Economy & Market

“RMC business will see a growth of 7-10% in the next 5 years”

Published

8 years ago

April 30, 2018

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– Arun Shukla, Chief of RMX & Aggregates, Nuvoco Vistas Corporation
Nuvoco Corporation (formerly LaFarge India) was acquired by Nirma about 18 months back. Nuvoco has three business verticals – cement, ready mix concrete (RMC) and aggregates. In cement, the company has plants Chattisgarh, West Bengal and Chittorgarh. In RMC, the company has close to 70 plants across India. In aggregates, the company has two quarries – one near Mumbai in Badlapur and other one in Kotputli in Rajasthan. Considering the focus of government on infrastructure and housing, how do you view the business of concrete and aggregates in the next five years?
I am quite bullish about the market for concrete and aggregates. Cement consumption in India is close to 180 kg per person per year, which is very low. Out of that, 60 per cent is being used for concrete. If you compare this consumption with China, which is also a developing country, their growth rate is much faster than ours. China’s cement consumption is close to 2,000 kg per person per annum.
Given the push on infrastructure and housing for all, I see an immense potential of RMC going further. Our ambition is to partner with the vision of our country and do a lot of infrastructure development, and contribute towards giving housing to all people who are not having houses as of now. The next five years will be quite bullish for RMC business.
In typical construction sites, there are issues like scarcity of labours. In smaller towns, there are site mixes. But now, the pollution control agencies are so strict that they are not allowing you to have site mixes. So, RMC is bound to go to all those places where even site mix is practiced. I am quite sure that the RMC business, and I see a growth of 7-10 per cent in the next five years. Right now, RMC capacity is close to 45 million cum3, which is the relevant market size where we operate in.
It will double (to 100 million cm3) in the next 4-5 years. Traditionally RMC industry has been dominated by local and unorganised players. Do you see any change in the structure?
Factually this industry is quite fragmented. If you take the top five players, they are holding a market share of close to 35-40 per cent. And rest of the concrete requirement is being fulfilled by local players. That way this is quite fragmented. But there are a lot of regulations and structural changes (like RERA and GST) that have happened in the recent past. These changes will encourage the industry going forward. So there is going to be much more level-playing field. I think, GST will impact logistics. For supporting individual house builders, what sort of customer service offerings are available from Nuvoco concrete and what is its USP?
In this, we stand out from others. In our portfolio, we have a lot of value-added products that are going to address concerns that individual homebuilders have. We have a product called ‘Agile’, which is a self compacting concrete, a free flow concrete. So there you do not need much labour because I talked about the scarcity of labour at job site. We have other products like ‘Artiste’, wherein you can really have a different texture, different kind of patterns, and this is going to be a good alternative to tiles. Tiles have smaller life, but if you use Artiste, it will have a longer life.
We have a lot of other products as well. We have got light-weight concrete, which is called ‘X Light’. A typical concrete has a density of 2,400 kg per cm3, but our concrete has around 800 to 1,600 per kg.
We have solutions for hospitals too. In cancer hospitals there are radiations done. We have a solution wherein the radiation does not come out. This concrete is radiation proof. We have a solution wherein we can do concrete in running water as well. Then, we have a concrete solution for cold weather where the temperature is very low. We do produce from M35 to M95.
We have Insta-mix, which is a revolutionary product in the RMC industry, and we supply green concrete in bags. For eg: If any trucks cannot reach the construction site, then we have a solution of supplying wet concrete in bags. You just need to go and pour it on site, no need to add water. This has got retention of up to eight hours, while normal concrete has only retention period of four hours. This product is having very good acceptability in the market because this addresses the concerns of typically constricted bylanes of India where you have a small requirement of concrete. From LaFarge to Nuvoco – how did this brand transition take place?
We emphasised that we are going to retain all those key features for which Lafarge is known in the market. Our USP was to kind of differentiate ourselves in the market by way of providing different products and service to our customers. After this transition, we are much more focused in this area. Our endeavour is to exceed expectations of customers in terms of delivery of service and quality of product. All those products which we had before, are still being continued. That way our focus is on differentiating solution-centric organisation, getting ready for customers requirement, giving them the quality they want, fulfilling our commitment to the customer. We have demonstrated all these qualities with much more focus. That is how our customers do not feel any change. Our products are well accepted, our entire team is intact including me. I am there in this organisation since beginning. Where it really matters, nothing has changed. We have been in touch with our customers throughout the entire transitions. Wherever a change was taking place they were kept in the loop, right from the CEO down the line. They had access to everybody. The entire transition took place very smoothly.The market is shifting from natural sand to manufactured sand. How do you look at this picture.
We do have an opportunity to help in building this business. This is our vision and now we are going to be helpful in creating sustainable and smarter product. There is push on infrastructure and housing, and we will be part of the growth story. We are operating two crushers one near Mumbai and second close to the NCR region. But gradually now market is shifting from this natural sand to manufactured sand. But I think gradually things are going to change because this sand issue will be there to an extent going forward as well. So better to find some solution by which we come out with raw material which can replace sand. So like in Mumbai, there is no natural sand. Entire concrete is being made of crushed sand. But still in some of the markets, I think people have a mindset that natural sand and river sand is better than manufactured sand. Things are changing and I am sure things are going to change gradually. What is the role of cost in manufactured sand?
That depends because raw material cost is basically logistics intensive. If your logistics cost is high – be it natural sand or not – cost is going to be in that proportion. You can have a fixed rule that natural sand is costlier than crushed sand and vice versa. It all depends on the logistics.Can it be manufactured anywhere or it requires a special kind of raw material?
You need a rock for that. And manufacture sand is going to be sustainable solution for this scarcity of natural sand.What technological changes you foresee in construction strategies of infrastructure sector which may affect your sector?
