Technology
Environmentally Sustainable Mining Practices In India
Published
6 years agoon
By
admin
Sustainability has assumed considerable importance in developed countries which are extensively involved in mining practices, like Australia, Canada, USA, South Africa and Papua New Guinea etc. They take comprehensive view of sustainable development in mining which includes important dimensions such as local stakeholder engagement, socio-economic development in mining project areas and transparency in communication with the stakeholders, along with environment. These developed nations undertake mining activities with all compliances to regulatory requirements and environmental laws leads to lessen the impact of mining and strictly implement it. These compliances include provisions for mine closure and associated reclamation and rehabilitation of mined land.
In India, major mining companies have taken steps for socio-economic development projects in their mining areas. The Indian mineral industry comprises of large and small mines that are covered under public, private and informal sectors, covering most minerals being extracted. The public sector continues to play a dominant role in production of various major minerals (like coal, lignite, petroleum, iron and steel, bauxite and aluminium) where as a large number of small mines (including quarries for extracting minor minerals) operated by private players in most states. These present difficult challenges for sustainable development as their financial, technical and managerial limitations restrict their ability to take effective corrective measures against the negative impacts of mining.
Major mining companies uses advanced technology, adopt comprehensive environment protection measures, sensitise their personnel on sustainability issues and progressively try to improve their environmental performance. There are other large, medium and even small companies whose environment obligation consists in strictly conforming to the prescribed legal provisions. Major threats for adopting sustainable mining practices are illegal workings, where legal compliances are not observed to the fullest extent. It is reported that the illegal mining of sand is largely responsible for the environmental degradation especially the river beds of all major rivers including Ganga and Jamuna. There are only little checks for controlling illegal and rampant mining, whereas the political interference has turned the situation grim. Even legal mines flout norms and damage the environment considerably.
Concerns for environmentally sustainable mining
Today, the sustainable mining is the key to the security of raw materials and energy for many countries in the world. The sustainable development of mining of mineral resources is a major concern for today’s global world, addressed to mining companies, people of science associated with mining and many other institutions and organisations. Public awareness that the mineral resources are non-renewable assets, is, unfortunately, small and therefore improvements or changes to the situation in this area is another key concerns, it should be followed by concrete actions.
Modern mining, which is considered for negatively affecting the environment, and also causes discomfort for people living in mining areas or their immediate surroundings, must have the public acceptance for its activities. Thus, the real concern about the environment is becoming an important factor for obtaining such public acceptance. Mining in the twenty-first century, while striving for sustainable development, must provide employees with a safe working environment, therefore the problems regarding safety, due to its complexity, is a major challenge for mine operators. The trend of increasing the depth of mines, observed in the world, means that work safety is, and will continue to be a key area of concern for the sustainable development of the mining industry.
The complexity of the problems for the sustainable development of mining and the resulting diversity on a global scale point at the need for the continuous exchange of experience in the field of knowledge, methods, technologies and other solutions. They should provide a sustainable and socially acceptable development and continued operation of mining, invariably needed by people, to provide necessary mineral resources.
Objectives and Effects of sustainable mining practices –
There are several objectives of sustainable mining practices, which are interrelated and success will involve the issues most frequently linked to another. They can be summarised as follows:
Implementation of Sustainable Mining Practices –
Two major methods of implementing sustainable mining practices are – 1) Good governance from Global, Central & State Government bodies resulting in effective laws and regulations for implementation –
Every now and then, the various Government bodies, judiciary systems of India has shown their concerns over bad mining practices and not following sustainable approach. Also efforts are being made by them to implement these mining practices for betterment for eco-system.
At global level, the heads of 193 UN member states prepared a set of 17 Sustainable Development Goals (SDGs), which is for global development framework available for the society and generations. Mining companies have the potential to become leading partners in achieving the SDGs. Through their direct operations, mining companies can generate profits, employment, and economic growth in low-income countries. And through partnerships with government and civil society, they can ensure that benefits of mining extend beyond the life of the mine itself, so that the mining industry has a positive impact on the natural environment, climate change, and social capital.
