

In his inaugural address, Hardeep Singh Puri, Union Minister of State with Independent Charge, Ministry of Housing and Urban Affairs (MoHUA) said, "Between now and 2030, India needs to build 700 to 900 million square metres of urban space every year, which is equivalent to a Chicago. And I would like to tell you that it’s already being done." He elaborated on how government programmes like Swachh Bharat Mission, housing for all under the Pradhan Mantri Awas Yojana (PMAY), Atal Mission for Rejuvenation and Urban Transformation (AMRUT), construction of metro rail projects and development of smart cities were providing an impetus to development. "These five flagship programmes and an economy which is growing, offer a massive opportunity to our own economic entities and our partners throughout the world."

Puri urged the industry to ensure that by the next CONCREATECH it also became the "world’s greenest cement industry". He added that MoHUA would shortly announce a global green construction technology challenge.

REMOULDING THE NARRATIVE
The head of a leading cement major admitted in a private gathering that ICR also attended that the Indian cement industry was negatively perceived over allegations such as cartelisation. "We suffer from a problem of perception as over the past several decades we as an industry have failed to properly communicate the important role played by the sector in the nation’s development." Therefore, the urgency to change the discourse around the sector was quite palpable in the press conference that the CMA office bearers addressed on the sidelines of the event.

As recently as July this year, Nitin Gadkari, Minister for Roads & Highways had informed lawmakers in parliament that cartel pricing by cement makers was proving to be a stumbling block in his ministry’s mission to build more concrete roads across India. The minister had warned that unless the practice was discontinued, the government might be forced to bring cement under the Essential Commodities Act to ensure greater price uniformity.

In response to a question on the issue, Dr. Shailendra Chouksey, outgoing President CMA and Whole Time Director JK Lakshmi Cement observed, "Proof of the pudding lies in the eating. These days wholesale cement prices are listed in all newspapers. If you minus the cost of freight and then check the ex-factory price, there has hardly been a 2 per cent change in the last two years." Pointing out that the GST on cement was the same as on luxury goods, he urged the government to reconsider the high tax component on the commodity.

"We have approached the Ministry of Finance and also spoken to the GST Council to impress upon them the irony of the situation. If cement, which is an essential item, removed from the category of luxury goods, its consumption will increase in rural India," he added. CMA’s larger objective is to position cement as a sustainable product that helps in the conservation of local resources. It was highlighted how the industry was playing a commendable role through its various corporate social responsibility (CSR) initiatives long before that was made mandatory by law. "The industry has been taking various initiatives to uplift the communities wherever it is located by not just providing a push to the economic activity in the area but also through facilitation of transportation, employment, schools, horticulture and introduction of latest technologies," surmised Chouksey.

"All cement plants are trying to contribute in a big way to increase employability, to enhance livelihood and to also harvest water. Today, many of the cement plants are water positive," stressed Mahendra Singhi, the newly elected President CMA and Managing Director & CEO, Dalmia Bharat Cement.

Aparna Dutt Sharma, Secretary-General, CMA asserted, "In fact, if you were to look at numbers alone, then we (cement industry) are far ahead of the pack. We spend much more than the mandated 2 per cent on CSR, almost 4 per cent. DEMAND RECOVERY TO BE PROLONGED The cement industry also welcomed the revival in demand since 2016. Averred Chouksey, "The last 12 months have seen 12-14 per cent growth. Since it is coming from those sectors where there are very sustainable efforts going on, we have a very reasonable ground to expect that this demand growth may not really be temporary but it is here to stay." He attributed the recovery to factors like the government’s infrastructure creation drive, housing for all scheme, developments around the Swachh Bharat Mission and growth in GDP numbers.

KK Maheshwari, Managing Director, Ultratech Cement added, "Clearly the experience in India as well as globally has been that while housing is the largest segment of demand, it’s never the highest growth driver in any economy, including in China that has seen a huge growth in cement production and consumption. It is always infrastructure, which has the highest growth rate, and the proportion of cement demand that varies from 15-25 per cent at different points of time followed by industrial and commercial segments." He attributed the growth to especially the ongoing work in roads & highways and railway sectors. Even in the otherwise stressed construction industry on account of concerns around the Real Estate Regulation and Development Act (RERA), the low-cost housing scheme has resulted in a growth rate of 9 per cent.

