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Friction-free conveyors are the way to go

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Sagta Engineering, a Shanghai, China, based engineering consulting company, is trying to introduce air cushion technology in conveyor systems in India. Frank Wang, General Manager, and U.K. Mullick, Chief Consultant of Sagta, say it is a maintenance free and environment friendly technology.

Material transportation equipment plays an important role cement plants. What are the innovative products you have?
Frank Wang (FW):
Roller and tubular conveyor systems are well known among user. But both of them require a lot of maintenance because of friction they generate. We are in the process of introducing air cushion conveyor in India. Air cushion lifts up the rubber belt, removing friction in air cushion conveyors (ACC). It brings in several advantages – energy saving, environment-friendly and requiring minimal maintenance. We have introduced air cushion technology to Tata Steel, NTPC and MECON, an engineering and consulting company, etc., in India.

What are the key differences between belt and air cushion conveyor systems?
UK Mullick (UKM): In a conventional belt conveyor, where belt is running on rollers, a number of rollers appear along it. Basically the concept of ACC is very much similar to that of conventional belt conveyor, but the difference is there are no rollers in the new technology. Instead of rollers there are certain modules and on the surface of the modules there are a number of small holes through which pressurised air comes and keeps the belt afloat, so that the material loaded onto the conveyor belt moves on the airfill. A very thin airfill is generated due to high pressure air jet that comes from the module.

What are the advantages an air cushion conveyor user can expect?
UKM:
The majority of power consumption of a conveyor is for overcoming the frictional resistance of number of rollers present in the system. If there are no rollers, then there is no friction due to which the power consumption will come down drastically. And this reduction is seen to be in the range of 20-70 per cent, which is really a great phenomenon- we are not only saving money, but also saving costly energy. Secondly, this 20-70 per cent saving depends on the length of the conveyor, longer the more.

FW: The lifespan of rubber belt in a conveyor is very important. Generally, due to friction the rubber belt lasts about three or four years and needs replacement. Sometimes it gets broken. There is a lot of downtime that goes into repairing the belt. Due to friction-free air cushion the lifetime of the rubber tends to be much longer. To our surprise, the rubber belt of our first project is still there even after 15 years, and no replacement needed anytime soon.

Is there any advantage in installation cost?
UKM:
Cost is generally based on length of the conveyor – if it is less than a kilometre, the cost of ACC is slightly more compared to the conventional one. In a long distance conveyor, say 10-20 km, the installation cost is more or less the same. Simple reason is, say for a 15-km conventional conveyor’s power installation needed is 4,200 kW, while for ACC technology the installed capacity required is 2,500 kW. That is a drastic difference due to absence of rollers. So, this is definitely an innovation so far not tried out in India and they are the way to go.

Are there any disadvantages or limitations for ACC when compared conventional conveyor…
UKM:
If you ask me, is it possible to convey big boulders? The answer is simply "no." The maximum weight that can be conveyed by ACC is approximately 50 milli meters (mm). As for angle of inclination, it can take a very good angle of inclination up to 35-40 degrees. But one should be conscious about a thing – it cannot take right or left turn, and it has to be straight. As such this is very good for long distance material handling. For that purpose we have already approached JSW and they are planning to implement long distance conveyor and this technology is under their active consideration, subject to their visiting China and seeing it physically.

So it cannot be implemented in all terrains…
UKM:
If the conveyor route has to pass through hills and mountains and have to take several twists and turns, you may need to install different types of conveyors ? conventional conveyor for a portion of it, pipe conveyors where twists and turns are there, and ACC where the route is straight. Since Sagta Engineering is capable of supplying any kind of conveyors or a combination of all the three, it can offer the best solution to any terrain.

In India, the government follows L1 (least capital cost) method for choosing suppliers, though the trend is changing of late. How do you propose to pitch your product to them?
UKM:
If you want to adopt any innovative technology, at that point of time one cannot compare the initial investment cost. If it can pay back the additional cost incurred in about three years, that is great.

Any more innovative products in pipeline…
UKM:
Another innovative technology is friction-free coupling. Generally we have fixed coupling that is rigid coupling where bolts and nuts are used. Suppose if there is a little misalignment in drive and driven end, and if it is allowed to run at a very high speed, in no time the bolt or nut will shear and break, bringing the whole process/system to a standstill. Now for power transmission or stop transfers for motors of more than 30 kV we are using fluid coupling for different applications in power, mining, or cement sectors.

