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.

Alternative fuels reduce cement plants’ carbon footprint, but infrastructure challenges limit adoption. Technologies like the HOTDISC® Reactor help overcome these barriers.

Alternative fuels are a relatively straightforward and readily available means of reducing a cement plant’s carbon footprint. The technology is proven and well used worldwide, and with the right controls in place the switch from fossil fuels to waste-derived fuels does not impact the quality of the end product. In some countries, cement plants are achieving near 100 per cent substitution in the calciner and high levels of substitution in the kiln. However, this trend is not universal, and some countries are struggling to achieve a thermal substitution rate (TSR) of 25 per cent. In this article, we will look at the obstacles to alternative fuels use and the technology that is available to overcome them.

Advantages of alternative fuels
Alternative fuels offer three key environmental advantages.
1) A lower carbon alternative to coal or petcoke.
2) A pathway for waste that might otherwise be landfilled, including hazardous waste.
3) An alternative to waste incineration, which is typically done at lower temperatures where emissions tend to be higher.
In addition, the cost of alternative fuels can often be lower than fossil fuels and is not subject to the fluctuations of the energy market.
The sources of alternative fuels are many and varied – to the extent that the supply chain looks vastly different from one region to the next. For example, whereas India has abundant sources of biomass such as rice husk, in Western Europe there are plentiful supplies of refuse-derived fuel (RDF). This is partly a matter of industry and partly of infrastructure. But given the importance of reducing the cement industry’s reliance on coal, a lack of infrastructure must not prevent greater utilisation of alternative fuels – which is why FLSmidth Cement has for some time been developing alternative fuels solutions that reduce the burden of pre-processing and enable cement plants to more easily and more cost-effectively utilise a wide variety of waste streams.

A solution for all waste
Direct calciner injection may seem like the simplest way to replace fossil fuels with alternatives. However, it’s not always the best. The options for alternative fuels are limited by the necessity to pre-process fuel in preparation for burning, which, as stated, requires established infrastructure, or additional facilities at the plant.
Though the CAPEX cost of direct calciner injection is low, the calciner fuel substitution rate is also low, so this method doesn’t enable cement plants to optimise the potential for fuel replacement. Plant operators must also consider the impact on the process of direct injection, which doesn’t allow the long residence time that can be required to reduce process volatility. No plant wants to contend with greater instability or an increase in emissions from adding alternative fuels to the mix. Fortunately, direct calciner injection is not the only option. There are other ways of extracting energy from waste that require no pre-processing at all.
The HOTDISC® Reactor can handle a wide variety of solid waste in sizes up to 1.2m – from sludge or grains to whole truck tyres. There’s no need for expensive shredding or pre-drying, or any pre-processing, which removes one of the obstacles to adopting alternative fuels. The broad range of accepted fuel types also means cement plants are free to shop the market and not tied into one supplier. This makes it a very cost-effective solution because cement plants can select the lowest cost fuel without worrying about the quality.

How does the HOTDISC® work?
The HOTDISC® is a moving hearth furnace that is integrated into the pyroprocess below the calciner bottom and above the kiln riser. Coarse alternative fuels are fed onto a slowly rotating disc. Hot tertiary air is directed into the HOTDISC to provide an oxidising atmosphere for the alternative fuel to burn. As the alternative fuel slowly travels around approximately 270 degrees on the rotating disc, almost all of it fully combusts. Depending on the nature of the alternative fuel (size, heat content, moisture, etc.), the rotational speed of the HOTDISC can be adjusted to optimise the residence time (up to 45 minutes) and combustion rate. In addition, the temperature inside the HOTDISC is controlled by directing a portion of the preheated raw meal into the HOTDISC. The HOTDISC operation generates a controlled mix of hot gases, combustion residue (ash) and calcined raw meal that exits the HOTDISC. The combustion gases and finer materials are carried with the hot gases into the bottom of the calciner, while the coarser residues meet a scraper at the end of the 270 degrees rotation, where they are directed down into the riser duct. From there, this material falls into the kiln and is incorporated into the clinker.
The HOTDISC is designed to achieve a calciner substitution rate in the range of 50 to 80 per cent – or even higher – of the calciner fuel. Results vary by the specific plant conditions and fuel specification, but based on over 20 years of plant data it is possible to predict the substitution rate in each application.
The HOTDISC was originally designed for use with In-Line Calciners (ILCs), but new models are now available for use with Separate Line Calciners (SLCs), enabling the HOTDISC to be installed under the calciner and still deliver the same benefits. The HOTDISC-S is installed in the bottom part of the SLC calciner on the ground, the reject will be cooled and transported to a container or back into the system, gas flow and AF flow operates counter current.
For cement plants that wanted to utilise a wide range of alternative fuels, the HOTDISC®-S is a cost-saving solution that avoids the expense of changing the SLC to an ILC while enabling a high substitution of alternative fuels. Another model, the HOTDISC®-HMT (Hot Material Transport), enables quicker and easier installation of the HOTDISC in existing plants. Instead of directly integrating the exit of the HOTDISC reactor to the calciner and riser duct, the new layout allows the HOTDISC reactor to be mounted two to five metres away. It is then connected to the calciner and riser duct via a hot material transport chute for gas flows and combustion ashes.

