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Robots takeover Quality & Safety at plants

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Traditional laboratory processes have given way to robotics for ensuring quality control and avoiding health hazards in 24x7x365 operation of cement plants.
Quality control equipment of cement industry, which was automated over the years, is turning towards robotics, of late. In the early days, sample collection and transfer it to testing laboratory and adjusting the controls based on the laboratory results were being done manually. Then came semi-automatic sampling and automatic sample preparation; followed by automation of sample transportation; then a compact and interlaced design that suits a single integrated line or a clinker grinding facility was introduced, and now, robots have entered the arena. Today, human intervention in the process has been reduced to almost nil by robots.
Increasing environmental regulations, need for production efficiency and cost control at every level, need to curtail human errors in this continuous process industry, and growing demand for consistency of product quality by customers are placing increasingly tough requirements for sample analysis quality and complexity, and for sample throughput in cement plants. Besides, availability of skilled manpower in remote areas where many cement plants are located, and retaining them has become a difficult task for companies. So, remote operation, support from distant locations, and online assistance are all vital for the smooth operation of quality control systems in modern cement plants.
Indian cement industry is known to be one of the leaders in emission control in the world is also emulating global best practices in quality control, which strive to ensure:

  • High speed and accuracy of sample collection and results;
  • Stricter quality controls sought by cement markets;
  • Support for 24x7x365 operations; and
  • Zero health and safety hazards or incidents.

Robotics
The traditional process of cement sampling involved use of motorised or hand operated to collect material from the process, which used to be carried to the lab by a boy and the lab operator used a manual pulverising mill to grind it in a tungsten carbide or steel bowl to a fine powder, before using it for testing.
Most of the companies deployed manpower for collection and preparation of sample, which created manual lapses and error in sample itself, which ultimately affecting quality of product and its control actions. So, most of the companies are adopting lab automation and robotics for utmost accurate sampling analysis for their latest plants.
Suppliers today offer a range of fully automatic solutions from robot-free to multi-robot systems and also in phased manner to spread the investment over a few years. "The latest offering is use of robots or collaborative robots in laboratory automation, allowing a common shared space for both humans and machines as well as give a lot of flexibility to support future growth," says Jagdish Chandra Toshniwal, Managing Director, Wonder Cement Ltd, which is in the process of setting up the latest laboratory automation equipment in their factory.
This technology has matured over the years. The lab automation suppliers are moving their data over to cloud and perform analytics on the quality data by relating it to process data and this can be opened up for end-users of the product. And it can also be accessed on a mobile phone.
Companies like Emami Cement collect the sample through auto samplers controlled by robotic operations which are programmed in robo PC. "This ensures timely sample collection with utmost safety and without any human intervention. The other features include, auto sampling; auto sample preparation and analysis; provides safe, fast and reliable information; integrates all cement quality-control activities in a single system; and incorporates in-depth understanding of the production process," says Vivek Chawla, Whole-time Director & CEO, Emami Cement Limited.
The latest offering by lab automation suppliers to control entire quality from mining to cement production include pile analysis and control, Blend Ratio analysis and control software, automatic free lime calculation, Blaine analyser, automatic carbon sulphur analysers etc.
All material in a process flow must have an equal probability of being sampled. There are no methods of analysis that can compensate for errors/bias in the sampling stages. Therefore, it is crucial that the company always asks itself if the sampling method is adequate when investing in sophisticated analysis technology, says S Sankaralingam, QCX Sales, FLSmidth, which is one of the leading supplier of laboratory equipment for cement plants.
Integration of various systems in the process of manufacturing is the basic necessity for any lab automation equipment for reaping full benefits. "The integration between laboratory and power control enabled us to get uniform quality of raw mix, which in turn helps us to get stable running of kiln and cement mills with consistent quality," says Chawla. The lab automation system is integrated with various automation systems like cross belt analyser (CBA), Plant Central Control DCS system for Ratio Control of Raw Mix feed at Emami Cement.
Latest technologies ensure that chemistry of raw materials is constantly and automatically monitored without any human intervention. "The integration between the laboratory and power control is flawless which allows us to control the quality of raw mix, clinker as well as particle size distribution of cement products. Under this operation, change in desired mix, prompts the advanced quality control software POLAB? AQCnet software to re-calculate the raw mix finally through AQC net," says Toshniwal.
By monitoring quality of final products as well as intermediate raw meal or kiln feed, the manufacturer can stabilise the process leading to better productivity and to be more specific, capability of bringing down standard deviation of this system, leading to better throughput and production of consistent quality product.Installation
The cycle time for such installations typically takes about eight months depending on plant readiness and infrastructure availability. For a greenfield cement plant, however, this can be done in parallel to the main plant and machinery ordering, which anyway has a timeframe of 12-18 months of concept-to-market.
For Wonder Cement, which is installing the lab equipment at its plants, the cost incurred is approximately Rs 200 million, including one CBA and two XRF for managing two lines of operation. "Depending on plant size the cost could be anywhere in the range of Rs 80-120 million, with analysers costing another Rs 30-40 million," says Toshniwal.
Responding to a query on return on investment (RoI), Toshniwal added, "Approximately three years," considering indirect benefits from increased productivity and efficiency, better lining life of kiln, optimised use of additives, reduced kiln stoppages, reduced clinker factor. Over and above, production of quality products consistently, reflects in better image in the market which gives leverage for enhancing sales, he feels.

