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Milestone event of the last century

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The author has long experience and exposure in the industry at executive level and has worked with ILO as Senior Employers’ Specialist for South Asian Region. He has taken stock of the situation in view of the present Covid-19 pandemic, its antecedence and impact on enterprises today.

There were three milestone events of the last century that impacted people, nations and enterprises. The first milestone event of last century was end of First World War in 1918. The end of the First World War saw the spread of Spanish flu pandemic in various countries of the world including India. The Spanish flu, also known as the 1918 flu pandemic, was an unusually deadly influenza pandemic caused by the H1N1 influenza A virus. Lasting from spring 1918 through spring or early summer 1919, it infected 500 million people, i.e. about a third of the world’s population at that time. It is estimated, that in India, nearly 18 million people which was 6 per cent of the population at that time, lost their lives in this disease, which locally was called plague. This pandemic impacted many families in India. Mahatma Gandhi lost his daughter-in-law and a grandchild in this pandemic, and was himself a victim and was cured and we all know his contribution to India in the freedom struggle.

The second milestone event of last century was end of Second World War in 1945. Second World War was a major conflict in human history, which marked the death of 70 to 85 million people in the world, most of whom were civilians in the Soviet Union and China. Following the end of Second World War, most countries became independent nations between 1945 and 1965 varying from a peaceful to protracted revolutionary process. Also, the end of Second World War led to the birth of the United Nations. Also, the International Labour Organization (ILO), which was born at the end of First World War, became a specialised agency of United Nations. Also, at the end of Second World War, countries in Europe gradually lost their colonies.

Hence, the European countries opened their economies with reference to movement of people, currency, goods and information by becoming open economies. At the same time colonies that became independent nations, took an approach of being closed or open or mixed economies depending upon their choice. India on independence in 1947 chose to be a mixed economy, with the core sector such as cement, steel, coal, electricity, interstate bus transport, railways, airlines, etc. being price controlled or/and state controlled; and also setting up a large number of public sector undertakings later and also nationalising sick private sector units plus the banks and insurance business plus the oil companies. We in India had strict control on movement of foreign currency in terms of a monitored exchange rate, high import duties coupled with Rupee trade with USSR, strict rules with reference to visas on employment of foreign nationals.

The third milestone event of last century was end of Cold War in 1989. The Cold War finally came to an end in 1989 with the fall of the Berlin Wall and the collapse of the communist regimes in Eastern Europe as well as USSR, a former communist country in eastern Europe and northern Asia. This led to all countries in the world that were closed or mixed economies becoming to varying degree open economies including India. It is in 1991, that India shifted gear from a mixed economy to an open economy, by devaluing the currency, permitting flow of foreign direct investment plus foreign institutional investment, reducing and rationalising the import duty based on WTO tariffs and permitting foreign made goods to be easily imported and available, relaxation on movement of persons from foreign countries to work in India.

The impact of the opening up of the economy in India was that large number of domestic enterprises post 1991 restructured their product portfolios as well as resources, including the permanent workforce working for the enterprise through voluntary retirement scheme (VRS), as labour laws did not go through change. The restructuring exercise of enterprises led to enterprises getting various activities, which were done inhouse being outsourced and/or subcontracted resulting in substantial growth of ancillaries, as well as the supply chain. Certain enterprises got acquired under new ownership and in certain cases also closed down.

New milestone event
In the present century, we had SARS (Severe Acute Respiratory Syndrome) coronavirus (SARS-CoV) "identified in 2003 infecting humans in the Guangdong province of Southern China in 2002. Then Middle East Respiratory Syndrome (MERS) a viral respiratory disease identified in Saudi Arabia in 2012. Then Ebola Virus Disease (EVD), formerly known as Ebola haemorrhagic fever outbreak in 2014-2016 in West Africa covering Guinea, Sierra Leone and Liberia, but none of these impacted the world and the enterprises of every country.

However, Coronavirus disease 19 (Covid-19), which is a highly transmittable and pathogenic viral infection caused by severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2), emerged in Wuhan in 2019 has affected 212 countries and territories around the world. Covid-19 has impacted every country of the world, and this pandemic is a mile stone event of the current century which is impacting life, livelihood, enterprises and the economy of every country in the world.

There is no easy solution to preventing the spread of the Covid-19, unless the citizens fully cooperate in implementing the lockdown guidelines laid by the government of the country. Countries will have to review their public health expenditure percentage to country’s GDP for the future and bring it to at least three to five percent and this is not easy.