At the same time, mining companies will be called on to extract with responsibility, produce with less waste, use safer processes, incorporate new sustainable technologies, promote the improved wellbeing of local communities, curb emissions, and improve environmental stewardship. Mining companies committed to the SDGs will benefit from improved relationships with governments and communities and better access to financial resources; those that fail to engage meaningfully with the SDGs will put their operations at risk in the short and long term.
Based on interviews with over 60 global experts from industry, civil society, governments, academia, and financial institutions, the report identifies where sustainable mining practices can enhance the positive impacts it has and mitigate the negative impacts across the 17 SDGs (see figure below).
A Planning Commission report from 2012 titled "Sustainable Development, Emerging issues in India’s mineral sector" observed that in the mineral-rich states of Odisha, Goa, Karnataka and Jharkhand, mining has brought about economic development. At the same time, it has caused significant environmental damages and negatively impacted communities in project areas. To that extent the mining and environmental laws and regulations have not been very effective.
As per the report published by NITI Ayog in 2017 on "Socio Economic Impact Study of Mining and Mining Polices on the Livelihoods of Local Population" has mentioned that mining is considered as one of the necessary evils of the modern world, which provides the materials required to sustain quality of life. While improving the quality of life and giving an impetus to economic development, it has also brought in its wake, a notable impact on the environment as well as socio-economic conditions of local people (Vagholikar and Moghe, 2003).The proposed mining areas and activities have been severely criticized by environmentalists and social activists, on the subjects of potential loss of forests and displacement of villages as the mines increase in number and size of operations. Insufficient attention to managing impacts on the environment and the socio-economic fabric observed in the past, has reflected adversely on public support for reform and private investment needed for accelerating growth in the state.
The most important environmental requirement for a mining project is a comprehensive environment assessment (EIA) programme, which was started in 1994. However, laws and regulatory instruments work unsatisfactorily due to weak enforcement and inadequate coordination among government agencies. Although mining companies tend to meet the legal requirement of preparing a mine closure plan, the implementation falls short. Local communities are not consulted in the preparation and implementation of mine closure plans.
The New Mineral Policy, 2019 has also been focused on main theme of mining being environmentally sustainable, we are going to explore those very efforts, which will answer the very question, and could mining activities ever become environmentally sustainable for both environment and our health?
The answer is, it very much possible to make mining more environmentally sustainable, there are few practices being followed across international mines, which can be implemented at Indian Mines to minimise environment pollution. All we have to do is to develop and integrate these practices that reduce environmental effects resulting from mining operations. Sustainable mining practices is basically mining practices that meets the present demand without compromising the future generation’s needs. In the process, the advent of new mining methods, tools, regulation and legislation, significant efforts are helpful to make mining more environmentally friendly.
2) Self-regulating mining enterprises which are economically viable, financially profitable and technically efficient i.e. innovative mining practices and use of technologies –
There are prime responsibility of mining companies towards the implementation of the principles of sustainability for mining. It has applications for all stages of the mine life cycle, i.e., starting from exploration, mine planning, development, mineral extraction to mine closure, post-closure reclamation and rehabilitation. These principles include elements such as intra and inter-generational equity, the precautionary principle, scientific mining, management of environmental and socio-economic impacts, creation of substitute capital in the form of social and physical infrastructure and most importantly stakeholder engagement..
In some cases, mining operations have been executed without concerning for the "carrying capacity"of the environment and other infrastructural limitations of the surroundings of the mine site. This has put unavoidable pressure on the environment and caused inconvenience to the people living alongside mining areas. Illegal mining in many cases has similar effect while additionally causing loss of public revenues. The mineral extraction and processing release several toxic materials, contaminating the soil and water which leads to deforestation and ground water degradation. Mineral extraction has also disproportionately affected health of forest ecosystems and the surrounding environment and furthermore the tribes as well as the forest dwelling populations are also adversely affected. However, the mining and mineral sectors are perceived to have failed to alleviate poverty for these vulnerable populations around the forest areas. Thus, the impacts of mining and mines upon natural ecosystems, biodiversity and tribal livelihoods have become a key environmental concern and source of conflict and socioeconomic tension.
