Economy & Market

Revival of small scale cement manufacturing

Published

8 years ago

January 7, 2019

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The availability of most of the AFR is limited or scattered which may not be economically viable for use in most of the large cement plants because of logistics, quantity, preparation and technical issues, says Dr KN Bhattacharjee.

The availability of most of the AFR is limited or scattered, which may not be economically viable for use in most of the large cement plants because of logistics, quantity, preparation and technical issues. This is a great roadblock for the effective use of AFR. However if an industry can find means to utilise its own by-product or waste in its own premises or nearby then it will be a win- win situation for all. Cement manufacturing process is a very appropriate process to recycle many industrial and agricultural wastes. The black meal process of vertical shaft kiln technology is a proven technology in China and India and can serve as a very good outlet for consuming AFR in the vicinity of industries generating the waste in small quantities.

This will also help in reducing environmental pollution. The author has carried out numerous plant scale trials with various industrial and agricultural wastes in VSK plants in India with reasonable success and feels that it may be worthwhile to go backward technology-wise to improve India’s usage of AFR. With the recognition of performance-based cements in most of the standards of world, composite cements are to gain ground and many alternate materials mainly industrial wastes can find profitable use again in small-sized cement plants.

The vertical shaft kiln (VSK) technology is an old technology of Portland Cement manufacture and even the modern versions have almost phased out from India mainly because of economics of scale and taxation issues. In China, still 30 per cent of its cement production comes from shaft kiln plants. The VSK process technology is still a workable proposition for use of wastes available in limited quantities. Also by virtue of the simple process a plethora of process issues associated with modern pre-heater, pre-calciner rotary kiln system are eradicated while using AFR. Plant scale trials with many wastes have shown improvement in VSK clinker quality and better productivity from the kilns. Also it is possible to add many wastes in small quantities directly to VSK clinker to produce high performing composite cements. Although the plan sounds to be reverse engineering but sometimes an old concept can regain its past glory due to changing national needs and environmental issues.

The modern vertical shaft kiln technology is technically sound and institutes like National Council of Cement and Building Materials (NCCBM) and the then Regional Research Laboratory (RRL), Jorhat had done a commendable work in modernising the technology in India. Also the village-based Saboo technology created a stir in India in the 80s when they brought cement manufacturing under the umbrella of small scale industry. During that period, the objective was to increase production as India was cement deficit and VSK technology was a partial answer to quickly bridge the gap between demand and supply. In the hilly terrain of North East, it is still a viable proposition to use scattered small limestone deposits in the midst of logistical challenges.

The advantages and disadvantages of black meal process of vertical shaft kiln technology:

Advantages:

Small scale cement production and still suitable in hilly terrains having limestone deposits for local distribution of cement.
Energy efficient process: Specific heat consumption is in the range 600 to 650 Kcal/kg of clinker. Specific power consumption is in the range 0f 60 to 70 Kwh/tonne OPC although authentic figures are not available. Since drying, pre-heating, calcining, burning and cooling are integrated in the same vessel, heat losses due to convection and radiation is much reduced.
Porous VSK clinker is much easier to grind thus cement grinding power requirement is less.
Very low refractory consumption as kiln is stationery and low abrasion as material flow is vertically downward with slow speed.
Vast scope of using AFR available in smaller quantities is the major advantage. Some alternate waste materials can act as flux or mineraliser. Mineralising ions can increase the rate of reaction in burning zone leading to complete burning in burning zone.
Thus the technology offers avenue not only in the use of wastes but also utilise the waste in improving burnability by stabilising phases at lower temperatures.
recirculation of obnoxious gases and materials which ensures smooth operation and higher productivity.
Due a constant bed of wet green nodules above the calcining zone the green nodules bed acts as an effective filter to arrest all dust particles. No additional gas cleaning device is required.
Since fuel is inter-ground with raw materials elaborate arrangement of fuel preparation and firing is eliminated
Very effective and controlled flow of material through flat grate using variable frequency drive (VFD). This helps to position the burning zone constantly at the same level.
Relatively simple machines to operate and maintain.
Gestation period of starting a new plant is very low.
No highly skilled manpower is required and local folk/plant staff can be easily trained for operations.
Possible to manufacture a variety of clinkers and thereafter produce various kinds of low cost Portland cements.
Very little chance of cold air in-leakages. Diversion of combustion air during clinker discharge has been ably dealt by either triple air locking arrangement or material block tube in the modern VSKs.
Since each nodule has its independent fuel system significantly higher temperatures are not achieved leading to no issues of NOx.

