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Robotic quality control lab from Wonder Cement

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R.K. Marble group had set up ultra modern cement plants in 2012 (line 1), in 2015 (line 2) and recently in July 2019 line 3 has been inaugurated. The combined capacity of the group is to manufacture 9.50 MTPA clinker at Nimbahera, Chittorgarh district in Rajasthan.

Wonder Cement is a cutting-edge cement manufacturing company with an ambition to establish itself as a leading player in the industry. Enriched with the heritage of R.K. Marble, a leading name in the marble industry, our corporate culture is built on the values of quality, trust and transparency. An emphasis on technological superiority enables us to differentiate our offering through impeccable quality and effective communication. With an extensive network of dealers, we endeavour to earn a place in the premium segment of the market.

Our cement producing capacity from Nimbahera, Rajasthan plant is 8 MTPA, from grinding unit at Nardana, Maharashtra is 2 MTPA. After completion of one more grinding unit at Badnawar, Madhya Pradesh by the end of this year, our total cement production capacity will be 12 MTPA.

The plant has been set up with technical collaboration from ThyssenKrupp and Pfeiffer, Germany, who are world leaders in cement technology. The entire design of the plant is based on the latest environment norms, with the help of Reverse Air Bag House and ESP, we are having maximum emission of 30 mgs, which enables the plant to be clean and dust free. We have captive power plant (CPP) of 40 MW capacities to cater the power requirements.

Our limestone mines have superior quality lime stone deposits, possessing cement grade quality that gives high early strength and ultimate long-term strength. Additional characteristic features of lime stone are low alkali, low magnesia and low chloride contents which are highly favourable constituents required for durability of concrete.

Our plants are equipped with advance technology equipment like cross belt analyser having Combi CBA with CNA technology, pre-blending equipment for all the raw materials, robotic technology POLAB for quality control, inline calciner at pre-heater for proper burning, polytrack cooler, closed circuit grinding system with high efficiency separators for maintaining optimum particle size distribution, these all ensures consistency in our product quality parameters and makes us in the best category of cement manufacturers.

We are having extensive network of channel partners in Rajasthan, Madhya Pradesh, Gujarat, Haryana, Delhi, Punjab, Uttar Pradesh, Uttarakhand and Maharashtra to cater to the customer needs effectively. In addition to this, the company has regional offices at New Delhi, Ghaziabad, Gurugram, Jaipur, Ahmedabad, Indore and Nashik to ensure regular support and services to customers.

The most advance technology, which helps us in manufacturing consistent good quality cement, and that makes us different from the entire cement manufacturer is POLAB AMT – Robotic Quality Control Lab.

POLAB configuration consists of a standard industrial robot placed in the centre of a circular arrangement of sample preparation and analytical equipment. Samples normally arrive automatically from the connected automatic sample transport system.

It offers a very high flexibility in terms of the number and types of equipment handled by the robot. Supported, fully automated preparation and analysis disciplines relevant to the cement industry include powder or fused bead preparation for x-ray analysis, particle sizing by laser or by conventional sieving analysis, sulphur/moisture combustion analysis, physical testing and collection of shift/daily composites.

For the typical cement lab project, a through put capacity of 10-20 samples will apply; but higher numbers in one robot cell are achievable (240 samples/day). The POLAB computer integrates the system components. It identifies incoming samples, downloads the relevant sample-handling specification and controls all intelligent devices in the configuration.

Sequence control includes priority handling, intelligent handling of equipment failure situations and much more. POLAB provides high quality in sample preparation and analysis. Quality not only meets the performance of the very competent lab scientist but is highly consistent over time. Thus, there are no fluctuations from shift to shift in analytical levels due to small differences in the practical procedures undertaken by human operators. Sampling is done at different stages like raw mill sample, C.F. Silo sample, kiln feed sample, clinker sample, ground cement sample and dispatch cement sample. Time required for one sample analysis is just 18 minutes.

AMT (Advanced Module Technology) optimally integrates and harmonises all required sample preparation and analysis components and still has an extremely small footprint. The AMT configuration is designed to ensure the highest standard of efficiency and provides impressively high sample throughput rates, easy operation and consistent modularity. The sample reception and preparation units (such as pneumatic tube, fine grinding, tablet pressing and cleaning modules) as well as the analyser units (such as fluorescence spectrometer, diffractometer, laser granulometer and colour difference analyser) are all placed within reach of the robot. The six-joint robot supplies all the analyser units with prepared samples and thus supports simultaneous analyses.

Pneumatic tube module: The samples of all initial, intermediate and finished products that are automatically taken at short intervals from the individual sections of the production process are sent in capsules to the pneumatic tube module. The subsequent volumetric dosing process takes place without contamination and is totally dust-free. The module permits manual loading and removal of pneumatic dispatch capsules, as well as the storage of reserve samples (e.g. for physical investigations).

Optimum process control: The aim of optimum process control is to provide comprehensive knowledge about the material compositions and properties before and during the production process. Based on the Spectrometer analysis, the x raw meal mixtures are optimally calculated and set x alkali cycles inside the kiln system are controlled and x sulphate phases are determined and the cement quality chemically controlled. The particle size fractions determined in the laser granulometer are the basis for controlling the separator speed or for operation of a higher ranking, intelligent mill regulation system, such as POLEXPERT? MCE. Through the application of rietveld software, the latest generation diffractometers generate a complete diffractogram and enable exact identification of all clinker phases in a matter of minutes. This opens totally new perspectives for regulating the material quality, operating the kiln under consideration of substitute fuels and optimising the cement manufacturing process.

Conclusion
Wonder cement is first company in North India that is using POLAB AMT, which eliminates human errors in sample collection, testing and analysing and ensures consistent quality of raw materials, intermediate product (clinker) and final product (cement).

ABOUT THE AUTHOR: Hitesh Mogra, Head – Technical Services, Wonder Cement

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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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