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Process

Price hikes, drop in input costs help cement industry to post positive margins: Care Ratings

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Region-wise,the southern region comprises 35% of the total cement capacity, followed by thenorthern, eastern, western and central region comprising 20%, 18%, 14% and 13%of the capacity, respectively.

The cement industry is expected to post positive margins on decent price hikes over the months, falling raw material prices and marked drop in overall production costs, said an analysis of Care Ratings.

Wholesale and retail prices of cement have increased 11.9% and 12.4%, respectively, in the current financial year. As whole prices have remained elevated in most of the markets in the months of FY20, against the corresponding period of the previous year.

Similarly, electricity and fuel cost have declined 11.9% during 9M FY20 due to drop in crude oil prices. Logistics costs, the biggest cost for cement industry, has also dropped 7.7% (selling and distribution) as the Railways extended the benefit of exemption from busy season surcharge. Moreover, the cost of raw materials, too, declined 5.1% given the price of limestone had fallen 11.3% in the same aforementioned period, the analysis said.

According to Care Ratings, though the overall sales revenue has increased only 1.3%, against 16% growth in the year-ago period, the overall expenditure has declined 3.2% which has benefited the industry largely given the moderation in sales.

Even though FY20 has been subdued in terms of production and demand, the fall in cost of production has still supported the cement industry by clocking in positive margins, the rating agency said.

Cement demand is closely linked to the overall economic growth, particularly the housing and infrastructure sector. The cement sector will be seeing a sharp growth in volumes mainly due to increasing demand from affordable housing and other government infrastructure projects like roads, metros, airports, irrigation.

The government’s newly introduced National Infrastructure Pipeline (NIP), with its target of becoming a $5-trillion economy by 2025, is a detailed road map focused on economic revival through infrastructure development.

The NIP covers a gamut of sectors; rural and urban infrastructure and entails investments of Rs.102 lakh crore to be undertaken by the central government, state governments and the private sector. Of the total projects of the NIP, 42% are under implementation while 19% are under development, 31% are at the conceptual stage and 8% are yet to be classified.

The sectors that will be of focus will be roads, railways, power (renewable and conventional), irrigation and urban infrastructure. These sectors together account for 79% of the proposed investments in six years to 2025. Given the government’s thrust on infrastructure creation, it is likely to benefit the cement industry going forward.

Similarly, the Pradhan Mantri Awaas Yojana, aimed at providing affordable housing, will be a strong driver to lift cement demand. Prices have started correcting Q4 FY20 onwards due to revival in demand of the commodity, the agency said in its analysis.

Industry’s sales revenue has grown at a CAGR of 7.3% during FY15-19 but has grown only 1.3% in the current financial year. Tepid demand throughout the country in the first half of the year has led to the contraction of sales revenue. Fall in the total expenditure of cement firms had aided in improving the operating profit and net profit margins of the industry (OPM was 15.2 during 9M FY19 and NPM was 3.1 during 9M FY19). Interest coverage ratio, too, has improved on an overall basis (ICR was 3.3 during 9M FY19).

According to Cement Manufacturers Association, India accounts for over 8% of the overall global installed capacity. Region-wise, the southern region comprises 35% of the total cement capacity, followed by the northern, eastern, western and central region comprising 20%, 18%, 14% and 13% of the capacity, respectively.

Installed capacity of domestic cement makers has increased at a CAGR of 4.9% during FY16-20. Manufacturers have been able to maintain a capacity utilisation rate above 65% in the past quinquennium. In the current financial year due to the prolonged rains in many parts of the country, the capacity utilisation rate has fallen from 70% during FY19 to 66% currently (YTD).

Source:moneycontrol.com

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Wonder Cement shows journey of cement with new campaign

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The campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV…

ETBrandEquity

Cement manufacturing company Wonder Cement, has announced the launch of a digital campaign ‘Har Raah Mein Wonder Hai’. The campaign has been designed specifically to run on platforms such as Instagram, Facebook and YouTube.

