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The next-gen packing

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As a global machine manufacturer, Lohia can offer machines for making bag of both types, i.e. unlaminated pillow type and laminated block bottom type.

Indian cement industry is facing issue of seepage of cement from uncoated bags, which is currently used around 80 per cent in packing of 50 kg cement. At present, the cement manufacturers are using similar packaging sack for the costlier product along with grey cement (pillow type bag). But, in the last few years, many of the cement manufacturers have started using Block bottom valve laminated sacks instead of regular pillow type woven sacks.

For instance, block bottom valve sacks or laminated PP bags with micro-perforation are considered as premium packaging products at an extra cost. Also, the manufacturers have freedom of choices in terms of getting branding and visibility as these sacks (block bottom valve laminated sacks) allow printing of high-quality graphics. The other factors that are propelling the change of pillow type bag to block bottom bag (laminated) in cement packaging are better quality and consistent end-use performance, the possibility to reduce the loss of cement during handling, transportation and storage and the increased compliance with government policies of large public interest related to health, safety, pollution- control and environmental protection including reuse and recycling of discarded sacks.

For the packaging of cement two BIS standards are given to maintain specification and requirements:

IS 11652:2017: Textile-high-density polyethylene HDPE/ Polypropylene PP woven sack for packaging of 50 kg cement-specification third revision
IS 16709:2017: Textile-polypropylene PP weaved laminated block bottom valve sacks for packaging of 50 kg cement- specification.

Ways of packaging of cement
Cement packaging is done in following ways:
50kg valve woven bags: 80 per cent of production is packed in 50 kg valve cement bags
Bulk containers: These are used for packaging large volumes

Lohia as a global manufacturer
As a global machine manufacturer, Lohia can offer machines for making bag of both types, i.e. unlaminated pillow type and laminated block bottom type. Cement companies and bag producers have to invest more as a capital investment in machines, but the investment has worth seeing environmental and human health issues due to cement dust oozing from uncoated bag. Today, the company has a full range of machinery in each of the technology vertical to cover almost the complete range of end use application of the plastic woven fabric.

Machines required for making cement bags:
Tape extrusion line:
We offer a comprehensive range of tape extrusion lines for producing high quality PP/HDPE tapes for a wide range of applications, such as G?? woven and knitted bags, jumbo bags i.e. flexible Intermediate Bulk Containers (FIBCs), carpet backings, tarpaulins, geo textiles, agro textiles, wrapping fabrics, ropes and twines. Our tape extrusion lines come in two distinct series, LOREX and duotec. The LOREX series is based on the conventional single stage stretching system while the duotec series uses a unique double stage stretching system.

Duotec series tapeline have following advantages for Lorex series:high line speed at max. 600mpm, possible to use higher filler masterbatch without compromising tape quality, and patented technology.

Co-extrusion technology: New patented technology which produce coextruded three layer tapes enabling use of high filler MB/recycle in core layer. This will have following advantages: less tape breakage, lower dust and glossy appearance due to presence of outer layer with high polymer content recipe.

Tape winders: We offer a wide range of precision and step precision winding machines designed for winding flat or fibrillated PP/HDPE tapes across a multitude of specifications in terms of tape width and denier. The warp & weft bobbins produced can be used in both circular and flat looms. The winders are classified under three distinct series " CM/FM series, CE/FE series and autoroto series.

Circular looms: Lohia Corp offers a comprehensive range of circular looms for weaving light to heavy weight tubular or flat PP/HDPE fabrics for a wide variety of end applications. Our looms are available under four distinct machine models: nova, LSL, LENO and venti.

Coating machine: Lohia’s lamicoat is designed for efficient and precise coating operations on tubular or flat PP/HDPE woven fabric. Both PP & LDPE polymer coating is possible, as is the simultaneous coating of both sides of tubular fabric, in a single operation. Coupling of an unwinding station to the standard machine, for additional substrates like BOPP film etc for lamination operations, is also possible.

Printing machine: Soloprint, Flexographic Printing Press combines Lohia Corp’s domain expertise with the technological capabilities of Pelican Rotoflex. This 6 colour printing press, equipped with new generation electronics, is distinctively designed and precisely machined for an accurate and dependable performance over its long life.

Bag conversion lines: Lohia Corp’s bag conversion line consists of machines which provide solutions for conversion of a wide variety of tubular fabrics into bags.

Different technologies are available to produce bags depending on their end use as well as the type of fabric. Our conversion line consists of two distinct machines, the Lohia bcs 850/45, bcs 1250/45 for making normal bags and the Lohia valvomatic & blokomatic for making valve type cement bags.

Valvomatic: Lohia Corp presents Valvomatic used for making pillow type valve bag in the cement industry, a one of a kind valve bag making machine that performs multiple operations in a single automated setup. More than 40,000 valve bags per day, which are perfect in terms of dimensional consistency and accuracy can be produced. This is also patented technology of Lohia and supplied more than 250 Machines to the market and many more to supply.

Lohia offers two types of machine i.e. one for cement bags and another is wider width machine which enables to process wide width bags to cater the market demand.Advantages of using Valvomatic over manual conversion: accurate valve dimensions, automatic conversion to valve type bags, saves material, manpower and less space requirement.

