Environment

Sustainability is emerging as a major motivator for cement manufacturers

Published

5 years ago

January 5, 2020

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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.

Concrete

Need for Reinvention Amid Recovery

Published

2 days ago

April 21, 2025

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The cement industry in India has just emerged from one of its most challenging years in recent history. FY25 witnessed the steepest year-on-year decline in cement prices in nearly two decades, driven by a combination of sustained capacity additions and subdued demand across key sectors. Even as volumes remained steady in many regions, profitability took a hit, revealing the fragile balance between supply dynamics and pricing power.
Looking ahead to FY26, industry analysts, including India Ratings and Research, predict demand growth in the mid-single digits. This projection is supported by a series of favourable indicators: a likely normal monsoon, continued infrastructure investments, improving real wage growth and momentum in urban housing. Yet, the central question remains—can cement manufacturers regain pricing discipline to restore margins?
The Cement Expo Forum 2025, recently held in Hyderabad, served as a timely platform to examine these issues. Leaders from across the value chain came together to discuss not only the sector’s growth trajectory but also the pressing need for sustainable practices. As India’s cement consumption grows, the environmental responsibilities of the industry grow with it. Cement companies are increasingly expected to meet rising demand while aligning with global decarbonisation goals. Energy efficiency, alternative fuels and clinker factor reduction are no longer optional—they are integral to long-term competitiveness
and compliance.
What emerged from the Forum was clear: the Indian cement industry stands at a pivotal juncture. Pricing strategy, capacity optimisation and green technology adoption must now work in tandem to secure resilient growth.
The Hyderabad Forum was but a preview. The much-anticipated
15th Cement Expo, to be held on November 12–13, 2025, at Yashobhoomi, Delhi, promises to be the definitive industry showcase of the year. As the sector navigates recovery and reinvention, this event will spotlight innovation, policy alignment and investment strategies shaping the future of Indian cement.

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Concrete

We are committed to being a trusted partner

Published

2 days ago

April 21, 2025

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Hitendra Bhargav, CEO, Klüber Lubrication, discusses how advanced synthetic lubricants are driving sustainability in the cement industry by enhancing energy efficiency, extending equipment life and reducing carbon emissions.

The Indian cement industry is making significant strides toward carbon neutrality while striving to enhance operational efficiency. As manufacturers seek high-performance solutions to optimise critical machinery—such as VRMs and gearboxes—extending equipment life and boosting productivity have become paramount. In an exclusive conversation, Hitendra Bhargav, CEO, Klüber Lubrication, shares how the company is driving innovation and sustainability-focused initiatives to help cement manufacturers achieve their net-zero ambitions.

How is Klüber Lubrication India supporting the cement industry’s sustainability goals?
The Indian cement industry is actively working towards carbon neutrality while maintaining operational efficiency. It is adopting various measures such as improving energy efficiency, clinker substitution, waste heat recovery and carbon capture to achieve its sustainability goals—helping India meet its target of reducing carbon emissions by 50 per cent by 2030.
At Klüber Lubrication India, we support this transition by offering high-performance synthetic lubricants that significantly enhance energy efficiency and reduce carbon emissions. A major portion of a cement plant’s energy consumption is related to its rotary equipment and machinery, such as vertical roller mills (VRM), ball mills, coal mills, bucket elevators, cooling towers and screw pumps. Our state-of-the-art gear oils and other lubricants help these machines consume less energy, optimise efficiency and, in turn, support cement plants in complying with regulatory frameworks like the Business Responsibility and Sustainability Reporting (BRSR), moving them closer to their net-zero targets.

Can you elaborate on Klüber Lubrication’s role in helping cement manufacturers achieve net-zero emissions?
Achieving net-zero emissions requires innovative solutions that minimise energy consumption and carbon footprints. Our Klüber Energy Efficiency solutions are specifically designed to support this goal. By switching from conventional mineral oils to our advanced synthetic lubricants, cement plants can achieve an average of three per cent savings in electrical energy consumption, leading to substantial reductions in CO2 emissions.
Our solutions extend equipment life,reduce downtime and improve overall plant efficiency—making sustainability not just an environmental responsibility but also an economically viable choice.
(Note: One unit of power saved is equivalent to approximately 0.6 kg of CO2 reduction when generated by a coal-based thermal power plant.)