Most of work done by mining industry to protect environment and address social concerns has not been received due attention of the Government, media and society. In spite of the fact that, their efforts of sustainable mining practices and operations, few NGOs and environmental protection agencies tries to malign all efforts based on stray incidents. With increasing stringent guidelines by the Governments to regulate mining and its impact, the mining industry has been relentlessly striving for not only achieving expectation of regulatory agencies, but also to exceed these and set international benchmarks. Mining companies are striving hard to contribute towards sustainable development of the country
To make mining environmentally friendly, few steps are suggested below, they are in regular discussion on various forums around the world. In India, mining companies can adopt these steps to achieve the goals of New Mineral Policy: –
Reclaimingof Materials used in worked out Mines and properly closing of the area-
This step involves usage of material from the old worked out mines, which affects the environment in a variety of ways, especially in its natural decaying, rotting and eroding processes, withal it can also lead to illegal or unregulated mining activity. This specially occurs in underground mines where support systems, cables, pipes etc, are left out with significant amount of ore, it decays and pollutes environment in a serious way. However, when these areas are adequately excavated, mining companies would find some materials that could be reused productively. In Opencast also, several waste materials like cables, pipes, etc, are left as is post mining and it is buried in mine overburden materials.
Every mining company has to research on these unused resources and materials throughout the mining process, to try and conserve its current "non-renewable" materials. Each company can form small decommissioning groups which study systems and the complete mining processing facilities and plants; this process will allow the pipelines to be drained, equipment and parts of the mine to be cleaned and sold off, the buildings can be repurposed or demolished, warehouse materials recovered and wasted disposed of. These groups then clean and sell off any remaining operational equipment and provided they are still structurally sound, repurpose the premises.
The main objective in reclaiming process is to return the site and the land which surrounds it back to reusable standards, ensuring that any landforms and structures are stable, and the watercourses need to be evaluated in order to regain water quality within the affected area.
This step needs the effective supervision during the process of mining and closure, its successful impacts on the environment could well be diluted through the re-use of materials that would have previously been left to decay.
Closing illegal and unregulated mines
In India, we find several illegal and unregulated mine which is operational. The New Mineral Policy 2019 has tried to curb these types of illegal mine workings. In context with enforcing regulations and maintaining steadfast legislation regarding the behaviour and processes of the mines,strict and swift closing of illegal or unregulated mining activity will set an environmental precedent within the industry.
For example, before 2010, most mines in China were completely unregulated which were affecting surrounding areas gravely. Details are mentioned in coming pages of this article, where effective steps taken by Chinese Government has helped in reducing the damage and provide a sustainable mining areas. Effective closing and reclamation of old mined out areas will significantly help in sustainable mining practices in and around the mineralised belts.
Accurate measurements and declaration of waste mining which creates pollution –
Mining companies always try to save face when it comes to the environmental conservation and try to hide the facts of actual pollution and maintain secrecy in reporting the toxic mining wastes produced by mining operations. These companies usually keep the public in the dark giving an accurate report of what’s being dumped into the environment and the various by not pollutants created by them.
New mineral Policy instructs to frame rules to recognise the actual pollution generated by mining companies; accordingly, a suitable step shall be taken to panelise these companies or to reduce pollution as much as possible, with suitable remedial measures to be suggested. Of course, strict penalties for violating companies have to be decided by State and Central Governments.
Use reusable waste to build and reuse/recycle of material –
At present ubiquitous, mining companies are discovering efficient ways to capitalize wholly on materials in order to provide sustainable goods and services. On the other hand, the society at large, wants to utilise less wood, metal, stone, plastic and other materials by adopting efficient practices.
One simple way is to start using reusable materials effectively while building new constructions and infrastructure affecting the surrounding environment of any mining. Recycling the metals from accumulated scrap and waste in landfills may be in some cases more economical than to mine ore deposits. For example, in 2008, the world steel industry produced over 1.3 billion tonnes of steel. It used 1.48 billion tons of raw materials, or 470 million tonnes less than, would have been needed to make the same volume of steel in the 1970s. Concerning aluminium, it is estimated that since 1880, approximately 900 million tons of aluminium were produced of which nearly 75% is still in use today. The demand for aluminium continues to skyrocket and recycling aluminium saves more than 90% of the energy required to producing new metal, thus rendering recycling very attractive. This scales down the amount of wasteful use on public and private level. Accordingly, mining companies can start use of durable goods that can be easily re-usable, re-manufactured, or recycled, undertaking environmentally sustainable practices will reduce its inimical impact. There are success stories in these re-usable material applications.