Constraints in manual conversion are no consistency in manpower as they are not available in harvesting and festive season, land area requirement is high in manual working, less bag dimensional accuracy and igher production cost.

Blokomatic: One of the most innovative technology "blokomatic" launched by Lohia Corp during K 2019 exhibition. We received impressive and remarkable feedback from visitors during the exhibition. Blokomatic is a high speed, reliable, efficient and fully automatic machine for conversion of laminated polypropylene woven fabric into block bottom valve bags without application of adhesive. The machine is provided with latest control engineering and high quality mechanical and electrical parts. This machine can run up to max. 120 bags per minute.

One of the major USPs of Blokomatic is automatic fabric inspection system. This is a revolutionary concept patented by Lohia to inspect fabric quality on some predefined parameters prior to final bag manufacturing. This avoids the production of rejected bags due to bad fabric quality and reduces the overall wastage. This system is installed in fully automatic valve block bottom bag manufacturing machine "Blokomatic". The fabric inspection is done online before the cutting of the fabric and defected fabric cuts are ejected during the running of the machine.

Block bottom bags are ideal for automated filling and packaging cement and act as a better substitute to paper bags. The rectangular-shaped BOPP Woven Block Bottom bags are produced without adhesives by heat- welding of the coating on the fabric. Being moisture- resistant and environment-friendly is the major advantage of these bags. The oozing of material from the bag which results in almost no pollution.

By Anvita Sarkari of Lohia Machines.

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Price hikes, drop in input costs help cement industry to post positive margins: Care Ratings

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Region-wise,the southern region comprises 35% of the total cement capacity, followed by thenorthern, eastern, western and central region comprising 20%, 18%, 14% and 13%of the capacity, respectively.

The cement industry is expected to post positive margins on decent price hikes over the months, falling raw material prices and marked drop in overall production costs, said an analysis of Care Ratings.

Wholesale and retail prices of cement have increased 11.9% and 12.4%, respectively, in the current financial year. As whole prices have remained elevated in most of the markets in the months of FY20, against the corresponding period of the previous year.

Similarly, electricity and fuel cost have declined 11.9% during 9M FY20 due to drop in crude oil prices. Logistics costs, the biggest cost for cement industry, has also dropped 7.7% (selling and distribution) as the Railways extended the benefit of exemption from busy season surcharge. Moreover, the cost of raw materials, too, declined 5.1% given the price of limestone had fallen 11.3% in the same aforementioned period, the analysis said.

According to Care Ratings, though the overall sales revenue has increased only 1.3%, against 16% growth in the year-ago period, the overall expenditure has declined 3.2% which has benefited the industry largely given the moderation in sales.

Even though FY20 has been subdued in terms of production and demand, the fall in cost of production has still supported the cement industry by clocking in positive margins, the rating agency said.

Cement demand is closely linked to the overall economic growth, particularly the housing and infrastructure sector. The cement sector will be seeing a sharp growth in volumes mainly due to increasing demand from affordable housing and other government infrastructure projects like roads, metros, airports, irrigation.

The government’s newly introduced National Infrastructure Pipeline (NIP), with its target of becoming a $5-trillion economy by 2025, is a detailed road map focused on economic revival through infrastructure development.

The NIP covers a gamut of sectors; rural and urban infrastructure and entails investments of Rs.102 lakh crore to be undertaken by the central government, state governments and the private sector. Of the total projects of the NIP, 42% are under implementation while 19% are under development, 31% are at the conceptual stage and 8% are yet to be classified.

The sectors that will be of focus will be roads, railways, power (renewable and conventional), irrigation and urban infrastructure. These sectors together account for 79% of the proposed investments in six years to 2025. Given the government’s thrust on infrastructure creation, it is likely to benefit the cement industry going forward.

Similarly, the Pradhan Mantri Awaas Yojana, aimed at providing affordable housing, will be a strong driver to lift cement demand. Prices have started correcting Q4 FY20 onwards due to revival in demand of the commodity, the agency said in its analysis.

Industry’s sales revenue has grown at a CAGR of 7.3% during FY15-19 but has grown only 1.3% in the current financial year. Tepid demand throughout the country in the first half of the year has led to the contraction of sales revenue. Fall in the total expenditure of cement firms had aided in improving the operating profit and net profit margins of the industry (OPM was 15.2 during 9M FY19 and NPM was 3.1 during 9M FY19). Interest coverage ratio, too, has improved on an overall basis (ICR was 3.3 during 9M FY19).

According to Cement Manufacturers Association, India accounts for over 8% of the overall global installed capacity. Region-wise, the southern region comprises 35% of the total cement capacity, followed by the northern, eastern, western and central region comprising 20%, 18%, 14% and 13% of the capacity, respectively.

Installed capacity of domestic cement makers has increased at a CAGR of 4.9% during FY16-20. Manufacturers have been able to maintain a capacity utilisation rate above 65% in the past quinquennium. In the current financial year due to the prolonged rains in many parts of the country, the capacity utilisation rate has fallen from 70% during FY19 to 66% currently (YTD).