"If you tend to look at smaller periods, yes, the industry went through an awfully bad period for five-six years. But if you look at the 25-year history, the industry has grown at about 7 per cent. Once the momentum picks up on things like infrastructure, the experience is that it continues unless there is a huge fiscal stress resulting in a total dislocation, which we hope, won’t be the case," opined Maheshwari.

The apex body of India’s largest cement manufacturers, CMA was founded in 1961. Now in its 57th year, it counts both private and state-owned companies in the fold. The maiden edition of CONCREATECH saw an enthusiastic participation by its members from all across the country. Sessions on a wide range of themes like nation building, sustainable development, leadership, supply chain management and adoption of low carbon solutions were also organised. Going forward, the symposium will be held every two years in order to initiate dialogue and build partnerships for a constructive agenda around the world’s fastest growing major economy’s cement sector.

– MANISH PANT

Concrete

JSW Cement Begins Production At Nagaur Rajasthan Plant

Greenfield integrated cement plant begins operations in Rajasthan

Published

19 hours ago

March 23, 2026

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JSW Cement has started production at a new greenfield integrated cement plant in Nagaur, Rajasthan, marking its first integrated facility in north India. The commissioning advances its national expansion and raises cement grinding capacity to 24.1 million tonnes per annum (MTPA) and clinker manufacturing capacity to nine point seven four MTPA including joint venture capacity. The plant is strategically located to serve high growth markets in Rajasthan, Haryana, Punjab and the National Capital Region.

The Nagaur plant comprises a three point three MTPA clinkerisation unit and a two point five MTPA cement grinding unit, with an additional one MTPA grinding unit under construction. The facility’s capacity additions enable it to meet regional demand and support infrastructure development. The project was funded by equity and long term debt and the company allocated Rs 8 bn from IPO proceeds to part finance the unit.

Company leadership said commissioning was completed within 21 months and that the expansion advances its aim to become a pan India player, with a mid term target of 41.85 MTPA and a long term vision of 60 MTPA. The plant includes sustainability features such as co processing of alternative fuels and a seven kilometre overland belt conveyor to transport limestone from the mines, reducing road transport impacts. The operation is expected to support economic growth and provide supplies for construction projects across the north.

The site will incorporate a 16 megawatt (MW) Waste Heat Recovery System to capture and reuse process heat, reducing the carbon footprint. JSW Cement’s operations include eight plants in India and a clinker unit in the UAE through a joint venture, providing a presence across the building materials value chain. The company emphasised use of industrial by products in manufacture and focus on producing eco friendly building materials.

Concrete

MAPEI India Celebrates 15 Years of Building Excellence

MAPEI India celebrates 15 years with growth, expansion and CSR impact

Published

19 hours ago

March 23, 2026

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MAPEI India marks its 15th anniversary, celebrating a journey defined by innovation, trust, and continuous growth. Beginning in 2011 with just four employees and a single manufacturing facility in Bengaluru, the company has evolved into a key player in India’s construction chemicals industry, now employing over 380 professionals across the country. Over the past 15 years, MAPEI India has delivered strong performance with a sales CAGR of 31 per cent. From zero production in its early years, the company shipped 1,71,000 metric tonnes of materials in 2025, demonstrating robust operational capabilities and rising market acceptance.

To support expanding demand, MAPEI India has steadily scaled its manufacturing footprint. Following the Bengaluru plant in 2011, new facilities were launched in Vadodara in 2016 and Kosi (Mathura) in 2022. A fourth facility in Kharagpur is set to go live in 2026, strengthening the company’s nationwide supply network.

As part of its commitment to global standards, MAPEI India operates under an Integrated Management System (IMS) certified for ISO 9001 (Quality), ISO 14001 (Environment) and ISO 45001 (Health & Safety). These certifications reinforce its dedication to delivering safe, sustainable, and high quality solutions.

With a diverse portfolio of over 20 product lines, MAPEI India has supported iconic projects such as the Atal Tunnel, the Statue of Unity, and major airport and metro developments. The company has also invested Rs 3.2 crore in CSR initiatives focused on education, women’s empowerment, and rehabilitation. As it steps into the future, MAPEI India remains committed to excellence, sustainability, and customer trust.

Mapei hai to bharosa hai.

Concrete

Material Flow Efficiency

Published

6 days ago

March 18, 2026

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We explore how material handling systems are becoming strategic assets in cement plants, enabling efficient movement of raw materials, clinker and finished cement. Advanced conveying, automation and digital technologies are improving plant productivity while supporting energy efficiency and sustainability goals.

