Concrete

The incomplete packaging solution!

Published

7 years ago

January 9, 2019

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As per a study conducted, on an average, a sack would have eight to nine hook marks by the time it reaches the destination. These hook marks further lead to cement losses, thus making the working conditions of the workers from bad to worse, writes Madhvi Lijhara.

Packaging is a very generic term that has been in existence for ages now. Man has used packaging since times unknown for storage, protection, handling and so on. The ways were quite crude but served their purpose well. With the advancement of time and technology, the purpose of packaging also changed, the ways changed, the materials change and it changed the mindsets too.

Today packaging has a much bigger role to play and satisfy much higher expectations of the consumers, marketeers, manufacturers and others in the supply chain. It’s not just about protecting the goods, giving ease of storage, handling, increasing the life of the product, but also serves as a mode of communication between the manufacturer and the consumer, between the marketer and the buyer. It talks about how to use the product, why to buy the product, why to buy that particular brand, price to pay; when was that particular product manufactured and by when to use. It also takes care of the government regulations and ensures on quality and quantity of the product to the user.

Besides the above mentioned attributes of packaging, we all forget a very important aspect of packaging and that is its contribution to "environment sustainability". In India at large the cement is packed in WPP sacks. The woven polypropylene fabric, PP is a kind of thermoplastic resin material that is produced by the polymerisation of propylene. The weave in two directions of the PP threads gives the strength to the fabric, its light weight and strong enough to carry weight of cement which is high density. The pores in the weave have a role to play – while cement filling, these pores help the air to escape from the sack preventing the bursting of the sacks. But at the same time these pores also lead to cement loss at various junctures of the journey from the factory to the point of use.

On an average, from one kg to 500 grams of cement is lost while in transit. At times the loss can be even more depending on the number of hands it exchanges. This cement lost is not just an economic value lost for the user or manufacturer but it actually leads to much more intangible loss, the loss of cement particles into the environment, polluting the the air we breathe in. It’s a surprising fact that the air quality inside the cement plant is much better than the place of storage of the cement or the place of use of the cement, and the major reason is the way cement is packed. Every time the sack is moved from one place to another it leads to cement loss, so much so that the branding, printing or any information printed on eth sack becomes invisible due to a cement dust layer on the sack. Thus the way in which cement is packed destroys all the attributes of packaging.

These pores also give easy way to the moisture in the air to penetrate inside the sack and thus reducing the shelf life of the product. Cement is hygroscopic and attracts water from the atmosphere to set . Thus the purpose of protection and increasing the shelf life is defeated.

The labourers use iron hooks for loading and unloading of cement sacks even though its banned as per the government directives. As per a study conducted, on an average, a sack would have eight to nine hook marks on the sacks. These hook marks further lead to cement losses thus making the working conditions of the workers from bad to worse.

Even worse is the recycling of the cement sack, although PP is recyclable but a major issue is that the cement is all stuck in the pores of the sack and therefore the sacks cannot be recycled easily. The sack needs to be absolutely clean to be recycled. Another issue is with the collection of the empty cement WPP sacks; there is no defined process under which the cement sacks are collected after the use and taken to recycling plant. In most of the cases these sacks land up into "land-fills". The end of the "product life cycle" of a WPP cement sack is very unfriendly to our environment.

It can be concluded that the way cement is packed in India is actually an "incomplete packaging solution". All the aspects of packaging are defeated when cement is packed in WPP. It neither protects the material, neither increases the shelf life, nor does it increase the brand value; in nutshell it serves no purpose of packaging other than holding the material together and giving it a partial ease of handling; a 50 kg bag with dead weight is really tough to handle. The only driving factor for WPP sacks is the price of the sacks. But the irony is that only the "price per sack" is considered and not the "actual cost of packing" is considered. The actual cost should include the wastage in transit, its contribution to air pollution and its impact on the health of the workers. Even though the industry would agree with this but very little efforts have been made to give a sustainable packaging solution for cement. It’s the need of the hour that we look at creating more cement packaging options that justify all the attributes of packaging including the environment sustainability aspect and improved working conditions of the laborers.

ABOUT THE AUTHOR:
Madhvi Lijhara, a paper and packaging specialist, is an economics graduate from Delhi university and a post graduate in Marketing management from Lucknow University. She has worked with paper and allied companies like APP India, Thomson Press, Ballarpur Industries (BILT) and BillerudKorsnas AB. While on the job, she has been closely associated with various cement companies promoting paper sacks for cement packaging in India. She can be contacted on: madhvi@hotmail.com

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

1 week ago

June 5, 2026

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

Concrete

Building a Greener Future Together

Published

1 week ago

June 4, 2026

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

Published

2 weeks ago

June 1, 2026

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.