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We can expect reduction in overall use of fuels like petcoke

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What is the general break-up of composition of fuel use in the Indian cement manufacturing process – particularly of coal, petcoke and AFR?
Between coal and petcoke, the two together account for an average 85-90 per cent of the total fuel requirement of the cement industry. Petcoke, which is also a feedstock, has a larger overall share and coal as a key fuel for power plants accounts for the remaining fuel consumption.

Renewable energy, power from waste and other non-conventional power sources account for almost 10 per cent of the fuel and power requirement of the industry.

What are the specific used of different fuels in your cement manufacturing process?
Which is the best source of energy considering the economics and cost of electricity? Petcoke is a key raw material for producing clinker (clinker is primary raw material for manufacturing cement). Clinker production accounts for majority fuel consumption in a cement industry. Petcoke is preferred due to its high carbon content, with higher calorific value (over approximately 7,500 Kcal/kg), which makes it a much more economical fuel for the cement manufacturers and they also blend it with coal to improve energy production.

The major downside is sulphur content in low quality petcoke (approximately 8-25 per cent), which is highly-polluting and also causes formation of a layer of sulphur, which leads to higher maintenance/downtime of cement plants. Petcoke becomes a key raw material with a fewer substitutes especially for clinker production. Thus petcoke is proving to be economical for the industry, followed by coal is the preferred source of fuel for power plants.

Coal on the other hand is used as fuel for power plants by the captive power producers in the cement industry. But in case of power, renewable energy offers a much better alternative in terms of no-emission and low cost of maintenance and operations.

What are the precautions cement manufacturers have to take while adopting a particular fuel and what are the constraints (including cost fluctuations) you have faced while using them?
In terms of precautions, there are two considerations manufacturers need to keep in mind. One is the environmental consideration wherein regulatory or judicial interventions could be very disruptive, like petcoke ban implemented in the past which had a major impact on large number of players in the sector. Fuels like coal and petcoke have this major drawback wherein restrictions especially judicial interventions pose a major challenge for the sector. The industry has to work towards finding alternatives or substitute some of these fuels used for manufacturing as well as improve the overall efficiency in usage and minimize wastage.

The other key challenge is prices of commodity and currency movements. Cement is more of a commodity and thus, passing on costs, especially in competitive market conditions is quite difficult. We have already seen, how prices of crude and coal globally has impacted the margins of the industry in FY19. Additionally, it is the availability of these fuels as in case of domestic coal and their transportation costs or availability of rakes too impacts its users.

These are broad areas where the industry has to be continuously cautious as well as proactive especially when adopting a particular fuel.

Are there any supply constraints witnessed in any of these fuels? What are the supply-chain constraints of these fuels?
The supply chain revolves around availability of rakes for the sector. As the priority of cement industry is less than power plants, availability of railways rakes becomes a key issue, especially for supplying domestic or imported coal to manufacturers. In terms of road transport, the lead time has reduced part of which could be also attributed to GST, which has eased movement of coal and other fuel like petcoke even between states.

What are the environmental concerns these fuels pose and what are the technologies that could help reduce their environmental impact? What are the alternative fuels that are available to these manufacturers?
The impact of using fuel like petcoke and coal is quite evident as they emit greenhouse gases and other highly polluting gases containing sulphur (SO2) into the atmosphere. The sector contributes considerably towards carbon emission among manufacturing industries (approximately 3-4 per cent globally). Since emission are highly regulated, there are enough measures and safeguards already implemented by cement manufacturers in the industry, but there is always scope to improve by following the highest global standards like in some European nations.

Additionally, waste disposal is a major challenge, especially disposing coal ash and other hazardous residues. Re-use and recycling waste addresses these problems to an extent, "Co-processing" or the process of using waste from the industry as a substitute for and recovering energy is a the most sustainable way of addressing the issue of disposal of waste. The benefit of co-processing is that it addresses the issue of disposing off both hazardous as well as non-hazardous waste. Other existing methods are incineration, landfills, recovery, etc.

What is the kind of fuel mix do you see for the industry, say by 2025?
The share of renewable and other non-conventional energy sources is expected to increase to at least 25 per cent over the next five years. With adequate renewable energy capacity addition already taking place, they provide a suitable and much-needed alternative for the industry at very competitive prices.

We can also expect reduction in overall use of fuels especially petcoke. Natural gas could also become a viable substitute for coal being used currently by 2025.

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Economy & Market

Power Build’s Core Gear Series

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A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

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Economy & Market

Conveyor belts are a vital link in the supply chain

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Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.

In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.

Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.

How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.

How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.

What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.

How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.

What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.

How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.

What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.

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Economy & Market

Impactful Branding

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Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.

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