Disadvantages:

Viability can be at stake due to taxation policies and lower scale of operation. However if Government gives tax rebates on use of AFR the plants can be viable. Also it is possible to reduce cost of production by using low cost or free of cost non- conventional materials and waste fuels available locally. Maybe the savings can be shared with customers.
Quality issues: Many believe that VSK clinker cannot be at par with modern rotary plant clinker. In this respect a few conflicting issues are prevalent. It is true that using the same raw materials and fuel the modern rotary clinker will be better performing especially the later age compressive strengths and soundness of cements produced. However the soft burnt nature of the VSK clinker opens up possibilities of addressing customer requirements of good early age compressive strength and early setting in the case of PPC and PSC. The author has found that early age compressive strengths and setting can be matched with modern plants while making PPC with a maximum of 30 per cent fly ash absorption. The Black meal process is capable of producing sound clinkers with less than 1.5 per cent free lime and 45 per cent C3S component. The author’s experience in few VSK plants in Jodhpur-Rajasthan region supports this viewpoint. Experiences with various limestone in Northern India and Bhutan reveals that the technology cannot tolerate high magnesia limestone primarily due to the absence of rapid cooling arrangement but adding certain industrial wastes with mineralising minor constituents gives amazing results in reducing or mitigating this deleterious effect.
Consistency of clinker: Consistency does get affected if the raw mix is not well homogenised and nodulisation is not controlled. However these can be easily solved by using good homogenisation and blending techniques. Nodulisation can be automated to yield nodules of good strength. In some cases nodule strength can be improved by double nodulisation. Various industrial wastes like bagasse from sugar industry have been found to improve nodule strength together with bonus addition of heat value. Waste oils can be added at this stage to give very good results.
Heat difference between the central and peripheral charge especially in the large dia kilns of 100 TPD per day can be a matter of concern in some cases depending of raw materials and fuels used. The 50 tonne/day Saboo shaft kiln design was found to very efficient in this respect. Crust formations were found to be minimal. Dustry clinker due to beta to gamma conversion of C2S is prevalent in few cases but can be eliminated by stabilisation of phases even with the inherent disadvantage of rapid or quench cooling.

Plant scale trials using various alternate materials and fuels:

Use of pond ash, bottom ash and boiler fired rice husk ash in a 50 TPD VSK plant in Kanpur Dehat, Uttar Pradesh: Both bottom and pond ash were procured from Panki Thermal power plant and were used as components of raw mix separately as a source of Silica and Alumina by partial replacement of plastic clay by 15 to 20 per cent. There was drop in free lime from 2.2 per cent to 1.8 per cent and the dust content in clinker reduced drastically. There was increase of 1.5 to 2.0 MPa in 3 days and 3 MPa in 28days compressive strength of 43 grade OPC. The pond and bottom ash had substantial carbon particles (LOI- 15 to 20 per cent) which added some heat value and perhaps the reactivity of the raw mix increased by the presence of some amount of reactive alumino-silicates. Indirect effects noticed was smooth kiln operations with a slight increase of production from the 50 TPD VSK. Pond ash which is generally wet can be added directly during nodulisation if a dosing arrangement is designed to avoid the drying operation. Boiler fired Rice Husk was tried in the same plant which gave very good results in improving clinker quality. The material was black in colour with LOI around 10 per cent indicating unburnt carbon which must have supplemented the heat input. It was possible to add rice husk as it is but plant scale trial was not attempted with the apprehension that the husk fibres may not give a homozenised mix in the existing raw grinding arrangement.
Use of Phosphorus furnace slag, alkali bypass dust and bag house dust from a Calcium Carbide plant: All these materials were tried with a contention to capitalise mineralising effect from the wastes due to some minor constituents or the presence of reactive silica or Alumina. Even granulated blast furnace slag (GBFS) was also tried. Improvements in kiln productivity and quality was noticed of clinker in most of the cases. In VSK operation any measure which goes to ensure completion of the reactions in the short burning zone will definitely go in improving clinker quality and smooth kiln operations. Appropriate raw mix fineness with correct proportioning of waste materials and fuels, homogenisation hold the key to success.
Additions of alternate waste materials with VSK clinker to make composite cements The future of cement making is composite cements. This not will helps to use some industrial or agricultural wastes in the final product but also help to improve performance of cements and reduce the carbon footprint. In many cases it can lead to low cost cements together with better performance.

