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Sustainability is emerging as a major motivator for cement manufacturers

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– Manu Karan, Vice President, CleanMax

Will you please introduce your company to our readers?
CleanMax is the sustainability partner of choice for leading corporates and institutions in Asia. Our cumulative operating solar power capacity is over 575+MW across rooftop projects and opens access solar farms across India. We will be expanding our solar farms across multiple States in India by mid – 2020. We aim to achieve a cumulative installed capacity of over 2 GW by 2022 across geographies.

CleanMax has over 200 employees spread across projects, business development, finance and operations to cover all spectrum of the business. Head quartered out of Mumbai, we have seven offices across India, UAE and Thailand. Currently, in UAE, we have a project portfolio of over 25 MW and expanding our footprint in Thailand rapidly. Our track record with India’s top companies has made CleanMax a preferred partner for commercial and Industrial (C&I) across sectors, namely cement, manufacturing, food and beverages, automotive, pharmaceuticals, information technology, Education amongst others.

What has been the response in general from the cement industry to renewable power?
India is the second largest cement producer in the world and the demand for cement is further only expected to grow by multitudes due to demand in key sectors such as construction, infrastructure, real estate, etc.

The Indian cement industry is recognised globally as one of the most energy efficient in the world, with relatively large production units and the use of low-carbon, cost-effective technologies. The sector will still need to make significant efforts to achieve its carbon footprint reduction objectives. India’s cement industry has demonstrated its willingness to invest and reduce CO2 emissions and achieve a low-carbon future. The renowned cement company, ACC is one of our esteemed clients drawing per annum approximately 15 million solar electricity units from our solar farms and is reducing their carbon print significantly by abating around 14,400 tonnes of CO2 annually which is equivalent to planting 2,16,007 trees or getting 2,774 cars off the road.

How does the solar farm business operate?
Solar farms are large scale installations where photovoltaic panels, referred to as solar panels are used to harvest the power of the sun. The Solar farm business is operated in open access models, where the generated power from an offsite location is wheeled into the Cement producer’s facility by paying small charges to the grid operator Most corporates are making a stronger push towards going green, also sourcing solar power is the best way for them to reduce their carbon footprint. Environmentally conscious corporates are also adopting sustainable practices to fulfill their RE100 obligations. These companies are buying solar electricity through private solar farms to hedge their energy costs at the current prices for future use which is potentially 20 to 25 years. Including the servicing and maintenance costs of the plant over the years, the costs are negligible as compared to buying power from the grid. Most importantly, using solar power also demonstrates the sustainability commitment of the company.

Wheeling power from an "offsite" solar farm through the grid allows consumers to move the majority of their power requirement to renewables. The modalities vary from state to state, as regulations differ. But in nearly all large industrial states, CleanMax is now offering these solutions from a solar farm project within the state. In most cases, this requires a "group captive" legal structure, with some shareholding from the consumer. But there is now clarity on how regulations will treat these projects, and it is a great option for consumers to move the majority of their power consumption over to renewable energy.

While building a solar farm points to be kept in mind:
As a developer of solar farms, India is blessed with abundant sunlight which makes it ideal to adoption of Solar. Clear land without any shadows is of paramount importance. Demand from the local consumers, industries and easy grid connectivity are key factors which will determine the size of the farm, the equipment and the investments required.

Depending on the State where the farm is planned, the solar policy of the State, incentives if any, transmission and infrastructure charges throughout the life cycle; are factors to be considered during the planning stages. Accessible roads and/or the need to be constructed as part of the project will impact the costs of the farm. The financing of the project needs to be secured which could be equity or debt and this could vary from client to client depending on their respective requirements.

Adhering to safety standard and following security protocols are pertinent too. The project technicians should conform to all safety precautions at all times while installing or maintaining solar power plants. CleanMax prioritises the safety of people as well as the system; hence we carry out a Job Safety Analysis (JSA) before every project. This is important to pinpoint potential safety hazards and address them accordingly. As the solar power plant installations are at ground level, there is a possibility of accidental human contact; hence the area needs to be well isolated. Also, adequate and appropriate safety gear and processes adhered to is of crucial importance during maintenance activities.