Construction industry in India is still evolving. We have issues of skilled manpower. Updated technology and also the availability of routine product. I see a good scope of improvement in construction industry in India. We do have an expertise of supplying very high grade of concrete. Typically in India till now lower grades of concrete was being used. But now people have realised if they use this higher grade of concrete then they are going to get multiple benefit. I think the kind of knowhow which we are going to share with our customers with that they are going to reduce their overall cost and also fasten their construction, retaining the quality without compromising. This is what we are partnering with our customers. Also our strategy is to partner with our customer right at the beginning when they conceptualise their project, we suggest them that if they are going to use these products then that is going to bring down their overall cost and ease of execution. And we have got construction development and innovation centre to support our initiative. We keep on doing innovation in building material space as to what is the next step and what is the next package that is going to help all construction sites.Tell us about customer discovery.
We have a nice process of what we call customer discovery. We go and sit with customers and we understand them and what all issues they are facing and based on that, we try to go back to them with some solution. So there is a process like we go and discover customers requirement, then we work on various ideas to address those issues. These are steps of innovation that we follow. We have a very systematic approach of understanding customers requirements. Insta-mix was born out of one such need and that is why it was created in our laboratory in India.How do you manage smaller quantities?
If you ask ready mix plant to supply one third of cubic metre they are not going to supply because of cost factor. How will a 6-cm3 truck carry one-third of cubic metre. And if at all they are going to supply they are going to charge you heavily. We are the only company to supply wet concrete in bags. It is supplied in buckets but not bags. So we have a monopoly in that segment.What is your prime focus – retail or institutional business?
We are looking for opportunities in all segments. As there is a lot of push on infrastructure and housing, these businesses will offer us a lot of opportunity, which we do not want to miss. We are expanding ourselves to areas where we do not have any presence and we find a good opportunity. For instance, we have set up a plant in Lucknow very recently. We see a lot is happening in the northern part of India. We have plans to set up plants in other emerging markets as well. We want to grow in the retail segment too because the market is offering an opportunity and customers are looking for solutions. We have expertise and knowhow and we will go and reach out to them and supply them the solution they want.What is the market size for decorative concrete in India and how is it shaping up?
There is no structured data available as such. We are one of the biggest players of decorative concretes in India. This segment is growing, you only need to to make your customers aware of the solution and convert them from one solution to another. I will not limit this segment to a particular cubic metre as of now.That means you want to bring this from unorganised sector to organised sector?
Decorative concrete is a solution that his going to last for years to come. Our products are used in amusement parks, especially at entrance where you have a lot of footfalls. This can withstand that kind of pressure and wear and tear and still be there for decades to come.Have you associated with any infrastructure project that is approaching completion?
We are really proud to be associated with lot of good infrastructure projects. For instance, we were engaged in Delhi Metro. We have also partnered with some of the construction companies for Noida metro. We are executing Jaipur Metro job and we are one of the suppliers in concrete of Mumbai metro. Our contribution and presence is quite good. In fact, we are known to be an expert in metro projects. Our focus is going to be there on infrastructure jobs because this is the place where we can give a lot of additional value to the contractor and the agencies which are there. How do you handle safety and environment in RMC and what about conservation of concrete?
It very important and it is very close to our heart as well. health safety and environment is part of our value system. Our philosophy is that wherever we are operating, our environmental footprint should be the minimum. How we are going to conserve the scarce resources and how are you going to ensure that we do not disturb the ecology of the ambience? We shall offer a product which is kind of conserving some natural resources. For instance now you must have heard of green building concept. How we are going to reduce cement consumption in ready mix concrete? If you are going to reduce cement content in ready mix then you are going to help environment in many ways. One is to reduce carbon footprint. Second is also you are going to preserve limestone which is scarce and you do not have limestone reserve forever. If you are not going to conserve it today then how future generations are going to take benefit of that reserve. This is our philosophy. So we work on kind of designing a product wherein we can use alternative raw material to reduce limestone consumption without impacting quality product. Health and safety I think we have proper system wherein any person who is coming to our plant is properly trained, he is given safety induction, he has to go through a medical test and then he is deployed at job site. We do have a branch where each and every day our plant people are going through a checklist. Health and safety is a holistic approach for us. We are not only kind of trying to take responsibility of our people but all the stakeholders are involved in our business. All those truck drivers who are being deployed at our plant they mandatorily have to go through this training on defensive driving. We have got defensive driving training. They will go through that training. So suppose my plant is there and I fit it at one place and job site is 10 km is away. Then we prepare this with risk management and we communicate this to our rider. So all those hazards and all those risky areas or traffic areas, we tell them before that this is how they are going to negotiate on that track. We have got a very systematic approach. Any equipment where we do some preventive maintenance or breakdown maintenance we have got a system of permit so our people are going to take permit, we prepare this and we risk assessment of that job, we communicate that risk assessment to our team members, these are risk and this is how you are going to eliminate and these things you are going to deploy. Then only those guys go and work on it. So we have a very robust system of health and safety. Wherein we are not going to take even an iota of risk. For us doing business is alright but if you can save a person’s life and I think we have done it.
Also our customers have appreciated it and requested us to conduct workshops at their own sites. We do that also. For us it is important that it is not just we who are contentious but as many people we can inform and educate about this it is only everybody else who benefits out of it.