Source:moneycontrol.com

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Wonder Cement shows journey of cement with new campaign

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The campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV…

ETBrandEquity

Cement manufacturing company Wonder Cement, has announced the launch of a digital campaign ‘Har Raah Mein Wonder Hai’. The campaign has been designed specifically to run on platforms such as Instagram, Facebook and YouTube.

#HarRaahMeinWonderHai is a one-minute video, designed and conceptualised by its digital media partner Triature Digital Marketing and Technologies Pvt Ltd. The entire journey of the cement brand from leaving the factory, going through various weather conditions and witnessing the beauty of nature and wonders through the way until it reaches the destination i.e., to the consumer is very intriguing and the brand has tried to showcase the same with the film.

Sanjay Joshi, executive director, Wonder Cement, said, "Cement as a product poses a unique marketing challenge. Most consumers will build their homes once and therefore buy cement once in a lifetime. It is critical for a cement company to connect with their consumers emotionally. As a part of our communication strategy, it is our endeavor to reach out to a large audience of this country through digital. Wonder Cement always a pioneer in digital, with the launch of our IGTV campaign #HarRahMeinWonderHai, is the first brand in the cement category to venture into this space. Through this campaign, we have captured the emotional journey of a cement bag through its own perspective and depicted what it takes to lay the foundation of one’s dreams and turn them into reality."

The story begins with a family performing the bhoomi poojan of their new plot. It is the place where they are investing their life-long earnings; and planning to build a dream house for the family and children. The family believes in the tradition of having a ‘perfect shuruaat’ (perfect beginning) for their future dream house. The video later highlights the process of construction and in sequence it is emphasising the value of ‘Perfect Shuruaat’ through the eyes of a cement bag.

Tarun Singh Chauhan, management advisor and brand consultant, Wonder Cement, said, "Our objective with this campaign was to show that the cement produced at the Wonder Cement plant speaks for itself, its quality, trust and most of all perfection. The only way this was possible was to take the perspective of a cement bag and showing its journey of perfection from beginning till the end."

According to the company, the campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV. No other brand in this category has created content specific to the platform.

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In spite of company’s optimism, demand weakness in cement is seen in the 4% y-o-y drop in sales volume. (Reuters)

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Cost cuts and better realizations save? the ?day ?for ?UltraTech Cement, Updated: 27 Jan 2020, Vatsala Kamat from Live Mint

Lower cost of energy and logistics helped Ebitda per tonne rise by about 29% in Q3
Premiumization of acquired brands, synergistic?operations hold promise for future profit growth Topics

UltraTech Cement
India’s largest cement producer UltraTech Cement Ltd turned out a bittersweet show in the December quarter. A sharp drop in fuel costs and higher realizations helped drive profit growth. But the inherent demand weakness was evident in the sales volumes drop during the quarter.

Better realizations during the December quarter, in spite of the 4% year-on-year volume decline, minimized the pain. Net stand-alone revenue fell by 2.6% to ?9,981.8 crore.

But as pointed out earlier, lower costs on most fronts helped profitability. The chart alongside shows the sharp drop in energy costs led by lower petcoke prices, lower fuel consumption and higher use of green power. Logistics costs, too, fell due to lower railway freight charges and synergies from the acquired assets. These savings helped offset the increase in raw material costs.

The upshot: Q3 Ebitda (earnings before interest, tax, depreciation and amortization) of about ?990 per tonne was 29% higher from a year ago. The jump in profit on a per tonne basis was more or less along expected lines, given the increase in realizations. "Besides, the reduction in net debt by about ?2,000 crore is a key positive," said Binod Modi, analyst at Reliance Securities Ltd.

Graphic by Santosh Sharma/Mint
What also impressed analysts is the nimble-footed integration of the recently merged cement assets of Nathdwara and Century, which was a concern on the Street.

Kunal Shah, analyst (institutional equities) at Yes Securities (India) Ltd, said: "The company has proved its ability of asset integration. Century’s cement assets were ramped up to 79% capacity utilization in December, even as they operated Nathdwara generating an Ebitda of ?1,500 per tonne."

Looks like the demand weakness mirrored in weak sales during the quarter was masked by the deft integration and synergies derived from these acquired assets. This drove UltraTech’s stock up by 2.6% to ?4,643 after the Q3 results were declared on Friday.

Brand transition from Century to UltraTech, which is 55% complete, is likely to touch 80% by September 2020. A report by Jefferies India Pvt. Ltd highlights that the Ebitda per tonne for premium brands is about ?5-10 higher per bag than the average (A cement bag weighs 50kg). Of course, with competition increasing in the arena, it remains to be seen how brand premiumization in the cement industry will pan out. UltraTech Cement scores well among peers here.

However, there are road bumps ahead for the cement sector and for UltraTech. Falling gross domestic product growth, fiscal slippages and lower budgetary allocation to infrastructure sector are making industry houses jittery on growth. Although UltraTech’s management is confident that cement demand is looking up, sustainability and pricing power remains a worry for the near term.

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