Can you elaborate on remote monitoring and operation & maintenance? What kind of IT infrastructure you have deployed?
Operation and maintenance (O&M) is one of the most critical ways to ensure that the solar farm operates most optimally throughout its life-cycle. At CleanMax, we work to maintain the solar farm infrastructure and equipment, with the goal of improving the equipment’s life by preventing excess depreciation and impairment.

The O&M of solar farm requires periodic checks for ensuring optimal performance and security. All our solar farms are connected via SCADA (Supervisory Control and Data Acquisition Systems) and this is monitored at our central location across various parameters that measure the performance within a defined parameter. Any anomaly triggers an alarm that is relayed to ground staff to ensure a physical verification to prevent damage and rectify any errors as the case might be.

What are the main drivers for the cement industry to adopt solar energy? Some typical examples you would like to quote from the cement industry.
Sustainability is emerging as a major motivator for cement manufacturers. More and more corporates in India and around the world are making public pledges to source their power from renewable sources, such as through RE100. Equally important, they are making concrete plans to achieve these goals. Amongst the many options available, zero-investment renewable energy is a straightforward way for manufacturers to make meaningful progress towards sustainability goals in a single action method and without disruption to their operations.

For most companies, cost reduction is the most important factor to adopt solar power as the cement industry is a high guzzler of power. Across India, solar power provides electricity tariffs that are 30 to 50 per cent lower than the prevailing grid electricity tariffs for a rooftop or onsite solar farms. Solar farms can also provide large volumes of renewable power through the grid, in an open access or group captive basis, in most large states in India, also at a discount to grid electricity tariffs. All of this is possible with much any investment from the consumers’ end, which is a very attractive proposition.

Secondly, CleanMax’s innovative OPEX Model allows companies with healthy credit ratings to buy solar power without any capital expenditure and in a hassle-free manner. Thus, making it the most logical and reliable option of energy.

How can CleanMax help manufacturing units to reduce dependence on the grid without any investment?
At CleanMax, our mission has always been to help corporates achieve their sustainability targets while also saving cost. We offer manufacturers a way to reduce their power costs by 30 to 50 per cent (depending on the state), with zero or minimal investment through solar solutions.

We also take seriously the need to help clients get to their 100 per cent renewable goals. Rooftop solar plants are possible anywhere in India and are very cost effective, but they typically meet less than 15 to 20 per cent of a factory’s power consumption, and often much less. To source the majority of their consumption from renewables, consumers need to get power from solar farms through the grid, via open access or group captive power procurement models.

To service this need, CleanMax has expanded its large-scale offerings to almost all major states – if a manufacturer has factories in different states in India, chances are we can provide grid-connected renewable energy in most of those. The only states where we don’t provide open access power are those which don’t permit it at all. We are successfully providing approximately 17 million units of solar electricity annually to leading cement companies across different locations in India through our open access solar farms and rooftop solar projects, which means abating around 15,840 tonne CO2 per annum, equivalent to planting 2,37,608 trees or taking off 3,051 vehicles off the road.

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Concrete

India donates 225t of cement for Myanmar earthquake relief

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On 23 May 2025, the Indian Navy ship UMS Myitkyina arrived at Thilawa (MITT) port carrying 225 tonnes of cement provided by the Indian government to aid post-earthquake rebuilding efforts in Myanmar. As reported by the Global Light of Myanmar, a formal handover of 4500 50kg cement bags took place that afternoon. The Yangon Region authorities managed the loading of the cement onto trucks for distribution to the earthquake-affected zones.

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Concrete

Reclamation of Used Oil for a Greener Future

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In this insightful article, KB Mathur, Founder and Director, Global Technical Services, explores how reclaiming used lubricants through advanced filtration and on-site testing can drive cost savings, enhance productivity, and support a greener industrial future. Read on to discover how oil regeneration is revolutionising sustainability in cement and core industries.