Significant improvement was observed when 5 per cent bag house dust from a calcium carbide plant was added in a quaternary mix of 60 per cent Granulated Blast Furnace slag (GBFS) and 3 per cent gypsum using VSK clinker. Initial setting time was reduced from 180 minutes to 40 minutes when compared with plain control sample of PSC. There was an improvement of 2 MPa at 3 days and 28 days compressive strength was more or less the same. Quaternary blends using Alkali bypass dust and 60 to 70 per cent GBFS , gypsum and VSK clinker also performed well in terms of faster setting and improvement of early age compressive strength. Similar results were obtained while using brick kiln ash and calcined clay Pozzolana in dosages of 15 to 20 per cent while making PPC mixes using VSK clinker.

Thus VSK clinker can act as a performance enhancer for early setting and early age compressive strength in presence of high dosage GBFS containing PSC cements and fly ash/CCP based Pozzolanic cements. Hydration studies have revealed that the soft burnt VSK clinker releases soft burnt lime at a faster rate in the early ages leading to higher quantity hydration products both with GBFS and Pozzolana.

Conclusion
The author was associated with VSK plants for six years while doing his Ph.D. His doctoral work is mainly associated with hydration studies of composite cements and VSK clinker doped with ions coming from various industrial and agricultural wastes. He feels that the black meal process using modern vertical shaft kiln technology can be a viable proposition to use localised waste materials available in limited quantities. The process simplicity of the Black Meal process opens up immense potential for use of wastes (both agricultural and Industrial) with improved cement performance in many cases. Waste generating plants can have captive VSK plants or sub let this activity to local entrepreneurs. All performance enhancements have been validated by actual hydration studies which is available with the author for anyone who is interested. This has been a part of the author’s doctoral work. The author feels that for India till we incorporate large scale AFR facilities catering to large cement plants the VSK plants can be revived mainly for use of localised AFR as the project cost and gestation period from concept to commissioning is very low.

Acknowledgement
The author is grateful to AKS University administration for allowing to publish this paper.

About the author
Prof (Dr) KN Bhattacharjee has 37 years experience in the global cement industry. He has worked with all process technologies of cement manufacture and has done considerable work on use of AFR in mini-cement plants. His Ph.D thesis is in applied cement chemistry and his findings helped many mini-cement plants in India to improve their profitability during the late 80s. He has publications in reputed international and national journals like Cement and Concrete Research, ZKG International, Silicate Industrials, Transactions of Indian Ceramic Society, etc. After his retirement in 2016 from Dangote-Africa, he is teaching cement technology to B.Tech students in AKS University, Satna. Dr KNB has worked with ACC in India, two plants in Oman, Lafarge Canada and Dangote, Africa.

Economy & Market

The Road Ahead Begins Here

Published

1 day ago

August 11, 2026

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The future of India’s roads took centrestage at RAHSTA Expo 2026, where policymakers, contractors and industry leaders came together under one roof. The event blended thought leadership, technology showcase and industry recognition into a single powerful platform.

India’s roads and highways community gathered in full strength at the Jio World Convention Centre, Mumbai, for the 16th edition of the RAHSTA Expo (Roads and Highways Sustainable Technologies & Advancement). Over two action-packed days, the event brought together policymakers, contractors, consultants, developers, equipment manufacturers, material suppliers, technology providers and investors to deliberate on the future of India’s ,infrastructure while showcasing the latest innovations driving the sector.

The event culminated in the prestigious RAHSTA Awards, where Shri. Ajay Tamta, Union Minister of State for Road Transport & Highways, felicitated organisations and professionals for their outstanding contributions to road construction, engineering, safety, sustainability and technology. With leading contractors, senior government officials, industry veterans and technology providers under one roof, the event reaffirmed RAHSTA’s position as one of India’s most influential platforms for the roads, highways, bridges and tunnels ecosystem.

Organised by FIRST Construction Council in association with ASAPP Info Global Group, RAHSTA has steadily evolved beyond an exhibition into a platform where policy, technology, engineering and business converge to address the opportunities and challenges shaping India’s next generation of transport infrastructure.

