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Embracing technology tools

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Indian cement industry has been a bit conservative in adopting new technologies. However, the adoption of digital technologies is having a major impact on cement production.

Companies worldwide are relying on emerging technologies more than ever to help drive innovation, strategy, growth and increase competitive advantage. Technology has become a crucial and indispensable part of almost every kind of business. Without the role of technology in business, many businesses simply could not survive. Just imagine a multinational organisation or a small business enterprise trying to operate without the use of a telephone or computer – or even the Internet. Today IT and technology have become two sides of the same coin.

Technology in business allows organisations to improve both the performance and overall effectiveness of products, systems and services, which, in turn, enables businesses to expand quickly and efficiently. Technology has a wide range of potential effects on management, as well as various ways it can impact the operations, productivity, profitability and sustainability of an organisation.

ERP
Enterprise Resource Planning (ERP) platform is a software package designed to support and integrate almost every functional area of a business process such as procurement of goods and services, sales and distribution, finance, accounting, human resource, manufacturing, production planning, logistics and warehouse management. Today many cement companies are using ERP platforms for effective management control. With the advent of the internet and management information systems, businesses have been able to transform from local to global. In order to keep up with competition as a result of internet commercialisation, companies are increasingly turning to information technology, or hardware, software and telecommunications networks, to streamline services and boost performance. As such, IT has become an essential feature in the business landscape.

IT streamlines communication
Efficient and effective communication is critical to company success. A key advantage of information technology lies in its ability to streamline communication both internally and externally. This has given businesses unparalleled access to customers & consumers, enabling organisations to deliver new and enhanced products.

For example, online meeting and video conferencing platforms such as Skype, Zoom and GoToMeeting provide businesses the opportunity to collaborate virtually in real-time, significantly reducing costs associated with bringing clients on-site or communicating with staffs who work remotely. In addition, IT allows organisations to connect almost effortlessly with international suppliers and consumers. All of us aware that this was more pronounced in the period of lockdown.

Although IT may seem expensive when first implemented, in the long run, however, it becomes incredibly cost-effective by streamlining a company’s operational and managerial processes. The implementation of online training programs is a classic example of IT improving an organisation’s internal processes by reducing costs and employee time spent outside of work. In effect, IT enables companies to do more with less, without sacrificing quality or value.

Let us now cover of some typical applications of technologies in cement industry: Use of ERP packages is quite common in multi-unit and widely spread cement groups. Jitendra Singh, CIO of JK Cement, said "companies are deriving benefits from such kind of implementations." A few more examples of UltraTech, ACC, Ambuja and Shree cement can be given.

Mine planning: Mine planning can be defined as the process of optimising the exploitation of mineral reserves for maximum added value aligned with the strategic goals and objectives of the business enterprise. A virtual 3D model of a mine can be created that is used for day today operation and extraction of material.

Of late, mining equipment are fitted with GPS based navigator, which provides access to the supplier of equipment who keeps tab on use or abuse of the machine even from distance and provides online service in case of breakdown. The mining industry in Australia is using driverless trucks and trains to transport the ore from mine to port for further shipment that involves the least human intervention. Driverless cars are just one of the many incredible technologies that are likely to be ushered in with 5G technology much talked about in telecom sector.

Use of drones in the mining sector is farfetched for us, may be due to lack of suitable policy. This technology once adopted is going to find several applications not only mines but also in other areas.

Plant operations: There are a number of software packages as standard or customised available depending on the requirement that can be deployed by plant management either for process optimisation and optimisation of specific a process parameter. Companies like ABB, thyssenkrupp or Schneider have been referred in this edition little more in details.

Plant maintenance: Either these can be used from ERP platform or there can be a dedicated one associated with an equipment e.g. VRM gets a software package for monitoring its performance. These packages have access to the suppliers who can remotely get connected and solves the problem.

Quality control: There is a great opportunity in the Indian cement industry for the use of technology in this area. Typical spread of a cement plant being huge and the sample collection points are at a fairly long distance, collection to be done in odd hours. This necessitated going for robotic labs. All most all recently commissioned plants in the last five years have robotic labs. We strongly feel that even older plants need to go for robotic sample collections over manual.