Further advances in alternative fuels technologies
Low or varying quality alternative fuels can be another inhibitor to substitution, given the requirements of the relatively delicate cement pyro process. FLSmidth Cement has expended considerable R&D effort developing solutions that can accommodate a wide range of fuel types, knowing that this is the easiest path to greater substitution and ultimately the near-elimination of fossil fuels. The FUELFLEX® Pyrolyzer was one result of this effort and offers an exciting prospect for cement plants wishing to achieve near – 100 per cent substitution in the calciner and minimise NOx emissions.

The FUELFLEX® Pyrolyzer utilises hot meal from the lower preheater cyclones (yellow arrows) to dry and pyrolyze RDF or biomass. Either part or the full stream of hot meal from a lower preheater cyclone is admitted to the Pyrolyzer via the U-Lock (controlled by two dividing gates). The U-Lock fluidises the hot meal, forming a U-shaped gas lock that prevents pyrolysis gases from flowing backwards through the process. Subsequently the hot meal stream flows into the Pyrolyzer vessel, which also has a U-shaped lower aerated section to contain the hot fluidised meal. Fuel is pneumatically fed to the pyrolyzer vessel wherein through contact with the hot meal, it is dried, heated and pyrolyzed to form reactive gases and char. The gases push upwards into the main pyrolyzer vessels while the char falls down into the fluidised meal bed, before being reunited and fed as a very reactive stream into the calciner. Aeration panels are used to fluidise the hot meal and drain gates are used to drain out debris and meal from the pyrolyzer to the kiln system in a controlled manner. The reactive stream of pyrolysis products reacts with rotary kiln NO by so-called ‘re-burning’ reactions, utilising pyrolysis gases to convert NO into free N2 in the reduction zone prior to mixing with preheated combustion air in the calciner. In addition, the full fuel pyrolysis preceding the calciner helps limit calciner NOx formation by limiting access to oxygen when burning.

By using the FUELFLEX® Pyrolyzer, cement plants can achieve up to 100 per cent fossil fuel replacement in the calciner, with the following benefits:

• Reduced CO2 emissions, as net CO2 emissions from alternative fuels generally are lower than from fossil fuels.
• Increased utilisation of local waste streams, avoiding the need to dispose of or store this waste in other ways.
• Reduced fuel costs, especially in times of fluctuating energy prices.
• Reduced fossil fuel use saves the associated environmental impact of fossil fuel extraction and transport.

Conclusion
The challenge is on: cement plants must reduce carbon emissions now, and continue to do so for the next several decades until the target of net zero is met. While there are some solutions that are not ready yet – i.e. carbon capture – alternative fuels offer a valuable means of reducing the cement industry’s environmental impact immediately, with the added benefit of providing a controlled means of waste disposal. New and proven technologies will help the cement industry to overcome alternative fuel supply chain problems and achieve a dramatic reduction in fossil fuel use.

(Communication by the management of the company)

Swapnil Jadhav, Director, SIDSA Environmental, discusses transforming waste into valuable resources through cutting-edge technology and innovative process solutions.

SIDSA Environmental brings decades of experience and expertise to the important niche of waste treatment and process technologies. As a global leader that is at the forefront of sustainable waste management, the company excels in recycling, waste-to-energy solutions and alternative fuel production. In this conversation, Swapnil Jadhav, Director, SIDSA Environmental, shares insights into their advanced shredding technology, its role in RDF production for the cement industry and emerging trends in waste-to-energy solutions.