Beyond expansion, towards value

The conference opened with a thought-provoking address by Pratap Padode, Founder and Editor-in-Chief, Construction World, who observed that India’s highways sector has reached an important inflection point. Introducing this year’s theme – ‘From Expansion to Value: The Next Phase of India’s Highways’ – he noted that while the country has successfully expanded its road network over the past two decades, the industry’s priorities are now shifting towards building infrastructure that delivers greater lifecycle value, durability, safety and operational efficiency. With funding pressures, asset monetisation and evolving project models changing the sector’s dynamics, he said the focus must now move beyond kilometres constructed to the quality and long-term performance of every asset.

Dr Brijesh Dixit, Managing Director, Maharashtra State Infrastructure Development Corporation (MSIDC), reminded delegates that successful infrastructure delivery is ultimately a collective effort. Emphasising on collaboration between government, industry and engineering professionals, he remarked, “There is no loser in a winning team, and there is no winner in a losing team,” urging stakeholders to work together to deliver projects with quality, financial sustainability and technological excellence.

Delivering the keynote address, Bidur Kant Jha, Director, New Technologies for Highway Development, Ministry of Road Transport & Highways (MoRTH), outlined the Government’s long-term vision for India’s highway network. Highlighting the country’s 6.26 million km roads network, he spoke about the growing adoption of digital planning tools such as BIM and GIS, bridge health monitoring systems and Integrated Smart Transport Corridors under the Vision 2047 roadmap. He emphasised that while India remains open to global innovations, every new technology must be adapted to Indian conditions before large-scale deployment.

Addressing the gathering during the awards ceremony, Tamta underlined the increasing role of specialised equipment and modern construction technologies in executing complex infrastructure projects across diverse terrains. Referring to challenging tunnel projects in Uttarakhand, he noted how advanced machinery has transformed execution capabilities, while also acknowledging the rapid evolution of Indian contractors into globally competitive infrastructure companies. Recognising excellence through industry awards, he said, motivates organisations to continually raise performance standards and embrace innovation.

Meanwhile, Dr Sanjay Mukherjee, IAS, Metropolitan Commissioner, MMRDA, highlighted that infrastructure development must increasingly focus on integrated urban mobility. Reflecting on Mumbai’s engineering journey – from its historic underground utility network to the Coastal Road and other transformative projects – he underlined that future infrastructure planning must seamlessly integrate roads, metro systems and public transport to create efficient, multimodal cities.

Uttar Pradesh takes centrestage

One of the highlights of the second day was Uttar Pradesh’s comprehensive presentation on its infrastructure-led industrial transformation.

Srihari Pratap Shahi, IAS, Additional CEO, Uttar Pradesh Expressways Industrial Development Authority (UPEIDA), demonstrated how the state’s expanding expressway network is evolving into a catalyst for industrial development through integrated manufacturing and logistics clusters. Expressways, he noted, are no longer merely transport corridors but engines of economic competitiveness.

Building on this narrative, Deeksha Jain, IAS, Additional Chief Executive Officer, Uttar Pradesh State Industrial Development Authority (UPSIDA), showcased the state’s rapidly expanding industrial ecosystem supported by extensive expressway connectivity, dedicated freight corridors, airports, industrial townships and investor-friendly policies. She highlighted Uttar Pradesh’s strong manufacturing growth, expanding industrial land bank, plug-and-play infrastructure and increasing use of digital governance to facilitate investments.

Further underlining the significance of the platform, Deepak Kumar, IAS, Infrastructure & Industrial Development Commissioner, Government of Uttar Pradesh, remarked, “RAHSTA provides an excellent platform for states to showcase our infrastructure progress and investment ecosystem. Uttar Pradesh has transformed significantly over the past decade, backed by more than 34 investor-friendly industrial policies, and platforms like RAHSTA help communicate these developments to industry stakeholders from across the country.”

Ideas that shaped the industry conversation

The two-day conference featured seven panel discussions, each examining a critical dimension of India’s evolving roads and highways sector.

The opening discussion on ‘Financing Roads & Highways in a Capital-Constrained Era’ brought together experts from Cube Highways, NIIF, SBI Capital Markets, Centrum Capital and Bandhan Infra Fund, who examined how the financing landscape is changing. Discussions revolved around asset monetisation, InvITs, institutional investments and new funding structures, with panellists agreeing that better project preparation, transparent governance and predictable returns will be crucial for attracting long-term capital into infrastructure.