Post Covid-19, the international trade will go through a change, as countries are likely to reduce their dependence on China, which had become a manufacturing hub for a large number of items for many countries after the end of cold war 1989. Countries world over will review their policies on global supply chain, as countries would work on strategies for being self-reliant in certain specific sectors to protect domestic enterprises and reduce dependence on imports and also safe guard jobs for the locals arising from the downturn. International deglobalisation is likely to be an approach by certain countries to reduce dependence of imports in specific areas.

Also, there might be reluctance by countries depending upon their size and economic strength, to abide by the agreed WTO tariffs; and probably WTO itself may get a jolt and be restructured, wherein its role could go through a change. Also, the funding of international agencies like WHO from some of the countries has already gone through a change, though the role of an organisation like WHO becomes vital and relevant, when such a pandemic impacting countries of the world occurs and needs to be reported and acted upon to prevent the spread. Also, WHO will have to do serious introspection with reference to its funding, performance plus its role and this could result in some restructuring of the organisation.

Impact on Indian enterprises
The Government of India adopted the lock down approach from March 25, 2020 initially for 21 days which in phases got extended till May 31, 2020 and may get further extended if needed, so as to reduce the spread of coronavirus disease 19 (Covid-19) amongst the citizens and also to improve the preparedness of the various states and districts in the country medically for tackling the epidemic. The annual public health expenditure by states and union territories together in India amounted to around Rs 1.58 trillion, which is estimated to be around 1.28 per cent of the country’s GDP and this will have to go up in the future.

The Government of India has come forward with an economic package for enterprises, farmers, migrant workers and individuals for reducing the negative impact of the lock down. Enterprises and individuals need to look at the economic package and see how it would benefit them in reducing their financial stress and take benefit of the same wherever possible. The intensity of the impact of the Covid-19 for each enterprise differs based on the sector in which it operates, cash liquidity, profitability and location.

There are certain sectors like aviation, travel, tourism, hotels, restaurants, automobiles, capital goods, film production, movie theatres, entertainment, trade fairs, event management, malls, real estate, etc., where the dip in revenue for enterprises in the financial year 2020-21 is likely to be more than 50 per cent because of substantial fall in demand. If an enterprise in these sectors has a low cash liquidity, coupled with low profitability, then these enterprises are likely to have a tough future for independent existence and in the worst case could lead to continue to be sick or being acquired by interested buyers, unless innovative steps are taken by the management to undertake heavy cut in fixed cost to survive. However, if they have a high cash liquidity and low or negligible debt to equity, then they would be able to sail through the turbulent duration of Covid-19 period, survive and later also grow.

There are certain sectors like pharmaceuticals, hospitals, medical equipment, PPE, IT, mobile networks, mobile phones, app-based platforms doing home delivery, FMCG, agrochemicals, fertilizers, seed growing and processing, dairy and dairy products, food processing, cash crops, tobacco, cigarettes, alcohol, etc. where the dip in revenue for the financial year 2020-21 for enterprises in this sector is likely to be low. Even if an enterprise in this sector has a low cash liquidity coupled with a medium/high debt to equity and low profitability, it will survive in the post Covid-19 period, though there will be some negative impact to enterprises in these sectors if they are located in the red zone.

Situation of enterprises in India
The impact of COVID-19 is that the smooth functioning of every enterprise whether in the informal or the formal sector (micro, small medium or large) in India has been tripped and each enterprise will continue to have a time period of tripping based on which colour zone (i.e. red, orange or green) they are located, as activity and movement will be hampered in red zones. Also, the duration for enterprises to operate before a cure for Covid-19 is available could be from two quarters to six quarters starting April 1, 2020, thus various scenarios will emerge for enterprises.

The duration of the tripping for an enterprise will depend on the sector and zone in which it operates, and this could result in a V shaped curve or a U-shaped curve or a L shaped curve. Functioning of each enterprise has been hampered due to the lockdown; there is a fall in income for practically every enterprise because of the lock down, likely continuation of a certain stagnation of demand for certain time period will be there in certain sectors, and there will be a revival of demand later for all. Every enterprise will have to assess in which curve they fall. For an enterprise falling in a L shaped curve, because of the sector and zone in which it operates, a long duration of low negligible demand will adversely affect them and all-out effort needs to be made to move to a U-shaped curve by innovative strategies.