The core principle of the circular economy is to redefine the life cycle of materials and products. Unlike traditional linear models where waste from industrial production is dumped/discarded into the environment causing immense harm to the environment;the circular model seeks to keep materials literally in continuous circulation. This is achievedthrough processes cycle of reduction, regeneration, validating (testing) and reuse. Product once
validated as fit, this model ensures that products and materials are reintroduced into the production system, minimising waste. The result? Cleaner and greener manufacturing that fosters a more sustainable planet for future generations.

The current landscape of lubricants
Modern lubricants, typically derived from refined hydrocarbons, made from highly refined petroleum base stocks from crude oil. These play a critical role in maintaining the performance of machinery by reducing friction, enabling smooth operation, preventing damage and wear. However, most of these lubricants; derived from finite petroleum resources pose an environmental challenge once used and disposed of. As industries become increasingly conscious of their environmental impact, the paramount importance or focus is shifting towards reducing the carbon footprint and maximising the lifespan of lubricants; not just for environmental reasons but also to optimise operational costs.
During operations, lubricants often lose their efficacy and performance due to contamination and depletion of additives. When these oils reach their rejection limits (as they will now offer poor or bad lubrication) determined through laboratory testing, they are typically discarded contributing to environmental contamination and pollution.
But here lies an opportunity: Used lubricants can be regenerated and recharged, restoring them to their original performance level. This not only mitigates environmental pollution but also supports a circular economy by reducing waste and conserving resources.

Circular economy in lubricants
In the world of industrial machinery, lubricating oils while essential; are often misunderstood in terms of their life cycle. When oils are used in machinery, they don’t simply ‘DIE’. Instead, they become contaminated with moisture (water) and solid contaminants like dust, dirt, and wear debris. These contaminants degrade the oil’s effectiveness but do not render it completely unusable. Used lubricants can be regenerated via advanced filtration processes/systems and recharged with the use of performance enhancing additives hence restoring them. These oils are brought back to ‘As-New’ levels. This new fresher lubricating oil is formulated to carry out its specific job providing heightened lubrication and reliable performance of the assets with a view of improved machine condition. Hence, contributing to not just cost savings but leading to magnified productivity, and diminished environmental stress.

Save oil, save environment
At Global Technical Services (GTS), we specialise in the regeneration of hydraulic oils and gear oils used in plant operations. While we don’t recommend the regeneration of engine oils due to the complexity of contaminants and additives, our process ensures the continued utility of oils in other applications, offering both cost-saving and environmental benefits.

Regeneration process
Our regeneration plant employs state-of-the-art advanced contamination removal systems including fine and depth filters designed to remove dirt, wear particles, sludge, varnish, and water. Once contaminants are removed, the oil undergoes comprehensive testing to assess its physico-chemical properties and contamination levels. The test results indicate the status of the regenerated oil as compared to the fresh oil.
Depending upon the status the oil is further supplemented with high performance additives to bring it back to the desired specifications, under the guidance of an experienced lubrication technologist.
Contamination Removal ? Testing ? Additive Addition
(to be determined after testing in oil test laboratory)

The steps involved in this process are as follows:
1. Contamination removal: Using advanced filtration techniques to remove contaminants.
2. Testing: Assessing the oil’s properties to determine if it meets the required performance standards.
3. Additive addition: Based on testing results, performance-enhancing additives are added to restore the oil’s original characteristics.