The other major breakthrough can be achieved is availability of real time test results. In QC labs the results are available after the material is packed. However if results are delivered when material is in process, corrective actions are possible. Procurement: The ERP platform as referred above is extremely useful for procurement as well as managing the finance including payment to vendors in a very transparent way. It has a separate sales module that gives flexibility to sales force in managing sales function.

Logistics: Truck and wagon loading is part of logistics where there is very wide scope to use contemporary technologies that includes use of RFID and GPS tracking for faster movement of trucks. In our one of earlier issues we had covered how Shree cement has reduced logistic cost by using technology.

Training: Machine learning and artificial intelligence (AI) are best used in imparting training on some of complex processes like burning and kiln operation. More and more use of technology is going to be there for training. Virtual reality and AI are two more examples of the breakthroughs that we can expect once the data network catches up with technological advancement.

CCTV: The job of keeping vigilance, crime detection has been made easy by use of close circuit television that is further enhanced by use of internet coupled with digital signals. Even at plant level after introduction of CCTV systems, the jobs have not only become easy but efficient and quick.

Security: As the use of internet and digital modes will increase, the users will have to ensure safe practices to avoid unlawful use. More care needs to be taken while doing financial transactions.

Slow in AFR: There are several reasons why Indian Cement Industry is still lagging in use of alternate fuels. One of the major one is lack of suitable technology support. CFD: We have covered more on this subject in greater details as a part of cover story. It is a new technique to solve problems using computer simulation packages. The inputs are quite informative.

e-commerce business: The article can’t be completed without a reference to e-commerce business. We, all are going to witness phenomenal rise in various sectors of E commerce business that will include business procurement. Let us keep our fingers crossed until 5G is rolled out in our country. Similarly e-commerce also will spread its wings in business procurement in the same way as Ola and Uber have done it urban mobility.

Use of technology is touching every function in cement production and sale. But in India, typically being a populous country, labour is a cheap input in manufacturing and it always becomes a hurdle in accepting new technologies on commercial yardsticks.

– VIKAS DAMLE

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Concrete

We consistently push the boundaries of technology

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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)

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Concrete

FORNNAX Technology lays foundation for a 23-acre facility in Gujarat

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FORNNAX Technology, a leading manufacturer of recycling equipment in India, has marked a major milestone with the Groundbreaking (Bhoomi Pujan) ceremony for its expansive 23-acre manufacturing facility in Gujarat. Specialising in high-capacity shredders and granulators, FORNNAX is strategically positioning itself as a global leader in the recycling industry. The new plant aims to produce 250 machinery units annually by 2030, making it one of the largest manufacturing facilities in the world.
The foundation stone for this ambitious project was laid by Jignesh Kundaria, CEO and Director, alongside Kaushik Kundaria, Director. The ceremony was attended by key leadership members and company staff, signifying a new chapter for FORNNAX as it meets the growing demand for reliable recycling solutions. Speaking on the occasion, Jignesh Kundaria stated, “This marks a historic moment for the recycling sector. Our high-quality equipment will address various waste categories, including tyre, municipal solid waste (msw), cables, e-waste, aluminium, and ferrous metals. this facility will strengthen our global presence while contributing to India’s Net Zero emissions goal by 2070.”
FORNNAX is actively expanding its footprint in critical markets such as Australia, Europe and the GCC, forging stronger sales and service partnerships. The facility will house an advanced Production Department to ensure seamless manufacturing.

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Concrete

Decarbonisation is a focus for our R&D effort

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Dyanesh Wanjale, Managing Director, Gebr. Pfeiffer discusses the need to innovate grinding technologies to make the manufacturing process more efficient and less fuel consuming.

Gebr. Pfeiffer stands at the forefront of grinding technology, delivering energy-efficient and customised solutions for cement manufacturers worldwide. From pioneering vertical roller mills to integrating AI-driven optimisation, the company is committed to enhancing efficiency and sustainability. In this interview, we explore how their cutting-edge technology is shaping the future of cement production.