One thing good on present date is that the number of mobile telecom subscribers in India as of December 2019 is over one billion, that means practically every working individual, including workers in the informal sector have mobile phone connectivity, though everybody will not have a smart phone. Also, internet usage in India has exceeded half a billion people and is estimated to be over 600 million users in end 2019. Enterprises continued their operations by asking employees to work from home wherever possible. The option of working from home has limitations in the case of manufacturing enterprises, as the input material has to be converted into a finished product, which involves movement and processing of the input material coupled with physical presence cum activity of persons to ensure completion of the operations safely. The present manufacturing facilities in the factories in India are not designed such, that they can operate without the physical presence of people. However, manufacturing enterprises are learning to operate their factories with limited workforce, at the same time ensuring compliance of the safety protocols laid down by the Government arising from Covid-19 pandemic in the country.

Physical distancing norms at work place will impact every enterprise, however the labour intensive enterprises will have a higher negative impact, as either the numbers engaged have to be reduced and/or the working method modified, so as to ensure maintenance of the required physical distance while working. Enterprises functioning in remote areas and small towns will be less impacted for availability of work force, than the ones situated in or near metropolis or large city.

Tackling the situation
Each enterprise in India will have to find its own solution for tackling the situation, as this is a phase of disruption for everybody. However, some things are common which the top management of each enterprise will have to work upon.

  • Ensure cash availability as top priority for sustainability
  • Continuously communicate with employees using available technology and if possible, also with their families to boost their morale to face the Covid-19 pandemic situations
  • Seek the suggestions of employees to tide over the problems
  • Seek employees, trade unions cooperation to tide over the crisis by continuously communicating with them
  • Ensure that the workplace of the enterprise is safe for employees to work, ensuring rigorous implementation of protocols and SOP to prevent any spread of Covid-19
  • Ensure insurance coverage and treatment of employees including contract workforce, if infected with Covid-19
  • Move to digitisation wherever possible
  • Move to work from home wherever feasible
  • Top management of the enterprise needs to ensure visible austerity measures with the need to cut fixed and variable costs wherever possible
  • Defer capital expenditure unless it is absolutely necessary
  • Measurement of impact because of this crisis on company’s brand image and reputation
  • Lessons learnt from this major crisis needs to be documented, so that the same is available for reference by "next set of management" during next major crisis

Conclusion
The business and employment model of enterprise in India post Covid-19 will drastically change compared to the business and employment model pre Covid-19. We all have to adapt to a new lifestyle as well as a different working style of enterprises as the Covid-19 is a tsunami, which has affected the world. It will take time before a vaccine to prevent the spread of Covid-19 is available to all of us.

Enterprises are likely to restructure their fixed as well as variable cost, and this could impact the persons that are presently employed at all levels in certain enterprises. Most enterprise post 1991 in India adopted a work force model wherein the enterprise had people to work and not employees. Hence, most enterprises presently have maximum executives, limited workers, and maximum contract workers through contractors/service providers. Presently in India, the contract workers in most enterprises are interstate migrants. The interstate migrant contract workers presently are making all-out effort to return to their home state by modes of transport that they consider viable, and substantial numbers have moved and will move.

It is a reality that Covid-19 has negatively impacted life, lifestyle of every individual and every enterprise whether in the informal or the formal sector (micro, small medium or large) in India. We, Indians have made all-out effort to ensure that we lose minimum lives of our citizens as our first priority. At the same time, we need to ensure that the enterprises and businesses in the informal and the formal sector while going through the hardship survive and continue to live which I am confident we all will do.

ABOUT THE AUTHOR: Dr. Rajen Mehrotra is Past President of Industrial Relations Institute of India (IRII), Former Senior Employers’ Specialist for South Asian Region with Internation.al Labour Organization (ILO) and Former Corporate Head of HR with ACC Ltd. and Former Corporate Head of Manufacturing and HR with Novartis India Ltd.

E-Mail: rajenmehrotra@gmail.com

Published in April – May – June 2020 issue of Current Labour Reports and Arbiter.

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Concrete

Boosting Concrete Workability with Grinding Aids

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Dr SB Hegde highlights how AdoCem® WE++ grinding aid improves cement fineness and reduces water demand, effectively minimising slump loss and enhancing concrete workability retention. The study confirms its role in improving both slump retention and compressive strength over time.