#HarRaahMeinWonderHai is a one-minute video, designed and conceptualised by its digital media partner Triature Digital Marketing and Technologies Pvt Ltd. The entire journey of the cement brand from leaving the factory, going through various weather conditions and witnessing the beauty of nature and wonders through the way until it reaches the destination i.e., to the consumer is very intriguing and the brand has tried to showcase the same with the film.

Sanjay Joshi, executive director, Wonder Cement, said, "Cement as a product poses a unique marketing challenge. Most consumers will build their homes once and therefore buy cement once in a lifetime. It is critical for a cement company to connect with their consumers emotionally. As a part of our communication strategy, it is our endeavor to reach out to a large audience of this country through digital. Wonder Cement always a pioneer in digital, with the launch of our IGTV campaign #HarRahMeinWonderHai, is the first brand in the cement category to venture into this space. Through this campaign, we have captured the emotional journey of a cement bag through its own perspective and depicted what it takes to lay the foundation of one’s dreams and turn them into reality."

The story begins with a family performing the bhoomi poojan of their new plot. It is the place where they are investing their life-long earnings; and planning to build a dream house for the family and children. The family believes in the tradition of having a ‘perfect shuruaat’ (perfect beginning) for their future dream house. The video later highlights the process of construction and in sequence it is emphasising the value of ‘Perfect Shuruaat’ through the eyes of a cement bag.

Tarun Singh Chauhan, management advisor and brand consultant, Wonder Cement, said, "Our objective with this campaign was to show that the cement produced at the Wonder Cement plant speaks for itself, its quality, trust and most of all perfection. The only way this was possible was to take the perspective of a cement bag and showing its journey of perfection from beginning till the end."

According to the company, the campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV. No other brand in this category has created content specific to the platform.

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In spite of company’s optimism, demand weakness in cement is seen in the 4% y-o-y drop in sales volume. (Reuters)

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Cost cuts and better realizations save? the ?day ?for ?UltraTech Cement, Updated: 27 Jan 2020, Vatsala Kamat from Live Mint

Lower cost of energy and logistics helped Ebitda per tonne rise by about 29% in Q3
Premiumization of acquired brands, synergistic?operations hold promise for future profit growth Topics

UltraTech Cement
India’s largest cement producer UltraTech Cement Ltd turned out a bittersweet show in the December quarter. A sharp drop in fuel costs and higher realizations helped drive profit growth. But the inherent demand weakness was evident in the sales volumes drop during the quarter.

Better realizations during the December quarter, in spite of the 4% year-on-year volume decline, minimized the pain. Net stand-alone revenue fell by 2.6% to ?9,981.8 crore.

But as pointed out earlier, lower costs on most fronts helped profitability. The chart alongside shows the sharp drop in energy costs led by lower petcoke prices, lower fuel consumption and higher use of green power. Logistics costs, too, fell due to lower railway freight charges and synergies from the acquired assets. These savings helped offset the increase in raw material costs.

The upshot: Q3 Ebitda (earnings before interest, tax, depreciation and amortization) of about ?990 per tonne was 29% higher from a year ago. The jump in profit on a per tonne basis was more or less along expected lines, given the increase in realizations. "Besides, the reduction in net debt by about ?2,000 crore is a key positive," said Binod Modi, analyst at Reliance Securities Ltd.

Graphic by Santosh Sharma/Mint
What also impressed analysts is the nimble-footed integration of the recently merged cement assets of Nathdwara and Century, which was a concern on the Street.

Kunal Shah, analyst (institutional equities) at Yes Securities (India) Ltd, said: "The company has proved its ability of asset integration. Century’s cement assets were ramped up to 79% capacity utilization in December, even as they operated Nathdwara generating an Ebitda of ?1,500 per tonne."

Looks like the demand weakness mirrored in weak sales during the quarter was masked by the deft integration and synergies derived from these acquired assets. This drove UltraTech’s stock up by 2.6% to ?4,643 after the Q3 results were declared on Friday.

Brand transition from Century to UltraTech, which is 55% complete, is likely to touch 80% by September 2020. A report by Jefferies India Pvt. Ltd highlights that the Ebitda per tonne for premium brands is about ?5-10 higher per bag than the average (A cement bag weighs 50kg). Of course, with competition increasing in the arena, it remains to be seen how brand premiumization in the cement industry will pan out. UltraTech Cement scores well among peers here.

However, there are road bumps ahead for the cement sector and for UltraTech. Falling gross domestic product growth, fiscal slippages and lower budgetary allocation to infrastructure sector are making industry houses jittery on growth. Although UltraTech’s management is confident that cement demand is looking up, sustainability and pricing power remains a worry for the near term.

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