Material handling systems form the operational backbone of cement plants, enabling the efficient movement of raw materials, clinker and finished cement across complex production networks. With India’s cement industry producing over 391 million tonnes of cement in FY2024 and possessing an installed capacity of around 668 mtpa, according to the CRISIL Research Industry Report, 2025, efficient material logistics have become critical to maintaining plant productivity and cost competitiveness. At the same time, cement production is highly energy intensive and contributes around 7 per cent to
8 per cent of global CO2 emissions, making efficient material flow and logistics optimisation essential for reducing operational inefficiencies and emissions states the International Energy Agency Cement Technology Roadmap, 2023. As plants scale capacity and integrate digital technologies, modern material handling systems, ranging from automated conveyors to intelligent stockyards, are increasingly recognised as strategic assets that influence plant stability, energy efficiency and environmental performance.

Strategic role of material handling
Material handling is no longer viewed as a secondary utility within cement plants; it is now recognised as a strategic system that directly influences production efficiency and process stability.
Cement manufacturing involves the continuous movement of large volumes of limestone, clay, additives, clinker and finished cement across multiple production stages. Even minor disruptions in conveying systems or storage infrastructure can lead to kiln feed fluctuations, production delays and significant financial losses. According to Indian Cement Industry Operational Benchmarking Study, 2024, unplanned downtime in large integrated cement plants can cost between Rs.15–20 lakh per hour, highlighting the economic importance of reliable material handling systems.
Modern cement plants are therefore investing in advanced mechanical handling systems designed for high throughput and operational reliability. Large integrated plants can process over 10,000 tonnes per day of clinker, requiring highly efficient conveying systems and automated stockyards to maintain continuous material flow, suggests the International Cement Review Industry Analysis, 2024. Efficient material handling also reduces spillage, minimises dust emissions and improves workplace safety. As cement plants become larger and more technologically advanced, the role of material handling is evolving from simple transport infrastructure to a critical operational system that supports both productivity and sustainability.

From quarry to plant
The transport of raw materials from quarry to processing plant represents one of the most energy-intensive stages of cement production. Traditionally, limestone and other raw materials were transported using diesel-powered trucks, which resulted in high fuel consumption, dust generation and increased operational costs. However, modern plants are increasingly adopting long-distance belt conveyors and pipe conveyors as a more efficient alternative. These systems allow continuous material transport over distances of 10–15 kilometres, significantly reducing fuel consumption and operating costs while improving environmental performance, states the FLSmidth Cement Industry Technology Report, 2024.
Milind Khangan, Marketing Manager, Vertex Market Research & Consulting, says, “Efficient and enclosed handling of fine materials such as cement, fly ash and slag requires modern pneumatic conveying systems. By optimising the air-to-material ratio, these systems can reduce energy consumption by 10 per cent to 15 per cent while ensuring smooth material flow. Closed-loop conveying further minimises dust loading and improves the performance of bag filters, supporting cleaner plant operations. In addition, flow-regulated conveying lines help prevent clogging and maintain reliable dispatch performance. Overall, automation in pneumatic conveying delivers immediate operational benefits, including improved equipment uptime, lower energy use, reduced material spillage and more stable kiln and mill performance.”
Pipe conveyor systems are particularly gaining traction because they provide a completely enclosed transport system that prevents material spillage and dust emissions. According to global cement engineering studies, conveyor-based transport can reduce energy consumption by up to 30 per cent compared to truck haulage, while also improving operational reliability. Several cement plants in India have already implemented such systems to stabilise quarry-to-plant logistics while reducing carbon emissions associated with diesel transport.

Stockyard management and homogenisation
Stockyards play a critical role in maintaining raw material consistency and stabilising kiln feed quality. Modern cement plants use advanced stacker and reclaimer systems to ensure efficient storage and blending of raw materials before they enter the grinding and pyroprocessing stages. Automated stacking methods such as chevron or windrow stacking enable uniform distribution of materials, while bridge-type or portal reclaimers ensure consistent extraction during kiln feed preparation. These systems are essential for maintaining stable chemical composition of raw meal, which directly influences kiln efficiency and clinker quality. The Cement Plant Operations Handbook, 2024 indicates that advanced homogenisation systems can reduce raw mix variability by up to 50 per cent, significantly improving kiln stability and energy efficiency. Integrated stockyard management systems also incorporate sensors for monitoring bulk density, moisture levels and stockpile volumes, enabling real-time control over material blending processes.