In the production of concrete, maintaining consistent workability is crucial for efficient mixing, transporting, and placing of the material. However, concrete slump loss, or the reduction in workability over time, is a common challenge, particularly in large-scale projects where the concrete mix needs to remain workable for extended periods, such as during long-distance transportation or complex placements. Slump loss greater than 150 mm within 3 hours can lead to difficulties in handling and finishing, impacting both the quality and the efficiency of construction.
One effective solution to control slump loss is the use of grinding aids during the cement production process. This technical note focuses on the application of AdoCem® WE++ grinding aid during the cement grinding of Ordinary Portland Cement (OPC) to resolve slump loss issues and improve concrete workability retention.

The role of AdoCem® WE++ grinding aid
AdoCem® WE++ is a high-performance grinding aid designed to improve the efficiency of cement grinding by reducing the energy required to achieve a desired fineness. It works by modifying the surface properties of cement particles, reducing agglomeration, and improving the flowability of the material. As a result, it enhances the production process, reduces specific energy consumption, and improves the overall quality of the cement.
In addition to its primary function in cement grinding, AdoCem® WE++ has been shown to have beneficial effects on the physical properties of the cement, particularly in terms of workability and water demand in concrete mixes. By optimising the cement particle size distribution, the grinding aid can reduce water requirements, resulting in better workability retention and lower slump loss over time.

Slump loss problem in concrete
Concrete slump loss is a significant issue
that affects the workability of fresh concrete. Over time, fresh concrete tends to lose its fluidity, which can lead to challenges in handling and placing the mix. The rate of slump loss is influenced by several factors, including:

  • Cement fineness: Finer cement particles tend to absorb more water, requiring higher water-to-cement ratios to maintain a constant slump. This leads to increased slump loss.
  • Cement composition: The chemical composition and particle size distribution of the cement affect hydration rates and, consequently, the workability over time.
  • Environmental conditions: Temperature, humidity, and mixing conditions also play a critical role in slump retention.

In this context, the introduction of AdoCem® WE++ grinding aid helps optimise cement properties, ensuring that the water demand is minimised and workability is better maintained over an extended period, thereby mitigating slump loss.

Research methodology 4.1 Materials

  • Cement: Ordinary Portland Cement (OPC) was used in this study.
  • Grinding aid: AdoCem® WE++ was used as the grinding aid, added at dosages of 0.06 per cent, 0.08 per cent, and 0.10 per cent by weight of cement.
  • Concrete mix: A standard concrete mix with a water-to-cement ratio of 0.50 was prepared. The target slump was 150 mm, with slump loss measurements taken at intervals up to 3 hours.

4.2 Experimental setup

  • Cement grinding: OPC was ground in a ball mill, with the addition of AdoCem® WE++ at the specified dosages. The energy consumption, fineness, and particle size distribution of the cement were analysed.
  • Concrete mix preparation: Concrete was mixed using cement treated with AdoCem® WE++ grinding aid, along with conventional mixing procedures.
  • Slump testing: Slump was measured using the standard slump cone test at 0, 30, 60, 90, and 180 minutes after mixing to determine the rate of slump loss.
  • Compressive strength: Concrete cubes (150 mm x 150 mm) were cast, cured, and tested at 7, 28, and 90 days to assess the impact of grinding aids on strength development.

Results and discussion
5.1 Cement fineness and energy consumption
The use of AdoCem® WE++ significantly improved the grinding efficiency, resulting in a more uniform particle size distribution. The cement treated with AdoCem® WE++ showed a Blaine fineness of 320 m²/kg, compared to 300 m²/kg for the control cement, indicating that the grinding aid allowed for finer grinding without increasing energy consumption. This reduced the production costs while improving cement quality.

5.2 Slump retention
The main focus of this study was to evaluate the effect of AdoCem® WE++ on slump retention. Concrete mixes with grinding aid-treated cement showed a notable improvement in slump retention over time compared to the control mix.

  • Control cement (no grinding aid): The control mix experienced a slump loss of 80 mm after
    2 hours.
  • AdoCem® WE++ at 0.06 per cent dosage: Concrete with cement treated with 0.06 per cent AdoCem® WE++ showed a slump loss of 100 mm after 3 hours, a significant improvement over the control mix.
  • AdoCem® WE++ at 0.08 per cent dosage: At a dosage of 0.08 per cent, the slump loss was reduced to 120 mm after 3 hours, demonstrating further improvement.
  • AdoCem® WE++ at 0.10 per cent dosage: The highest dosage of AdoCem® WE++ resulted in the best performance, with only a 150 mm slump loss after 3 hours, which meets the target of maintaining workability over extended periods.