This creative and increasing trend of scrap mining, or utilizing ever-reusable resource for other mining initiatives, saves from the environmental hazards. It is necessary to find out each and every detail of each piece which is being used and generated in a mining site, which will help the mining industry to take suitable steps towards re-use, for becoming a more sustainable industry. For similar examples, we can use recycling of copper waste, which takes seven times less energy than processing of copper ore, and recycling steel which uses three-and-a-half times less energy than processing of iron ore. These small steps will help us immensely in determining not only the longevity of a sustainable mining practices and also have its positive environmental impact.
This article has been reproduced from CEMENT, ENERGY AND ENVIRONMENT, a Bi-Annual journal of Cement Manufacturers Association of India in its July-Dec’2019 Issue. Part II of the same will be published in the next month.
About the author – "Author BHANU PRAKASH BHATNAGAR is B.E. Mining Engg. (Gold Medal), FCC, MBA, working as Head Mining, Adani Cementation Ltd, Ahmedabad. He is having more than 27 years" experience in Overall Mine management including Acquisition of mineral resources through Auction Process, New Mine Development, Production Planning, Mine Operations and Quality Management for Large Opencast Limestone Mines. He had previously worked with cement companies like ACC-Holcim, Reliance Cement Ltd and overseas mining experience."
Part I
Come up with better regulations and legislation
As observed by the Honourable Supreme Court in its judgement on mining in 2017, the present mining legislation that we have today is far from being effective or productive. Mining continues to affect the environment because companies never cease to take advantage and continue polluting environment by waste discharges. Regulation obviously differs from country to country, with some countries more advanced in terms of their legislation than others. However, the need for improvement is always there in this industry, which inevitably causes some environmental damage.
We have to learn a lot from other countries like, for example In Canada, where mines like the Island Copper Mine on Vancouver Island stands as a highly regulated mine site that is operational from 1971 to 1995 when it was closed for resource depletion.
It was forced by regulatory agencies and control of the government that a detailed mine closure plan was developed to comfortably close the mine in order to protect the few resources which remained, and the Mine enacted the contaminated sites regulation process which was awarded the Certificate of Conditional Compliance.
This step involves the effective framing of the mineral policy and as we found that the new Mineral Policy 2019 advocates for the stringent laws for environmentally sustainable mining practices.
Effective implementation of this policy will not only protect environmental and public health, but also improve the lifespan of the mining industry and provide sustainable mining. The new Mineral Policy elaborates that extraction of mineral impacts other natural resources like land, water, air and forest. It is necessary to take a comprehensive view to facilitate the choice or order of land use keeping in view of the needs of development as well as needs of protecting the forests, environment and ecology and to conserve biodiversity of areas to be mined.
Responsible and Regulated mining near surrounding habitations of Silver Mine at Peru.
The New Mineral Policy has also emphasised on the effective Mine Closure where once the resources in mine are completely exhausted there is need for scientific mine closure which will not only restore ecology and regenerate bio-diversity but also take into account the socio-economic aspects of such closure. Government has a role in ensuring that post production mine decommissioning and land reclamation are an integral part of mine development process. Consistent approaches are adopted for efficient and effective mine reclamation and rehabilitation.
Investing in Research and Development of Environmentally sustainable Mining Technology –
Mining industry is always in need of proper research and development in order to make sure the industry is ready for today’s ever-changing commitment to sustainability and turning the world into a more "environmentally sustainable" place.
New Mineral Policy has emphasised on "Scientific Methods of Mining" which state that the mine development and mineral conservation, as governed by the Rules and Regulations, will be on sound scientific basis, with the regulatory agencies like IBM and State Directorates, closely interacting with R&D organisation and scientific and professional bodies. This is to ensure the proper mining practices being followed by mining companies. Policy advocates for R&D effort shall be made to improve efficiency in process, operation and also the recovery of by-products and reduction in specification and consumption norms. R&D efforts shall be directed to find new and alternative uses for minerals whose traditional demand is on the wane.