What impact do energy-efficient lubricants have on the performance and longevity of machinery?
Energy-efficient lubricants play a crucial role in optimising the performance of cement plant machinery. Our synthetic lubricants reduce friction, minimise wear and tear, and offer superior thermal stability. This leads to lower energy consumption, fewer breakdowns and extended service life for critical equipment such as various types of mills, cooling towers and gearboxes. As a result, cement manufacturers benefit from improved productivity, reduced maintenance costs and enhanced reliability.

Klüber Lubrication India recently achieved the EcoVadis GOLD certification for the fourth consecutive year. What does this recognition mean to you?
Securing the EcoVadis GOLD certification for the fourth consecutive year is a testament to our unwavering commitment to sustainability and responsible business practices. This recognition places us among the top three per cent of companies worldwide. It underscores our dedication to minimising environmental impact, upholding ethical business practices, and promoting sustainable procurement. Our customers can be assured that our solutions are designed not only for superior performance but also for long-term environmental benefits.

What is your message to manufacturers looking to enhance their sustainability journey?
Sustainability is no longer an option; it is a necessity for long-term success. Cement manufacturers who proactively adopt energy-efficient solutions will not only reduce their environmental footprint but also improve operational efficiency and profitability. At Klüber Lubrication India, we are committed to being a trusted partner in this journey, providing cutting-edge lubrication solutions that help the industry transition towards a more sustainable and efficient future.
The cement industry is under immense pressure to improve sustainability while maintaining operational efficiency. At Klüber Lubrication India, we support this transition by offering high-performance synthetic lubricants that significantly enhance energy efficiency and reduce carbon emissions. Our solutions for critical machinery, such as VRM and main gearboxes, help manufacturers optimise their operations, comply with regulatory frameworks like the BRSR and move closer to their net-zero targets.

How do Klüber Lubrication’s energy efficiency projects provide a strong ROI?
One of the biggest concerns in adopting sustainability measures is the associated cost. However, our energy efficiency solutions present a compelling business case. With an investment of less than one crore rupees, cement manufacturers can achieve a payback period of less than a year.
For example, by using Klübersynth GEM 4-320 N, a single VRM gearbox with a sump capacity of 6,000 litres and a 6.5 MW motor rating can save over 1.3 million kWh annually. This translates to an average power saving of three per cent, leading to lower operational costs. Additionally, oil life is extended by three or four times compared to conventional mineral oil, contributing to a CO2 reduction of 715 tonnes. This ensures manufacturers achieve sustainability milestones while maximising profitability.

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Concrete

Decarbonising Cement Transportation

Published

2 days ago

April 21, 2025

admin

The Indian cement industry is embracing green logistics through electric and alternative fuel vehicles, digital innovations and sustainable transport strategies to reduce carbon emissions and improve efficiency. Kanika Mathur looks at the collaborative efforts between industry leaders and government initiatives driving this transformation toward a net-zero future.

The Indian cement industry, as the world’s second-largest producer, plays a pivotal role in the nation’s infrastructure development. However, this prominence comes with significant environmental challenges, particularly in logistics operations. Green logistics—integrating sustainable practices into transportation and supply chain management—has emerged as a critical focus area. By adopting eco-friendly transportation methods, optimising supply chains and leveraging technological innovations, the industry aims to reduce its carbon footprint and enhance operational efficiency.
According to Cargo Insights, the cement industry plans to invest around `40,000 crore to add 40 MTPA annually, targeting an increase of 100-120 MTPA over the next three years.
India is the sixth-largest market for medium and heavy-duty trucks (MHDTs), with over 200,000 vehicles sold in 2021 and more than 40 lakh trucks operating on its roads. However, the dominance of internal combustion engine (ICE) trucks, with over 90 per cent running on diesel, presents significant challenges, including high emissions and fuel dependency. In the cement industry, road transport plays a crucial role, with 74 to 76 per cent of cement, 15 to 20 per cent of clinker, and most limestone, fly ash, and other additives being transported by trucks. While coal and slag rely more on rail, the sector remains heavily dependent on road logistics, underscoring the urgent need for sustainable alternatives such as LNG and electric trucks to reduce environmental impact and improve efficiency, informs a report by the Confederation of Indian Industry (May 2024).