5.3 Hydration behaviour and setting time
The addition of AdoCem® WE++ appeared to slightly delay the initial setting time compared to the control mix. This delay in setting time helps to extend the period during which the concrete remains workable, thereby reducing the risk of excessive slump loss. The improved hydration behaviour
also contributed to better overall consistency in the concrete mix.

5.4 Compressive strength
Concrete cubes made with cement treated by AdoCem® WE++ exhibited slightly higher compressive strength compared to the control mix. At 28 days, the compressive strength of the AdoCem® WE++ mixes were 5 per cent to 8 per cent higher, indicating that the grinding aid not only improved workability but also contributed to more efficient cement hydration and stronger concrete.

Conclusion
The addition of AdoCem® WE++ grinding aid during the cement grinding process significantly improves the workability retention of concrete, effectively maintaining slump loss over a 3-hour period. By optimising the particle size distribution of cement, AdoCem® WE++ reduces water demand and enhances the stability of the concrete mix, thereby ensuring that the slump remains within the desired range (150 mm) for an extended period. Furthermore, the grinding aid improves cement efficiency, reduces energy consumption during grinding, and enhances the strength development of concrete.
This study demonstrates that AdoCem® WE++ is an effective solution for mitigating concrete slump loss, making it a valuable tool for construction projects where concrete workability must be maintained over longer periods. The optimal dosage of AdoCem® WE++ for achieving the best performance in terms of slump retention and strength is around 0.1 per cent by weight of cement.

About the author:
Dr SB Hegde, a global cement industry leader with over 30 years of experience, is a Professor at Jain College of Engineering, India, and a Visiting Professor at Pennsylvania State University, USA.

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Concrete

The main pushback against automation is budget

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Mehul Doshi, Head of Department — Customer Support and Service, HAVER & BOECKER, shares insights on leveraging diagnostics and optimisation tools to address challenges in automation of bagging, packaging, and palletising processes.

In the fiercely competitive cement industry, optimising bagging, packaging and palletising processes is no longer a luxury but a necessity. Cutting-edge diagnostics and tailored optimisation plans are transforming how plants enhance efficiency, reduce waste, and boost safety — all while advancing sustainability goals. Through a seamless blend of digital monitoring and hands-on audits, manufacturers are now able to identify bottlenecks, minimise product loss and future-proof their operations, shares Mehul Doshi, Head of Department — Customer Support and Service, HAVER & BOECKER, in this exclusive interview.

How do QUAT2RO® and POP enhance efficiency in bagging, packaging, and palletising for the cement industry?
Comprising the diagnostics section of HAVER & BOECKER’s PROcheck lifecycle approach, QUAT2RO® and the Plant Optimisation Plan (POP) help operations increase plant performance, optimise machine conditions, set up and use resources, raise health and safety standards and improve energy efficiency.
As the digital tool of HAVER & BOECKER’s diagnostics approach, QUAT2RO® collects short-term and long-term production data on all connected machines. The data combines performance and maintenance reports into a single dashboard to make monitoring equipment settings simple. QUAT2RO® System Monitoring alerts operators to any discrepancy in the packing or palletising machines to allow faster maintenance and increase efficiency on the packing line. HAVER & BOECKER recommends installing QUAT2RO® on packing lines before engaging in a Plant Optimisation Plan (POP) to collect information on the baseline performance of the line.
POP is the human approach toward diagnostics. For the POP, HAVER & BOECKER engineers visit the customer plant to observe the operation and recommend enhancements classified by level of urgency. The full plant audit considers all areas, from product storage and handling to packing, bag transport, palletising and loading lines, as well as surrounding machines and environmental factors. The engineers send a full report tagged with green, yellow or red to highlight areas for improvement, ensuring that critical updates are prioritised.
HAVER & BOECKER’s Bag Optimisation Plan (BOP) is a very important part of the POP and allows it to go beyond the mechanical equipment and into the important role of consumables. While the goal of the POP is to find the perfect harmony between the bag, the product and the machine, the BOP focuses on all aspects of the bag and includes a bag volume test, bag valve check, visual pallet check and a bag specification check. The HAVER & BOECKER Institute tests and analyses the bag and the product to optimise all three major factors in the packing process — machine, bag and product —resulting in the highest levels of productivity and efficiency.