Attention then shifted to execution realities during the panel on ‘Contractors’ Perspective: Execution Realities, Risks & the Quality Imperative.’ Representatives from GHV Infra Projects, PNC Infratech, NCC and Maccaferri candidly discussed the challenges of delivering projects amid contractual complexities, land acquisition delays, rising costs and tight timelines. While execution pressures remain significant, the discussion reinforced that better collaboration across the project value chain is essential for achieving both speed and quality.

Day 2 opened with a technically rich discussion on ‘Designing Roads for Sustainability, Durability & Climate Resilience’. Experts from CSIR-CRRI, IIT Bombay, IIT Madras, Zydex Group and SRMB Steel explored advanced pavement technologies, recycled materials, climate-resilient designs and scientific construction practices that can significantly improve durability while lowering lifecycle costs. Sustainability, they agreed, must become an integral part of road design rather than an afterthought.

The subsequent session on ‘Bridges & Tunnels: Complex Engineering, Safety & Future Readiness’ highlighted the growing complexity of India’s infrastructure projects. Panellists discussed advances in structural engineering, digital monitoring, risk management and safety practices that are enabling the successful delivery of increasingly ambitious bridge and tunnel projects across the country.

Technology remained a recurring theme during the discussion on ‘Technology as a Risk-Mitigation Tool for Developers & Investors’. Experts explained how AI, BIM, drones, predictive analytics, digital twins and intelligent monitoring systems are helping improve project planning, minimise execution risks, strengthen quality assurance and enhance asset management throughout the infrastructure lifecycle.

The construction equipment panel brought together leading industry experts to examine how technology, sustainability and digitalisation are redefining construction equipment in an era of rising cost pressures. Discussions centred on enhancing productivity, reducing lifecycle costs and preparing the industry for India’s infrastructure ambitions leading up to 2047.

The conference concluded with an engaging CXO Forum on ‘Rebuilding Confidence in India’s Roads & Highways Sector’, where senior industry leaders emphasised that stronger governance, better project preparation, digitalisation, transparent contracting and closer public-private collaboration will be essential to sustain India’s infrastructure growth over the coming decades.

Technology and recognition under one roof

Beyond the conference halls, RAHSTA Expo reflected the technological transformation underway across India’s road infrastructure ecosystem. Leading equipment manufacturers, technology companies and material suppliers showcased advanced construction equipment, intelligent digital platforms, pavement technologies, structural materials and productivity-enhancing solutions designed to improve project efficiency and asset performance. The exhibition created valuable opportunities for contractors, consultants, government agencies and project developers to evaluate new technologies while interacting directly with solution providers.

The event also served as a celebration of excellence through the RAHSTA Awards 2026, which recognised outstanding achievements across road construction, contracting, materials, equipment, technology, safety, sustainability and infrastructure development. Presented by Minister Tamta, the awards honoured organisations that are setting new benchmarks for quality, innovation and execution across India’s roads sector.

RAHSTA Expo 2026 also received extensive support from across the infrastructure ecosystem. Alongside leading corporate sponsors, the event was backed by industry bodies including the Builders Association of India (BAI), Construction Equipment Rental Association (CERA), Consulting Engineers Association of India (CEAI), International Road Federation (IRF), CSIR-CRRI, CILT India, All India Transporters Welfare Association, Hydraulic Trailer Owners Association (HTOA), Gujarat Contractors Association, Bitumen Forum, Fluid Power Society of India, Indian Institute of Material Management, Ministry of Ports, Shipping and Waterways, Gati Shakti Vishwavidyalaya and Mumbai First, reflecting the industry’s collective commitment to advancing India’s road infrastructure.

As the curtains came down on the two-day event, one message resonated throughout the conference: India’s highways story is entering a new chapter. While expansion will continue, the future will increasingly be defined by smarter planning, stronger partnerships, digital transformation, sustainable engineering and long-term value creation. By bringing together the entire infrastructure value chain on a single platform, RAHSTA Expo 2026 once again demonstrated why it has become one of the country’s most influential forums for shaping the future of roads, highways, bridges and tunnels.

Economy & Market

Fornnax Names Lukas Baur as Authorised Service Partner to Bolster EU Operations

Published

3 weeks ago

July 23, 2026

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Strapline: Fornnax Technology has appointed NOBA Maschinenservice’s Lukas Baur as its authorised service partner for the European Union, strengthening its commitment to delivering fast, reliable, and localised after-sales support across the region.