FW: But Sagta has come out with a new magnetic coupling which uses permanent magnet on either side – driver shaft side and driven shaft side. Suppose if the blower is installed, and between motor and blower if you put a magnetic coupling, and due to installation problem if there is some small misalignment, since these two items are not touching each other, (as they are held only by magnetic force), this is not going to hamper the driven or driven side operations. These particular couplings are available from 30 kW to 4500 kW. Friction-free coupling is also maintenance free and has a lifetime of 30 years, we can say. This product has been welcomed by the Chinese heavy industry, including steel plants.

Another product that is in the final stages of development is magnetic speed adjusting device used in motors and blowers. These can be used in the cement industry as well. It is also long lasting and maintenance-free.

– BS SRINIVASALU REDDY

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Economy & Market

Fornnax launches world’s biggest secondary/fine shredder for AFR pre-processing

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Fornnax has introduced its latest breakthrough – the R-MAX3300, for handling low-density waste streams, offering a powerful solution for cement AFR plants.

Fornnax Technology has launched its latest breakthrough – the R-MAX3300, the biggest secondary shredder in its class. The unveiling took place on 14th October, 2025 at IFAT India 2025 in Mumbai, one of the most prestigious events for environmental technologies, waste management, and sustainable resource innovation.

The launch ceremony was graced by esteemed industry leaders and dignitaries. The guest list included Md Fahim Sopariwala, CEO, GEPIL India; Sridhar Jagannathan, Vice President, Zigma Global; Priyesh Bhatti, CEO, GEPIL India; Shailendra Singh, Deputy General Manager, Prism Johnson (Cement Division); Ulhas Parlikar, Global Consultant, Waste Management, Circular Economy, Policy Advocacy and Co-processing; Saurabh Palsania, Joint President (Strategic Sourcing), Shree Cement; Rajeev Patel, DGM (Process), Mangalam Cement; and Anumodan Kumar Dubey, Mangalam Cement.

This state-of-the-art equipment represents a significant advancement for India’s recycling and waste processing landscape, offering a powerful solution for cement AFR plants and waste-to-energy facilities.

Building on the proven performance and legacy of the R Series secondary shredder, which has long been trusted for high-density materials like tyres and cables, the newly introduced R-MAX3300 is specifically engineered for handling low-density waste streams. These include Municipal Solid Waste (MSW), Commercial and Industrial (C&I) waste, Bulky waste, Legacy waste, Wood waste, and Construction & Demolition (C&D) waste.

By incorporating advanced shredding technology, the R-MAX3300 enables seamless and highly efficient production of Refuse Derived Fuel (RDF) and Solid Recovered Fuel (SRF) within the ideal particle size range of 30 to 50 mm. Its design prioritises versatility, durability and superior performance, directly supporting industrial operations that demand consistency and scale.

“The R-MAX3300 represents a monumental leap forward in our vision to become a global leader by 2030 in recycling technology through innovation,” said Jignesh Kundaria, Director and CEO, Fornnax Technology. “With the rising challenges of waste management in India and globally, this machine is not just a product; it’s a powerful tool for change. We engineered it to handle the most difficult waste streams with unparalleled efficiency, turning what was once considered unusable waste into a valuable resource. It directly addresses the urgent demand for effective, large-scale shredding technology that can support cement kilns and waste-to-energy facilities in achieving the desired output,” he added.

The launch of the R-MAX3300 arrives at a pivotal moment. India currently generates over 160,000 tons of municipal solid waste daily, while government-led initiatives such as Swachh Bharat Mission and Smart Cities are accelerating the demand for RDF and waste-to-energy solutions. Simultaneously, the global industrial shredder market is expected to grow at a 5–6 per cent CAGR, driven by stricter recycling regulations and increasing waste generation.

Kundaria further emphasised, “Our commitment goes beyond just selling machinery; it’s about empowering our customers to achieve lasting efficiency, sustainability, and growth. We see ourselves as a trusted partner who stands beside them at every step – from technology deployment to ongoing support, ensuring they can rely on Fornnax not only for performance but also for consistency, dependability, and long-term value.”

The R-MAX3300 is equipped to handle high-throughput processing of pre-shredded or coarse materials, making it ideal for SRF/RDF production, composting pre-treatment, and volume reduction for logistics optimisation. It is expected to play a crucial role in Integrated Waste Management Projects (IWMP) and bio-mining operations both within India and globally.