What common challenges in cement packing plants do your diagnostics tools address, and how are the solutions tailored?
HAVER & BOECKER diagnostics tools primarily focus on production issues, whether that’s tracking equipment efficiency through QUAT2RO® or providing recommendations for optimising existing equipment and processes. One of the biggest challenges plants face is dust escaping as bags are filled. Most packing equipment comes in a one-size-fits-all approach, meaning it’s not optimised for each individual product. If not treated properly, free-flowing powder material like cement will settle on the floor, equipment and operators instead of in the bag. HAVER & BOECKER diagnostics, specifically their POP and BOP, considers the individual properties of the cement being poured and how to direct it into the bag most effectively.
The bags used for packing cement can contribute to the amount of material lost in the packing process. Unsealed valve bags rely on the inner pressure of the bag to close, which results in the bag being only 70 per cent closed, leaving a 30 per cent opening for spillage. An improperly sealed bag results in material loss at a rapid rate while in storage and throughout transport, leading to a total product loss of up to 5 per cent. That’s why HAVER & BOECKER offers SEAL technology. Ultrasonic sealing effectively welds bags shut, resulting in the bag being 100 per cent closed. Unlike adhesive closed bags, this type of seal means bags won’t unstick over time and cause spillage if left in storage. This bag also eliminates product loss during transport.
If a facility is seeing similar product loss in their plant, HAVER & BOECKER will address the type of bag being used and recommend an upgrade to SEAL technology in their optimisation plan. They will also address any dust production issues in the full packing line to optimise production.

How does QUAT2RO® improve process efficiency, and which KPIs are critical?
QUAT2RO® detects issues before they become critical to the packing line. Operators can monitor machines’ production rates in real time to see how their equipment is performing. The results can be used to check production levels and identify solutions to productivity challenges and inefficiencies. This data can show any bottlenecks in the packing line so operators can address the issue immediately.
All data is stored in a single online portal with customisable alert systems and report templates. The portal keeps track of maintenance intervals for all assemblies and components and sends early notifications as a reminder to order wear parts. The system can also be accessed by the HAVER & BOECKER service team, providing cement plants with direct contact with our experts to address any of their concerns.

How do your solutions support sustainability goals like energy efficiency and waste reduction?
Sustainability and energy efficiency are at the heart of what we do. HAVER & BOECKER offers 10 energy saving solutions for packing lines that cover everything from optimising equipment performance to keeping equipment clean and having equipment serviced regularly. Optimising machine performance leads to energy efficiency because any material that escapes the packing process is a loss, which means the rest of the production plant needs to produce more to make up for it. Having a packing line fully optimised is one easy way to ensure energy efficiency and waste reduction.

How does the PROcheck lifecycle approach integrate with existing equipment in cement plants?
One of the many benefits of PROcheck lifestyle approach is that it can be integrated into the cement plant’s processes at any time. The first step to a full PROcheck is the Plant Optimisation Plan where an engineer comes to visit the plant and assess the technology, packing line and product being produced. No matter what technology is currently in use, our engineers provide a full report addressing any concerns and suggesting updates.

What trends in bagging, packaging, and palletising are shaping the cement industry?
Sustainability and automation are prime motivators for the cement industry right now. Whether that’s completely automating processes to increase efficiency or using electric equipment to cut down on carbon emissions, cement producers want to be able to produce better quality cement with more technologically advanced equipment.
The industry has seen a huge push toward automation in many places around the world. However, the main pushback against automation is budget. Budgetary restrictions are universal and often hold cement plants back from taking the plunge. We recognise this need and have started working with The Portland Company to provide Assemble to Order packing equipment with introductory automation that helps plants start their journey with plenty of room to expand into more customised equipment with us later. This ensures that all operations, no matter where in the world they’re located, can get an automated option suited for their unique packing line and access best-in-class service.

How does POP (and BOP) ensure optimal coordination of machines, bags, and products?
A POP includes a full plant audit that considers all areas, from product storage and handling to packing, bag transport, palletising and loading lines as well as surrounding machines and environmental factors. The goal of the report is to give plant managers a thorough, solid idea of how their plant is currently performing and where critical updates need to be made. The full POP, including the BOP, considers machines, bags and products to give an overarching recommendation on how all of them can work together for the best results.
The HAVER & BOECKER Institute completes the BOP, checking the chemical composition of the product, how the machine can aerate the product for maximum efficiency in filling and which bags provide the best protection for that specific product. The goal is to have a cohesive packing line that works together in the most efficient way possible.