Fornnax Technology, a leading manufacturer of industrial shredding solutions, has announced the appointment of Mr. Lukas Baur of NOBA Maschinenservice as its authorised service partner for the European Union. The partnership, formalised under the authorisation of Fornnax CEO Mr. Jignesh Kundaria, reinforces the company’s commitment to providing dependable, localised service support to its expanding customer base across Europe.

Strengthening Service Through Proven Expertise

With over two decades of experience in servicing, maintaining, and overhauling industrial shredders, Mr. Baur brings extensive technical expertise to the partnership. His capabilities span welding, hardfacing, shaft and knife rebuilding, complex assembly, hydraulics, and complete electrical engineering services, delivered in collaboration with a trusted partner company based in Halle/Saale.

Operating from Worbis, Germany, Mr. Baur is strategically positioned to provide emergency support across the European Union within 24 hours, covering an operational radius of approximately 1,000 kilometres.

Supporting this capability is a well-equipped service infrastructure comprising 12 Mercedes Sprinter service vans, a team of 24 skilled technicians, specialised bearing-change tools, a fully equipped hydraulic workshop, and a 1,000-square-metre facility with a five-ton crane track. Together, these resources position his team to manage the complete spectrum of Fornnax’s European service requirements efficiently and reliably.

Partnership Driven by Industry Insight

Having spent years servicing Eldan, Lindner, and Vecoplan shredders across the European recycling industry, Mr. Baur’s decision to collaborate with Fornnax is rooted in his understanding of market needs and customer expectations. His experience has provided valuable insight into what recycling plant operators require—not only from their machinery but also from the service teams supporting them.

According to Mr. Baur, Fornnax’s reputation for robust machine construction, superior wear protection, and maintenance-friendly design made the partnership a natural fit.

The collaboration comes at a time when Europe’s tyre recycling industry is facing mounting challenges, including rising cost pressures, shrinking margins, delayed investments, and a shortage of skilled labour. Mr. Baur believes these conditions reinforce the need for technically strong service partners capable of delivering rapid, dependable support.

Commenting on the partnership, he said, “Fornnax, with its exceptional price-performance ratio and superior quality, has the potential to become a market leader in Europe. We would like to be their service partner in this journey.”

Comprehensive Support Across the Equipment Lifecycle

As Fornnax’s authorised service partner, Mr. Baur will oversee the complete lifecycle support of the company’s equipment throughout the European Union. His responsibilities will include installation, commissioning, preventive maintenance, emergency repairs, and spare parts support across mechanical, hydraulic, and electrical systems.

Looking ahead, he also plans to develop a centralised spare parts distribution hub for European customers, particularly if Fornnax establishes a warehouse facility in Worbis to facilitate faster deliveries. To further strengthen service coverage, Mr. Baur intends to expand operations by adding two to three additional service teams and vehicles each year, progressively increasing capacity across the continent.

A Shared Commitment to Customer Excellence

Highlighting the strategic importance of the partnership, Mr. Jignesh Kundaria, Director and CEO of Fornnax, said:

“We strongly believe that by continuously improving our service quality and customer satisfaction index, we can build long-term relationships with our customers. Higher customer satisfaction leads to greater trust, which significantly increases repeat orders and ultimately drives sustained growth in our sales revenue.”

This customer-first philosophy underpins Fornnax’s strategy of building a dedicated European service partner network instead of relying solely on remote support. With Mr. Baur joining this network, customers across the European Union will benefit from faster response times, expert technical assistance, and dedicated on-ground support from a partner with extensive experience in high-throughput shredding operations.

Mr. Baur’s appointment also reflects Fornnax’s broader ambition to establish itself as the preferred shredding solutions provider for the European recycling industry, marking another important milestone in the company’s international growth strategy.

Concrete

Nuvoco Vistas launches Limla cement plant, expands Gujarat footprint

Published

1 month ago

July 13, 2026

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Nuvoco Vistas opens a 2 MMTPA grinding unit at Limla, entering Gujarat and advancing its target of 35 MMTPA capacity by FY 2028.

Surat (Gujarat)

Nuvoco Vistas Corporation Ltd, a part of Nirma Group and one of India’s leading building materials company, has inaugurated the Limla Cement Plant in Surat (Gujarat), one of Vadraj Cement Limited’s (VCL) principal manufacturing facilities. The commissioning represents a key milestone in Nuvoco’s acquisition and restoration of VCL, while supporting the company’s expansion across the Western Indian cement market.