Environmental imperative
Logistics in the cement industry is a major contributor to carbon emissions, primarily due to the extensive use of fossil fuel-powered transportation. With approximately 74 per cent of cement and clinker transport relying on roadways, the environmental impact is substantial. Transitioning to greener logistics solutions is essential to mitigate these emissions and align with global sustainability goals.
“Jassper Shipping is dedicated to reducing carbon footprints, including those of clients. Emission-reduction plans and carbon offset investments aim to achieve net-zero carbon emissions by 2035. Over the next two quarters, the number of EVs in the fleet will increase from 58 to 150. The last-mile delivery supply chain is becoming more sustainable and efficient with EV integration while maintaining high-quality service,” says Pushpank Kaushik, CEO, Jassper Shipping.
According to the Investment Information and Credit Rating Agency (ICRA), cement demand in India may touch approximately 460 million metric tonnes (MT) by 2025, and the sector is projected to grow its capacity by 5 per cent annually until
March 2027.
India’s per capita cement consumption remains below 300 kg, which is only half of the global average, indicating significant potential for growth. However, economic progress often comes at an environmental cost, with the cement industry accounting for approximately seven per cent of India’s total CO2 emissions due to its heavy reliance on coal. During China’s peak growth in 2008, the country produced 113.5 crore MT of cement, emitting approximately 0.46 MT of CO2 per MT of cement. In 2024, while India is producing only 40 per cent of China’s 2008 cement volumes, its specific emissions remain comparable. Additionally, environmental concerns are exacerbated by clinker dust, wastage during manufacturing and packaging, and transportation leaks, all of which contribute to the industry’s overall carbon footprint.
As India works toward its ambitious goal of becoming a net-zero emissions nation by 2070, it faces the challenge of balancing rapid economic growth with sustainability. The cement industry, as a key player in infrastructure development, must integrate green solutions at multiple levels of the value chain. This transformation involves optimising power consumption, improving manufacturing processes, developing eco-friendly products and implementing better preservation methods post-processing. By adopting these measures, the industry can contribute to India’s sustainability goals while maintaining its critical role in economic expansion.

The race for EVS
A significant stride toward green logistics is the industry’s pilot testing of electric trucks (E-trucks). Around 150 E-trucks have been deployed to assess their feasibility in cement transportation. Neeraj Akhoury, President, Cement Manufacturers’ Association (CMA), and Managing Director, Shree Cement, highlighted that while E-trucks can potentially reduce operating costs and emissions, challenges such as high ownership costs, heavy batteries, limited charging infrastructure and range constraints need to be addressed.
Companies like UltraTech Cement are leading the way by expanding their EV fleet. UltraTech has signed contracts to deploy approximately 100 EV trucks, aiming to transport 75,000 metric tonnes of clinker monthly. This initiative is part of a broader strategy to incorporate 500 electric trucks by
June 2025, aligning with the Government of India’s eFAST initiative.
The company has signed a transport service contract to deploy approximately 100 EV trucks, which will transport 75,000 MT of clinker each month. This initiative positions UltraTech as the first Indian cement company to integrate EV trucks on such a large scale for long-distance logistics.
By replacing conventional fossil-fuel-powered
trucks with EVs, the company expects to reduce its transport-related carbon emissions by 17,000 MT annually, making a significant contribution to sustainable logistics.
This large-scale deployment follows a successful pilot project launched in January 2024, which introduced five electric trucks on the same route. The pilot also focused on setting up essential charging infrastructure and implementing driver training programs to ensure smooth operations. Encouraged by the positive results, UltraTech is now evaluating additional routes for EV integration and is preparing for another pilot to facilitate clinker transport between two of its other manufacturing units. This phased approach demonstrates the company’s commitment to expanding green logistics solutions across its supply chain.
In a press release, KC Jhanwar, Managing Director, UltraTech Cement, stated, “UltraTech is fully committed to achieving its Net Zero goal by 2050. We have taken a holistic approach to embedding sustainability in our operations. Scaling up EV trucks in our logistics is a testament to our commitment to advancing sustainable practices in the industry.”
UltraTech plans to scale up its EV fleet to 500 trucks by June 2025 under the Government of India’s eFAST initiative. The company has been a pioneer in sustainable transportation, having introduced CNG vehicles in 2021 and LNG vehicles in 2022 before adopting EV trucks in 2024. Currently, its logistics network operates over 468 CNG and
67 LNG trucks, ensuring a reduced environmental footprint across multiple manufacturing units. This ambitious expansion further cements UltraTech’s leadership in integrating sustainability into its business operations while advancing India’s green energy and carbon reduction goals.