Clinker and cement conveying technologies
Once clinker is produced in the kiln, it must be efficiently transported to storage silos and subsequently to grinding and packing units. Modern cement plants rely on high-capacity belt conveyors, bucket elevators and pneumatic conveying systems to manage this stage of material flow. Steel-cord belt bucket elevators are now capable of lifting materials to heights exceeding 120 metres with capacities reaching 1,500 tonnes per hour, making them suitable for large-scale clinker production lines, states the European Cement Engineering Association Technical Paper, 2023.
For fine materials such as cement, fly ash and slag, pneumatic conveying systems provide a reliable and dust-free solution. These systems transport powdered materials using controlled airflow, ensuring enclosed and contamination-free movement between grinding units, silos and packing stations. Optimised pneumatic systems can reduce energy consumption by 10 per cent to 15 per cent compared to older conveying technologies, while also improving plant cleanliness and environmental compliance, according to the Global Cement Technology Review, 2024.

Automation and digitalisation
Digitalisation is transforming material handling systems by introducing real-time monitoring, predictive maintenance and automated control. Advanced sensors and Industrial Internet of Things (IIoT) platforms enable plant operators to track conveyor health, stockpile levels and equipment performance in real time. Predictive maintenance systems analyse vibration patterns, temperature fluctuations and equipment load data to detect potential failures before they occur. According to McKinsey’s Industry 4.0 Manufacturing Report, 2023, for heavy industries, digital monitoring and predictive maintenance technologies can reduce equipment downtime by up to 30 per cent and increase productivity by 10 per cent to 15 per cent. Digital control centres also integrate data from conveyors, stacker reclaimers and dispatch systems, enabling centralised management of material flows from quarry to dispatch.

Handling of AFR
The growing adoption of Alternative Fuels and Raw Materials (AFR) has introduced new challenges and opportunities for material handling systems in cement plants. AFR materials such as refuse-derived fuel (RDF), biomass and industrial waste often have irregular particle sizes, variable moisture content and lower bulk density compared to conventional fuels. As a result, specialised storage, dosing and feeding systems are required to ensure consistent kiln combustion. According to the Cement Sector Decarbonisation Roadmap published by NITI Aayog in 2026, increasing the use of AFR could enable India’s cement sector to achieve thermal substitution rates of around 20 per cent in the coming decades. To support this transition, plants are investing in automated receiving stations, shredding units, drying systems and precision dosing equipment to stabilise AFR supply and combustion performance.

Energy efficiency and dust control
Material handling systems also play a crucial role in improving plant energy efficiency and environmental performance. Modern conveyor systems equipped with variable speed drives and energy-efficient motors can significantly reduce electricity consumption. Permanent magnet motors used in conveyor drives can deliver 8 per cent to 12 per cent energy savings compared to conventional induction motors, improving overall plant energy efficiency according to the IEA Industrial Energy Efficiency Study, 2023. Dust control is another major concern in cement plants, particularly during material transfer and storage operations. Enclosed conveyors, dust extraction systems and advanced bag filters are widely used to minimise particulate emissions and improve workplace safety.

Future trends in material handling
The future of material handling in cement plants will be shaped by automation, digitalisation and sustainability considerations. Emerging technologies such as AI-driven logistics optimisation, autonomous mobile equipment and digital twins are expected to further improve plant efficiency and operational visibility. Digital twin models allow engineers to simulate material flow patterns, optimise stockyard operations and predict equipment performance under different operating conditions. According to the International Energy Agency Digitalisation and Energy Report, 2024, the adoption of advanced digital technologies could improve industrial energy efficiency by up to 20 per cent in heavy industries such as cement manufacturing. As cement plants expand capacity and adopt low-carbon technologies, intelligent material handling systems will play a critical role in maintaining productivity and reducing environmental impact.

Conclusion
Material handling systems have evolved from basic transport infrastructure into strategic operational systems that directly influence plant efficiency, reliability and sustainability. From quarry transport and automated stockyards to digital dispatch platforms and advanced conveying technologies, modern material handling solutions enable cement plants to manage large production volumes while maintaining process stability.
As India’s cement industry continues to expand to meet infrastructure and urban development demands, investments in advanced material handling technologies will become increasingly important. By integrating automation, digital monitoring and energy-efficient systems, cement manufacturers can improve operational performance while supporting the industry’s long-term sustainability and decarbonisation goals.