Economy & Market

SEW-EURODRIVE India Opens Drive Technology Centre in Chennai

Published

2 weeks ago

March 25, 2026

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The new facility strengthens SEW-EURODRIVE India’s manufacturing, assembly and service capabilities

SEW-EURODRIVE India has inaugurated a new Drive Technology Centre (DTC) in Chennai, marking a significant expansion of its manufacturing and service infrastructure in South India. The facility is positioned to enhance the company’s responsiveness and long-term support capabilities for customers across southern and eastern regions of the country.

Built across 12.27 acres, the facility includes a 21,350-square-metre assembly and service setup designed to support future industrial growth, evolving application requirements and capacity expansion. The centre reflects the company’s long-term strategy in India, combining global engineering practices with local manufacturing and service capabilities.

The new facility has been developed in line with green building standards and incorporates sustainable features such as natural daylight utilisation, solar power generation and rainwater harvesting systems. The company has also implemented energy-efficient construction and advanced climate control systems that help reduce shopfloor temperatures by up to 3°C, improving production stability, product quality and working conditions.

A key highlight of the centre is the 15,000-square-metre assembly shop, which features digitisation-ready assembly cells based on a single-piece flow manufacturing concept. The facility also houses SEW-EURODRIVE India’s first semi-automated painting booth, aimed at ensuring uniform surface finish and improving production throughput.

With the commissioning of the Chennai Drive Technology Centre, SEW-EURODRIVE India continues to strengthen its manufacturing footprint and reinforces its long-term commitment to supporting industrial growth and automation development in India.