Can you tell us about the grinding technology your company offers and its role in the cement industry?
We are pioneers in grinding technology, with our company being based in Germany and having a rich history of over 160 years, a milestone we will celebrate in 2024. We are widely recognised as one of the most efficient grinding technology suppliers globally. Our MBR mills are designed with energy efficiency at their core, and for the past five years, we have been focused on continuous improvements in power consumption and reducing the CO2 footprint. Innovation is an ongoing process for us, as we strive to enhance efficiency while supporting the cement industry’s sustainability goals. Our technology plays a critical role in helping manufacturers reduce their environmental impact while improving productivity.

The use of alternative fuels and raw materials (AFR) is an ever-evolving area in cement production. How does your technology adapt to these changes?
Our vertical roller mills are specifically designed to adapt to the use of alternative fuels and raw materials. These mills are energy-efficient, which is a key advantage when working with AFR since alternative fuels often generate less energy. By consuming less power, our technology helps bridge this gap effectively. Our solutions ensure that the use of AFR does not compromise the operational efficiency or productivity of cement plants. This adaptability positions our technology as a vital asset in the industry’s journey toward sustainability.

What are some of the challenges your company faces, both in the Indian and global cement industries?
One of the major challenges we face is the demand for expedited deliveries. While customers often take time to decide on placing orders, once the decision is made, they expect quick deliveries. However, our industry deals with heavy and highly customised machinery that cannot be produced off the shelf. Each piece of equipment is made-to-order based on the client’s unique requirements, which inherently requires time for manufacturing.
Another significant challenge comes from competition with Chinese suppliers. While the Indian cement industry traditionally favoured our technology over Chinese alternatives, a few customers have started exploring Chinese vertical roller mills. This is concerning because our German technology offers unmatched quality and longevity. For example, our mills are designed to last over 30 years, providing a long-term solution for customers. In contrast, Chinese equipment often does not offer the same durability or reliability. Despite the cost pressures, we firmly believe that our technology provides superior value in the long run.

You mentioned that your machinery is made-to-order. Can you elaborate on how you customise equipment to meet the specific requirements of different cement plants?
Absolutely. Every piece of machinery we produce is tailored to the specific needs of the customer. While we have standard mill sizes to cater to different capacity requirements, the components and configurations are customised based on the client’s operational parameters and budget. This process ensures that our solutions deliver optimal performance and cost efficiency. Since these are heavy and expensive items, maintaining an inventory of pre-made equipment is neither practical nor economical. By adopting a made-to-order approach, we ensure that our customers receive machinery that precisely meets their needs.

The cement industry is focusing not only on increasing production but also on decarbonising operations. How does your company contribute to this dual objective, and how do you see this evolving in the future?
Decarbonisation is a key focus for our research and development efforts. We are continuously working on innovative solutions to reduce CO2 emissions and improve overall sustainability. For example, we have significantly reduced water consumption in our processes, which was previously used extensively for stabilisation. Additionally, we are leveraging artificial intelligence to optimise mill operations. AI enables us to monitor the process in real-time, analyse feedback, and make adjustments to achieve optimal results within the given parameters.
Our commitment to innovation ensures that we are not only helping the industry decarbonise but also making operations more efficient. As the cement industry moves toward stricter sustainability goals, we are confident that our technology will play a pivotal role in achieving them.

Can you provide more details about the use of digitalisation and artificial intelligence in your processes? How does this improve your operations and benefit your customers?
Digitalisation and AI are integral to our operations, enabling us to offer advanced monitoring and optimisation solutions. We have developed three distinct models that allow customers to monitor mill performance through their computer systems. Additionally, our technology enables real-time feedback from our German headquarters to the customer. This feedback highlights any inefficiencies, such as when a parameter is outside the optimal range,
and provides actionable recommendations to address them.
By continuously monitoring every parameter in real time, our AI-driven systems ensure that mills operate at peak efficiency. This not only enhances production but also minimises downtime. I am proud to say that our mills have the lowest shutdown rates compared to other manufacturers. This reliability, combined with the insights provided by our digital solutions, ensures that customers achieve consistent and efficient operations. It’s a game-changer for reducing costs and enhancing overall productivity.

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