On-site oil testing laboratories
The used oil from the machine passes through 5th generation fine filtration to be reclaimed as ‘New Oil’ and fit to use as per stringent industry standards.
To effectively implement circular economy principles in oil reclamation from used oil, establishing an on-site oil testing laboratory is crucial at any large plants or sites. Scientific testing methods ensure that regenerated oil meets the specifications required for optimal machine performance, making it suitable for reuse as ‘New Oil’ (within specified tolerances). Hence, it can be reused safely by reintroducing it in the machines.
The key parameters to be tested for regenerated hydraulic, gear and transmission oils (except Engine oils) include both physical and chemical characteristics of the lubricant:

  • Kinematic Viscosity
  • Flash Point
  • Total Acid Number
  • Moisture / Water Content
  • Oil Cleanliness
  • Elemental Analysis (Particulates, Additives and Contaminants)
  • Insoluble

The presence of an on-site laboratory is essential for making quick decisions; ensuring that test reports are available within 36 to 48 hours and this prevents potential mechanical issues/ failures from arising due to poor lubrication. This symbiotic and cyclic process helps not only reduce waste and conserve oil, but also contributes in achieving cost savings and playing a big role in green economy.

Conclusion
The future of industrial operations depends on sustainability, and reclaiming used lubricating oils plays a critical role in this transformation. Through 5th Generation Filtration processes, lubricants can be regenerated and restored to their original levels, contributing to both environmental preservation and economic efficiency.
What would happen if we didn’t recycle our lubricants? Let’s review the quadruple impacts as mentioned below:
1. Oil Conservation and Environmental Impact: Used lubricating oils after usage are normally burnt or sold to a vendor which can be misused leading to pollution. Regenerating oils rather than discarding prevents unnecessary waste and reduces the environmental footprint of the industry. It helps save invaluable resources, aligning with the principles of sustainability and the circular economy. All lubricating oils (except engine oils) can be regenerated and brought to the level of ‘As New Oils’.
2. Cost Reduction Impact: By extending the life of lubricants, industries can significantly cut down on operating costs associated with frequent oil changes, leading to considerable savings over time. Lubricating oils are expensive and saving of lubricants by the process of regeneration will overall be a game changer and highly economical to the core industries.
3. Timely Decisions Impact: Having an oil testing laboratory at site is of prime importance for getting test reports within 36 to 48 hours enabling quick decisions in critical matters that may
lead to complete shutdown of the invaluable asset/equipment.
4. Green Economy Impact: Oil Regeneration is a fundamental part of the green economy. Supporting industries in their efforts to reduce waste, conserve resources, and minimise pollution is ‘The Need of Our Times’.

About the author:
KB Mathur, Founder & Director, Global Technical Services, is a seasoned mechanical engineer with 56 years of experience in India’s oil industry and industrial reliability. He pioneered ‘Total Lubrication Management’ and has been serving the mining and cement sectors since 1999.

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Concrete

Charting the Green Path

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The Indian cement industry has reached a critical juncture in its sustainability journey. In a landmark move, the Ministry of Environment, Forest and Climate Change has, for the first time, announced greenhouse gas (GHG) emission intensity reduction targets for 282 entities, including 186 cement plants, under the Carbon Credit Trading Scheme, 2023. These targets, to be enforced starting FY2025-26, are aligned with India’s overarching ambition of achieving net zero emissions by 2070.
Cement manufacturing is intrinsically carbon-intensive, contributing to around 7 per cent of global GHG emissions, or approximately 3.8 billion tonnes annually. In India, the sector is responsible for 6 per cent of total emissions, underscoring its critical role in national climate mitigation strategies. This regulatory push, though long overdue, marks a significant shift towards accountability and structured decarbonisation.
However, the path to a greener cement sector is fraught with challenges—economic viability, regulatory ambiguity, and technical limitations continue to hinder the widespread adoption of sustainable alternatives. A major gap lies in the lack of a clear, India-specific definition for ‘green cement’, which is essential to establish standards and drive industry-wide transformation.
Despite these hurdles, the industry holds immense potential to emerge as a climate champion. Studies estimate that through targeted decarbonisation strategies—ranging from clinker substitution and alternative fuels to carbon capture and innovative product development—the sector could reduce emissions by 400 to 500 million metric tonnes by 2030.
Collaborations between key stakeholders and industry-wide awareness initiatives (such as Earth Day) are already fostering momentum. The responsibility now lies with producers, regulators and technology providers to fast-track innovation and investment.
The time to act is now. A sustainable cement industry is not only possible—it is imperative.

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