Concrete

Material Flow Efficiency

Published

3 weeks 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.

Kanika Mathur

Concrete

Modernise to Optimise

Published

3 weeks ago

March 18, 2026

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Cement plant modernisation is reshaping the industry through upgrades in
kilns, energy systems, digitalisation, AFR integration and advanced material
handling. We explore these technologies that improve efficiency, reduce
emissions, strengthen competitiveness, while preparing the industry for India’s
next phase of infrastructure growth.

India’s cement industry, the world’s second-largest, is undergoing a rapid transformation driven by infrastructure demand, decarbonisation targets and technological advancement. The sector’s installed capacity stood at approximately 668 million tonnes per annum (mtpa) in FY2025 and is projected to reach 915–925 mtap by 2030, supported by large-scale capacity expansions and infrastructure investment cycles, suggests CRISIL Intelligence Industry Report, 2025. At the same time, cement production remains highly energy intensive and contributes about 6 per cent to 7 per cent of India’s total greenhouse gas emissions, making efficiency improvements and modernisation critical for long-term sustainability as stated in CareEdge ESG Research, 2025. As a result, cement manufacturers are investing in advanced kiln technologies, digital monitoring systems, waste heat recovery, alternative fuels, and modern material handling infrastructure to enhance productivity while aligning with global decarbonisation pathways.

Need for modernisation
The need for plant modernisation is closely linked to the sector’s rapid capacity expansion and rising operational complexity. India’s installed cement capacity has grown significantly in the last decade and is expected to exceed 900 mtpa by 2030, driven by demand from housing, infrastructure and urban development projects, as per the CRISIL Intelligence Industry Report, 2025. However, increasing scale also places pressure on energy efficiency, logistics, and production stability. The report also suggests that the cement plants must upgrade equipment and processes to operate at higher utilisation rates, which are projected to reach 75 per cent to 77 per cent by the end of the decade, compared to around 72 per cent to 74 per cent in FY2026.
Environmental imperatives are another major driver of modernisation. Cement manufacturing is responsible for a significant share of industrial emissions because clinker production requires high-temperature processes that depend heavily on fossil fuels. According to CareEdge ESG research, the cement sector contributes 6–7 per cent of India’s total greenhouse gas emissions, with approximately 97 per cent of emissions arising from direct fuel combustion and process emissions in kilns. Consequently, plant modernisation initiatives now focus not only on productivity improvements but also on reducing emissions intensity, energy consumption, and reliance on conventional fuels.
“One of the most impactful upgrades implemented at Shree Cement in the last five years has been the adoption of advanced data management platforms that provide real-time visibility across major process areas. This digital advancement has strengthened plant automation by enabling faster and more accurate responses to process variations while improving the reliability of control loops. Real-time dashboards, integrated analytics and automated alerts now support quicker, data-driven decision-making, helping optimise kiln and mill performance, improve energy control and detect deviations early. By consolidating data from multiple systems into a unified digital environment, the company has enhanced operational consistency, reduced downtime and improved both productivity and compliance. This shift towards intelligent automation and real-time data management has become a key driver of operational excellence and future-ready plant management,” says Satish Maheshwari, Chief Manufacturing Officer, Shree Cement.

Kiln and pyroprocessing upgradation
The kiln remains the technological heart of cement manufacturing, and modernisation efforts often begin with upgrades to pyroprocessing systems. Many older plants in India operate with four- or five-stage preheaters, while modern plants increasingly adopt six-stage preheater and pre-calciner systems that significantly improve heat efficiency and clinker output. These systems enhance heat transfer, reduce fuel consumption, and stabilise kiln operations under high throughput conditions.
Professor Procyon Mukherjee suggests, “Cement manufacturing is, at its core, a thermal process. The rotary kiln and calciner together account for energy consumption and emissions. The theoretical thermal requirement for clinker production is around 1700–1800 MJ per tonne, yet real-world plants often operate far above this benchmark due to inefficiencies in combustion, heat recovery and material flow. Modernisation, therefore, must begin with the
kiln system, and not peripheral automation or
isolated upgrades. The shift from wet to dry process kilns, combined with multi-stage preheaters and precalciners, has already delivered step-change improvements, making dry kilns nearly 50 per cent more energy efficient.”
Recent investment programmes across the industry have included kiln cooler upgrades, advanced burners, and improved refractory materials designed to increase operational reliability and reduce specific heat consumption. Such upgrades are essential because cement production remains highly energy intensive, and continuous efficiency improvements are required to meet global decarbonisation targets. According to the International Energy Agency (IEA) Cement Tracking Report, 2023, the cement sector must achieve annual emissions intensity reductions of around 4 per cent through 2030 to align with global net-zero scenarios.