Vadraj Cement Limited is a subsidiary of Nuvoco Vistas Corporation Limited and has installed cement capacity of 6 MMTPA across its assets. The Limla inauguration therefore represents the first operational step in the acquired platform’s wider revival, while the Kutch facilities provide clinker supply, mineral security and coastal logistics support for the western business.

Nuvoco completed its acquisition of Vadraj Cement Limited, then under the Corporate Insolvency Resolution Process, after paying a consideration of Rs 1,800 crore in June 2025. VCL’s asset portfolio comprises a clinker unit at Kutch and a grinding unit at Limla in Surat. It also includes high-quality captive limestone reserves and a captive jetty at Kutch, supporting more efficient logistics. Following the takeover, Nuvoco began an extensive programme of restoration, refurbishment and expansion at both locations, leading to the commissioning of the Limla plant.

The Limla Cement Plant is expected to support a phased increase in sales volumes across Gujarat. It will also help Nuvoco supply neighbouring markets in Western Maharashtra and release cement capacity from its northern plants, which can consequently be redirected towards markets in North India. The plant will manufacture a full portfolio comprising Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. It will additionally produce the complete Nuvoco Duraguard range, including the premium Nuvoco Duraguard Microfibre product. The acquisition is also expected to generate operational synergies with Nuvoco’s existing plants at Nimbol and Chittorgarh in Rajasthan, improving logistics optimisation and market reach across important regional markets.

The grinding unit at the Limla Cement Plant was completed ahead of schedule, with 2 MMTPA of capacity now inaugurated to expand Nuvoco’s operating scale and customer reach. After Vadraj Cement’s assets become fully operational, plants in North and West India are expected to account for nearly 40 per cent of Nuvoco’s total cement capacity. This will broaden the company’s manufacturing network, strengthen access to high-growth markets and support its plan to increase consolidated cement capacity to 35 MMTPA by FY 2028, reinforcing its longer-term growth strategy.

Commenting on the development, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said: “The inauguration of the Limla Grinding Unit in Surat is an important milestone in Nuvoco’s growth journey and demonstrates our commitment to disciplined, value-accretive expansion. Gujarat is strategically significant for Nuvoco, with substantial opportunities arising from infrastructure investment, industrial growth, rapid urbanisation and continuing demand from the housing and construction sectors. The facility strengthens our regional footprint, improves operational flexibility and increases our ability to serve customers across northern and western markets with greater reliability and efficiency.”

He added: “Through the Vadraj acquisition, we have refurbished and restarted a strategically important asset, returning it to operations in record time through strong execution and collaboration between teams. The achievement demonstrates our ability to create value from acquired assets, fulfil our commitments and retain the confidence of stakeholders. It also highlights the strength of our project delivery capabilities and our continued focus on building sustainable, profitable growth over the long term.”

Nuvoco Vistas Corporation Limited is a building materials company whose vision is to build a safer, smarter and more sustainable world. It is among the leading players in East India and has a significant presence across North and West India. Nuvoco began operations in 2014 with a greenfield cement plant at Nimbol, Rajasthan. It later acquired Lafarge India Limited, which had entered India in 1999, followed by Emami Cement Limited in 2020 and Vadraj Cement Limited in April 2025. The company has also announced an expansion in eastern India through a new grinding mill at the Arasmeta Cement Plant, supported by several debottlenecking programmes involving equipment upgrades, process improvements and internal capacity initiatives. These developments place Nuvoco on track to achieve total cement capacity of approximately 35 MMTPA. The company reported total income of Rs 11,362 crore in FY 2025-26, reflecting its continuing growth trajectory.

Nuvoco operates a diversified portfolio across three segments: Cement, Ready-Mix Concrete and Modern Building Materials. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem, covering Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. Its pan-India RMX business provides value-added products under Concreto for performance concrete, Artiste for decorative concrete, InstaMix for ready-to-use bagged concrete, X-Con covering M20 to M60 grades, and Ecodure for specialised green concrete. Nuvoco has supplied materials to projects including the Mumbai-Ahmedabad Bullet Train, Birsa Munda Hockey Stadium in Rourkela, Aquatic Gallery at Science City in Ahmedabad, and metro railway projects in Delhi, Jaipur, Noida and Mumbai.