With this grand launch, Fornnax continues to set global benchmark and move decisively towards the vision of becoming global leader in recycling technology by 2030 that is state-of-the-art, innovative, economical, efficient reliable and eco-friendly.

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Concrete

Fornnax wins Top Domestic Sales Award 2024-25 by AIRIA

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Fornnax bags the Excellence in Top Domestic Sales Award 2024–25 by the All India Rubber Industries Association (AIRIA).

The company has been honoured with the Excellence in Top Domestic Sales Award 2024–25 by the All India Rubber Industries Association (AIRIA) under the Rubber Machineries and Equipment category. The award recognises Fornnax’s exceptional market leadership, strong sales performance and continued commitment to sustainable innovation.

With over a decade of specialised expertise, Fornnax has emerged as a transformative force in India’s tyre recycling sector, commanding nearly 90 per cent of the domestic market while steadily expanding across Europe, Australia, the GCC, and other global regions.

Fornnax’s advanced recycling systems—comprising the SR-Series Primary Shredders, R-Series Secondary Shredders, and TR-Series Granulators—are engineered for durability, efficiency, and high-output performance. These technologies are widely deployed in end-of-life tyre (ELT) processing and other waste management applications, reinforcing Fornnax’s reputation as a trusted industry partner.

Expressing his gratitude, Jignesh Kundaria, Director & CEO, Fornnax, said, “We are incredibly proud to receive this recognition from AIRIA. This award validates the trust that our customers and partners have placed in us over the years. I would like to extend my heartfelt gratitude to all our clients and partners who have been an integral part of this journey and our continued success. At Fornnax, our goal has always been to empower the recycling industry with innovative, high-performance solutions that make sustainability both achievable and profitable.”

The award also underscores Fornnax’s pivotal role in promoting circular economy practices by enabling the conversion of end-of-life tyres and rubber waste into reusable raw materials. Through ongoing R&D, new product innovation, and a solutions-driven approach, the company continues to help industries worldwide adopt eco-conscious, scalable recycling models.

As India’s recycling landscape evolves to meet global sustainability benchmarks, Fornnax stands at the forefront with internationally certified technology, a proven track record, and a clear vision for environmentally responsible growth.

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Concrete

Pacific Avenue Completes Acquisition of FLSmidth Cement; Rebrands as Fuller Technologies

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The acquisition of FLSmidth Cement by Pacific Avenue Capital Partners marks a new phase of focused growth and innovation.
Rebranded as Fuller® Technologies, the company will continue delivering world-class solutions with renewed investment and direction.

Pacific Avenue Capital Partners (“Pacific Avenue”), a global private equity firm, has completed its acquisition of FLSmidth Cement following the fulfillment of all customary closing conditions and regulatory approvals. The transaction includes all of FLSmidth Cement’s intellectual property, technology, employees, manufacturing facilities, and global sales and service organizations.

As Fuller Technologies, the company will continue to seamlessly support its customers while advancing its robust portfolio of capital equipment, digital solutions, and service offerings. With a sharpened focus on Pyro and Grinding technologies, alongside core brands such as PFISTER®, Ventomatic®, Pneumatic Conveying, and Automation, Fuller Technologies aims to deliver enhanced value and reliability across the cement and industrial sectors.

Under Pacific Avenue’s ownership, Fuller Technologies will benefit from increased investment in people, products, and innovation. The dedicated management team will work to optimize operations and strengthen customer relationships, ensuring continuity and excellence during this exciting transition.

“We are proud to be the new owner of FLSmidth Cement, now Fuller Technologies, a global leader with a rich history of providing mission-critical equipment and aftermarket solutions in the cement and industrial sectors. We will continue to build upon the Company’s legacy of being at the forefront of technological innovation, service delivery, and product quality as we support our customers’ operations,” says Chris Sznewajs, Managing Partner and Founder of Pacific Avenue Capital Partners.

Pacific Avenue’s deep experience in executing complex industrial carve-outs and guiding standalone businesses into their next growth phase will be instrumental in shaping Fuller Technologies’ future. With a proven track record in building products and capital equipment industries, Pacific Avenue is poised to help Fuller Technologies optimize performance, accelerate growth, and create long-term value for its customers and stakeholders worldwide.

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