Energy efficiency and WHRS
Energy efficiency remains one of the most important areas of modernisation in cement manufacturing, given the sector’s heavy reliance on thermal and electrical energy. Modern plants deploy advanced process controls, efficient grinding systems, and improved combustion technologies to reduce specific energy consumption. The adoption of energy-efficient technologies is particularly important in India, where energy costs account for a large share of production expenses. As demand grows and plants expand capacity, improving energy performance becomes essential to maintain competitiveness.
Waste Heat Recovery Systems (WHRS) have emerged as a key solution for improving plant energy efficiency. During cement production, large volumes of high-temperature gases are released from kilns and coolers. WHRS technology captures this waste heat and converts it into electricity, thereby reducing reliance on external power sources. According to energy benchmarking studies for the Indian cement industry, installed waste heat recovery capacity in the sector has reached approximately 840 MW, with an additional potential of around 500 MW states the Green Business Centre, Energy Benchmarking Report, 2023. Several leading producers have already implemented large WHRS installations; for example, UltraTech Cement has deployed systems with around 121 MW of waste heat recovery capacity, reducing carbon emissions by nearly 0.5 million tonnes annually according to the Energy Alternatives India Case Study, 2024.

Integration of AFR
The integration of Alternative Fuels and Raw Materials (AFR) is another critical dimension of cement plant modernisation. AFR refers to the use of industrial waste, biomass, refuse-derived fuel (RDF), and other non-fossil materials as substitutes for conventional fuels such as coal and petcoke. Increasing the use of AFR helps reduce fossil fuel consumption while simultaneously addressing waste management challenges. According to the NITI Aayog Decarbonisation Roadmap, 2026, scaling the use of RDF and other alternative fuels could enable the sector to achieve thermal substitution rates of around 20 per cent in the coming decades.
However, integrating AFR requires significant plant modifications and operational adjustments. Waste-derived fuels often have inconsistent calorific values, higher moisture content, and heterogeneous physical properties compared to traditional fuels. As a result, modern plants invest in advanced fuel preparation systems, dedicated feeding equipment, and automated dosing technologies to ensure stable kiln operation. These upgrades allow plants to maintain consistent clinker quality while increasing the share of alternative fuels in their energy mix.

Digitalisation and smart plant operations
Digitalisation is rapidly transforming cement plant operations by enabling data-driven decision-making and predictive maintenance. Industry 4.0 technologies such as IoT sensors, artificial intelligence (AI), and advanced analytics are now used to monitor equipment performance, optimise process parameters, and anticipate maintenance requirements. These digital tools enable plant operators to detect early signs of equipment failure, minimise unplanned downtime, and improve operational efficiency. Predictive maintenance systems, for example, analyse vibration, temperature, and acoustic signals from rotating equipment to identify potential faults
before they escalate into major breakdowns. Digital twins and integrated control systems further allow operators to simulate plant performance under different scenarios and optimise production strategies. Such technologies are becoming increasingly important as cement plants operate at larger scales and higher levels of process complexity.
Maheshwari also adds, “Plant modernisation is also increasingly central to the global competitiveness of Indian cement manufacturers. As cost pressures rise across energy, logistics and regulatory compliance, modern plants offer the structural efficiency required to operate reliably and competitively over the long term. Technologies such as AI-driven Advanced Process Control (APC) integrated with real-time data systems are emerging as essential investments for the future. These platforms use predictive algorithms, machine learning and live process inputs to optimise kiln, mill and utility operations with greater precision than traditional control systems. By continuously analysing variations in feed chemistry, temperature profiles, energy demand and equipment behaviour, APC enables stable operations, lower specific energy consumption, reduced emissions and improved product consistency. As regulatory expectations tighten and plants pursue higher efficiency with lower carbon intensity, AI-enabled APC will play a crucial role in strengthening automation, enhancing decision-making and ensuring long-term operational resilience.”