Integrating alternative fuels and renewable energy
Beyond electrification, the industry is exploring alternative fuels to power logistics operations. JK Lakshmi Cement, in collaboration with GreenLine Logistics, has introduced LNG-fueled heavy trucks to decarbonise its road logistics. This initiative marks a significant step toward reducing emissions associated with cement transportation.
Back in 2022, JK Lakshmi Cement had announced its tie-up with GreenLine, an Indian green and smart logistics company. This collaboration introduced LNG-fueled heavy trucks in the company’s logistics protocol. While Arun Shukla, President and Director, JK Lakshmi Cement, had hailed this as their first step towards sustainable transportation in an official statement, the company has come a long way in integrating green logistics in its supply chain over the years. Companies such as GreenLine Logistics are helping the cement transportation industry become more eco-conscious, thereby facilitating the transition towards a more circular economy.
Heavy trucking contributes approximately 10 to 12 per cent of total emissions. Switching to LNG-fuelled trucks can reduce CO2 emissions by 28 per cent, NOx by 59 per cent, SOx by 100 per cent, and particulate matter by 91 per cent, while also cutting noise pollution by 30 per cent. This transition
offers a cleaner, more sustainable alternative for freight transport.
Additionally, the adoption of renewable energy sources within manufacturing and logistics operations is gaining momentum. The Indian cement industry has been proactive in utilising waste heat recovery systems and renewable energy, contributing to a reduction in overall carbon emissions.
Another dimension to consider is improving the supply chain efficiency. The integration of digital technologies is revolutionising supply chain management in the cement industry. Advanced tracking systems, data analytics and the Industrial Internet of Things (IIoT) are being employed to optimise routes, monitor vehicle performance, and reduce fuel consumption. These technologies not only enhance efficiency but also contribute to sustainability by minimising unnecessary transportation and associated emissions.

Challenges in implementing green logistics
Despite the clear benefits, the transition to green logistics is fraught with challenges:

High initial investment: The upfront costs for EVs and alternative fuel vehicles are considerably higher than traditional diesel trucks.
Infrastructure limitations: The lack of adequate charging stations and refueling infrastructure for alternative fuels hampers widespread adoption.
Regulatory Hurdles: Navigating the evolving landscape of environmental regulations and standards can be complex and resource-intensive.
Technological adaptation: Integrating new technologies requires substantial changes in existing operational frameworks and workforce training.

“At Fleetronix, we are constantly looking ahead to the future of logistics, and we see a massive opportunity in using technology to make fleet management smarter and more sustainable. Right now, fleet maintenance is often reactive – issues are fixed after they cause downtime. But we envision a future where predictive maintenance becomes the norm. Our goal is to develop a system that identifies potential problems before they turn into costly breakdowns, ensuring trucks run efficiently and reducing unnecessary emissions,” says Anuradha Parakala, Co-founder, Chief Strategy and Product Officer, Fleetronix Systems.
“As the industry moves towards hybrid and electric vehicles, we see Fleetronix playing a key role in optimising fleet transitions – from smart route planning that maximises battery efficiency to integrated tracking for EV charging. Our vision is clear: healthier trucks, lower emissions, and a logistics industry that’s not just efficient, but truly sustainable. And we are actively building the technology to make it happen,” she adds.

Collaborative efforts and government initiatives
Addressing these challenges necessitates collaboration between industry stakeholders and government bodies. The Indian government is facilitating Memorandums of Understanding (MoUs) for new technologies, promoting research and development through incentives, and providing subsidies to encourage the adoption of green logistics practices. Such partnerships are crucial for creating an ecosystem conducive to sustainable logistics.
Furthermore, the Indian cement industry’s commitment to green logistics is poised to yield significant environmental and economic benefits. As technological advancements continue and infrastructure improves, the adoption of sustainable practices is expected to accelerate. This transition not only aligns with global sustainability targets but also positions the industry competitively in a rapidly evolving market.

Conclusion
Embracing green logistics is imperative for the Indian cement industry to mitigate its environmental impact and ensure long-term sustainability. Through the adoption of electric and alternative fuel vehicles, integration of renewable energy, and leveraging technological innovations, the industry is making commendable strides toward eco-friendly operations. Continued collaboration among industry players, government agencies and technology providers will be essential to overcome existing challenges and
fully realise the potential of green logistics in
cement manufacturing.