What new innovations or upgrades are you introducing to improve packing plant performance?
Our newest products are meant to continually improve the packing line and provide the best support possible throughout the packing process. One major update we’ve introduced is the AMICUS Advanced Robot Family. The AMICUS DEPAL Edition depalletises bags and places them on an automatic bag applicator while the AMICUS PAL Edition palletises bags, boxes, drums and pails for transport. The AMICUS DEPAL replaces a previously manual process and increases safety, which is one of the major benefits of the system. If a facility invests in both an AMICUS PAL and DEPAL, they can create a fully automated packing line from empty to full bag.
Another optimisation HAVER & BOECKER is focused on is the unique ADAMS® Technology. ADAMS® is the system for packing cement into PE bags, offering an unlimited list of advantages. There has been rapid growth in the way ADAMS® is used, including how it has expanded into the cement sector. The FFS film bags used with the ADAMS® ROTO-PACKER protect powder cement from the elements while in transit and in storage. The waterproof, weatherproof bags offer a variety of benefits to all the industries we touch, which is an exciting expansion of our pre-existing line.

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Concrete

Condition-based maintenance avoids over-servicing

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JayaKrishna Kokku, Lead – Technical Operations, APAC & Middle East, Nanoprecise Sci Corp shares how their AI-powered IoT solution boosts productivity and sustainability in dusty cement plants through predictive maintenance. Read the full interview to learn more.

In an industry where dust, heat and vibration constantly challenge the health of critical equipment, predictive maintenance is fast becoming a game-changer. In this conversation, JayaKrishna Kokku, Lead – Technical Operations, APAC & Middle East, explains how Nanoprecise’s IoT solution is tackling the harsh realities of cement environments, delivering real-time equipment insights, accurate Remaining Useful Life (RUL) predictions and ensuring longer asset life and fewer costly breakdowns.

How does Nanoprecise IoT solution tackle equipment monitoring challenges in dusty cement plant environments?
Its wireless sensors are rugged, IP68 rated, and can reliably operate in high-dust environments without degradation. These sensors continuously monitor vibration, temperature, acoustic signals, humidity, Magnetic flux and RPM on critical rotating equipment. Data is transmitted securely to the cloud, enabling continuous, remote asset health monitoring, even in areas difficult for human inspection.

What role does your AI-driven analytics platform play in improving operational efficiency in cement plants?
The AI-driven analytics platform from Nanoprecise processes sensor data using advanced machine learning and physics-based algorithms. It detects early signs of component degradation (e.g., bearing faults, misalignment, imbalance) and provides actionable insights. By identifying potential failures weeks or months in advance, the platform allows cement plant operators to shift from reactive to proactive maintenance.

How do accurate RUL (Remaining Useful Life) insights help cement manufacturers optimise maintenance and reduce downtime?
Nanoprecise RUL predictions are powered by AI models that analyse sensor data fault trends over time. By accurately forecasting how long a component or system will function before failure, maintenance teams can plan interventions only, when necessary, rather than on fixed schedules. This minimises unnecessary maintenance, avoids catastrophic breakdowns, and ensures spare parts and labour are optimally allocated—drastically reducing both planned and unplanned downtime.

Can predictive maintenance be using your technology boost productivity while lowering operational disruptions?
Absolutely! Predictive maintenance enabled by Nanoprecise technology provides early fault detection and automated diagnostics, ensuring that equipment is always in optimal working condition. By addressing issues before they escalate, plants can maintain continuous operations, increase equipment uptime, and reduce the risk of costly shutdowns.

How does your solution support both productivity and sustainability goals in cement manufacturing?

  • Reduced Energy Waste: Equipment running inefficiently consumes more energy. Early detection of faults ensures machines run optimally, reducing unnecessary energy usage.
  • Lower Carbon Emissions: Improved efficiency and reduced downtime mean lower emissions per ton of cement produced.
  • Extended Equipment Life: Condition-based maintenance avoids over-servicing, extending the life of components and reducing waste.

Together, these benefits support sustainable operations without compromising output.

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