Modern material handling and logistics
Material handling systems play a critical role in ensuring smooth plant operations and efficient logistics. Modern cement plants rely on advanced conveying systems, automated stockyards, and digital dispatch platforms to manage the movement of raw materials, clinker, and finished cement. Long-distance belt conveyors and pipe conveyors are increasingly replacing truck-based transport between quarries and plants, reducing fuel consumption, dust emissions, and operational costs. Automated stacker-reclaimers ensure consistent blending of raw materials,
which improves kiln stability and clinker quality. Meanwhile, advanced packing and dispatch systems equipped with high-speed rotary packers and robotic palletisers enhance throughput and reduce manual labour. These technologies allow cement plants to optimise logistics efficiency while supporting higher production capacities.

Emission control and environmental compliance
Environmental compliance has become a central focus of cement plant modernisation as regulators and investors place greater emphasis on sustainability performance. Modern plants deploy advanced emission control technologies such as high-efficiency bag filters, electrostatic precipitators, and selective non-catalytic reduction systems to reduce particulate matter and nitrogen oxide emissions.
Sine Bogh Skaarup, Vice President, Head of Green Innovation and R&D, Fuller Technologies says, “One of our key focus areas is decarbonisation. We help cement producers reduce CO2 and overall carbon emissions. We offer alternative fuel solutions and calcined clay technologies to enable the production of LC3 cement, which play a significant role in decarbonising the cement industry. By combining alternative fuels and calcined clay solutions, CO2 emissions can be reduced by up to 50 per cent, making this a highly impactful approach for sustainable cement production.”
Continuous emission monitoring systems are increasingly used to track environmental performance in real time and ensure compliance with regulatory standards. In addition to air pollution control, cement companies are also investing in water recycling systems, renewable energy integration, and carbon reduction initiatives. These measures are essential for aligning the sector with national climate goals and improving the environmental footprint of
cement manufacturing.

Economic benefits and future outlook
Beyond environmental and operational advantages, cement plant modernisation also delivers significant economic benefits. Energy efficiency improvements, digital process optimisation, and advanced material handling systems reduce operating costs and improve asset utilisation. Waste heat recovery and alternative fuels help lower fuel expenditure and reduce exposure to volatile fossil fuel markets. As the industry expands capacity to meet growing demand, modernised plants are better positioned to achieve higher productivity and maintain profitability. The long-term outlook for the sector remains positive, with India expected to continue large-scale infrastructure investments in roads, housing, railways, and urban development.
Milan R Trivedi, Vice President – Projects, Prod & QC, MR, Shree Digvijay Cement, says, “The main focus in case of modernisation projects drives through the investment decision, which is mainly based on IRR and impact on overall efficiency improvement, cost optimisation and improvement in reliability. However, there are certain modernisation, which has high impact on environmental impact, statutory requirements, etc. has higher priority irrespective of ROI or payback period.”
“The energy efficiency and reliability investment projects generally provide fast return on investment whereas strategic, digitalisation and environmental investment projects provide long term and compounded benefits. Typical modernisation investment projects are decided with IRR of about > 20 per cent, payback period of typically 2-3 years for fast-track projects,” he adds.
In this context, modernisation will remain a key strategic priority for cement manufacturers seeking to maintain competitiveness in an increasingly sustainability-focused market.

Conclusion
The modernisation of cement plants is no longer a purely technical upgrade but a strategic transformation that reshapes how the industry operates. As India’s cement sector expands capacity toward the next growth cycle, improvements in energy efficiency, digitalisation, alternative fuels and advanced logistics will determine the competitiveness of individual plants. Modern technologies allow producers to operate at higher productivity levels while simultaneously reducing energy consumption and emissions intensity.
Looking ahead, the pace of technological adoption will play a decisive role in shaping the future of
the cement industry. Companies that successfully integrate modern equipment, digital systems, and sustainable production practices will be better positioned to meet rising infrastructure demand while aligning with global climate commitments. In this evolving landscape, plant modernisation stands as the cornerstone of both operational excellence and environmental responsibility.