Can you give us an overview of SIDSA Environmental’s role in waste treatment and process technologies?
SIDSA is a leading innovator in the field of waste treatment and process technologies, dedicated to delivering sustainable solutions that address the growing challenges of waste management.
SIDSA is a more than 52-year-old organisation with worldwide presence and has successfully realised over 1100 projects.
Our expertise is in the engineering and development of cutting-edge systems that enable the conversion of waste materials into valuable resources. This includes recycling technologies, waste-to-energy (W2E) systems, and advanced methods for producing alternative fuels such as refuse derived fuel (RDF). The organisation prioritises environmental stewardship by integrating energy-efficient processes and technologies, supporting industrial sectors—including the cement industry—in reducing their carbon footprint. Through our comprehensive approach, we aim to promote a circular economy where waste is no longer a burden but a resource to be harnessed.

How does SIDSA Environmental’s shredding technology contribute to the cement industry, especially in the production of RDF?
SIDSA’s shredding technology is pivotal in transforming diverse waste streams into high-quality RDF. Cement kilns require fuel with specific calorific values and uniform composition to ensure efficient combustion and operational stability, and this is where our shredding systems excel. In India, we are segment leaders with more than 30 projects including over 50 equipment of varied capacity successfully realised. Some of the solutions were supplied as complete turnkey plants for high capacity AFR processing. Our esteemed client list comprises reputed cement manufacturers and chemical industries. Our technology processes various types of waste—such as plastics, textiles and industrial residues—breaking them down into consistent particles suitable for energy recovery.

Key features include:

• High efficiency: Ensures optimal throughput for large volumes of waste.
• Adaptability: Handles mixed and heterogeneous waste streams, including contaminated or complex materials.
• Reliability: Reduces the likelihood of operational disruptions in RDF production. By standardising RDF properties, our shredding technology enables cement plants to achieve greater energy efficiency while adhering to environmental regulations.

What are the key benefits of using alternative fuels like RDF in cement kilns?
The adoption of RDF and other alternative fuels offers significant advantages across environmental, economic and social dimensions:

• Environmental benefits: Cement kilns using RDF emit fewer greenhouse gases compared to those reliant on fossil fuels like coal or petroleum coke. RDF also helps mitigate the issue of overflowing landfills by diverting waste toward energy recovery.
• Economic savings: Alternative fuels are often more cost-effective than traditional energy sources, allowing cement plants to reduce operational expenses.
• Sustainability and resource efficiency: RDF facilitates the circular economy by repurposing waste materials into energy, conserving finite natural resources.
• Operational flexibility: Cement kilns designed to use RDF can seamlessly switch between different fuel types, enhancing adaptability to market conditions.

What innovations have been introduced in waste-to-energy (W2E) and recycling solutions?
SIDSA’s machinery is meticulously engineered to handle the complex requirements of processing hazardous and bulky waste.

This includes:

• Robust construction: Our equipment is designed to manage heavy loads and challenging waste streams, such as industrial debris, tires and large furniture.
• Advanced safety features: Intelligent sensors and automated controls ensure safe operation when dealing with potentially harmful materials, such as chemical waste.
• Compliance with standards: Machinery is built to adhere to international environmental and safety regulations, guaranteeing reliability under stringent conditions.
• Modular design: Allows for customisation and scalability to meet the unique needs of various waste management facilities.

How does your organisation customised solutions help cement plants improve sustainability and efficiency?
We consistently push the boundaries of technology to enhance waste management outcomes.
General innovations and new product development focus on:

• Energy-efficient shredders: These machines consume less power while maintaining high throughput, contributing to lower operational costs.
• AI-powered sorting systems: Utilise advanced algorithms to automate waste classification, increasing material recovery rates and minimising errors.
• Advanced gasification technologies: Convert waste into syngas (a clean energy source) while minimising emissions and residue.
• Closed-loop recycling solutions: Enable the extraction and repurposing of materials from waste streams, maximising resource use while reducing environmental impact.

What future trends do you foresee in waste management and alternative fuel usage in the cement sector?
Looking ahead, several trends are likely to shape the future of waste management and alternative fuels in the cement industry:

• AI integration: AI-driven technologies will enhance waste sorting and optimise RDF production, enabling greater efficiency.
• Bio-based fuels: Increased use of biofuels derived from organic waste as a renewable and low-carbon energy source.
• Collaborative approaches: Strengthened partnerships between governments, private industries and technology providers will facilitate large-scale implementation of sustainable practices.
• Circular economy expansion: The cement sector will increasingly adopt closed-loop systems, reducing waste and maximising resource reuse.
• Regulatory evolution: More stringent environmental laws and incentives for using alternative fuels will accelerate the transition toward sustainable energy solutions.

(Communication by the management of the company)