In this regard, as per the latest News published by NCCBM (NCB News, Sept 2019), the NCCBM has achieved great success with recent research and development with Investigation of standardization of new clinker for blended cement. The objective of the study was to investigate effects of high MgO clinker on performance characteristics of resultant OPC, PPC and PSC. The project was undertaken on accelerated mode and the report to be submitted to BIS is under preparation. The main agenda was to promote utilization of low-grade limestone containing higher MgO with good result. This will certainly result in increase of mine life.
Reduce resources inputs for effective mining practices –
The mining industry consumes large amount of water and land in their operations. One solution to becoming more environmentally sustainable is to reduce the input of the mine. By diverting surface water and pumping groundwater, mines can reduce both the quantity and quality of water available downstream for aquatic ecosystems and other use.
With regard to energy, a mining company can look into alternative energy sources such as solar or wind power. By reducing the energy usage, a mine can reduce greenhouse gases and extend the life of fossil fuel reserves. Mining companies will also be able to reduce the cost to produce the product and thus reduce the cost of the commodity itself. The New Mineral policy advocates for minimising the inputs for mining processes.
Improving the efficiency of mining processes –
This step is very much in discussion globally for closely monitoring the standard mining supply chain, mining industry/companies will be forced to confront ways in which a company can improve its efficiency where its lacking in terms of sustainability and green mining initiatives, improving the efficiency of this process can help trim down environmental impact. This also allows companies to regulate processes which may be inadequate in terms of environmental friendliness.
This needs a proper supervision of the mining and ancillary process that will allow mining companies to change elements/activities that are inefficient or that use too many natural resources. Conducting a material flows analysis will effectively track the physical flows of natural resources through extraction, production, fabrication, use, recycling and final disposal. This will develop new ways of thinking, new metrics, business process re-engineering and new management/supervisory tools that will help cushion the transition into more efficient and less environmental toxic patterns of resource used in modern societies. This process change will allow supervisors to develop new processes that are more efficient and sustainable than previous ones. Across the world, organizations like The World Resources Institute (WRI) are currently conducting research on most frequently used resources and materials, in order to better understand how the industry can conserve its non-renewable materials. The WRI has been working towards developing a database, and can now indicate the flow of materials through industrial economies. Material flows analyses, as mentioned above, will track the physical flows of natural resources in every step of mining process, accounting for both the gains and losses occurring throughout the supply chain.
The New Mineral policy mentions that the use of equipment and machinery which will improve the efficiency, productivity and economics of mining operations as well as mineral beneficiation process, safety, health of persons working in mines/beneficiation plant and surrounding area shall be encouraged.
Re-evaluating Cut-off Grades
A Raw mill cut-off grade is the level set that is considered to be the lowest quality of already mined ore which is economically feasible to continue processing. Different materials have different properties that determine a feasible cut-off grade. Often these grades are set at over-conservative levels. The easiest way to improve efficiency in mining and to reduce waste products is to decrease the mill cut-off grade of the mine. Re-evaluating these grades at each mine will significantly reduce waste.
A lower mill cut-off grade may decrease the quality of the material, but certain final uses of the material do not need a very pure compound. Cut-off grades will be determined on a mine-by-mine basis by looking at the precedents for the material in question and taking the future use of the material into consideration.
For example, the above mentioned recent R&D study done by NCCBM, has very encouraging results in terms of re-evaluating the MgO (Magnesia) content in Limestone for Clinker manufacturing, which earlier assumed to be less than 3.5%. Three types of high MgO clinker samples were obtained and designated as Clinker-1 (MgO~6.2%), Clinker-2 (MgO~6.8%) and Clinker-3 (MgO~7.5%).
PPC & PSC got succeeded in Clinker-1 & Clinker-2 in all respect, while testing with OPC autoclave expansion was observed. The performance results obtained so far are quite encouraging which will pave the way for utilization of low grade limestone containing high MgO, increased mine life (~15 years) besides improved sustainability during cement manufacture. This will also add to the utilisation of waste material of mine, thus leading to sustainable mining practices.
Replenishing the environment
A seemingly simple step, but it is rarely prioritized, replenishing mine sites and mine environment is one of the key factors to not only earning respect and cooperation of those living surrounding the mine site, but it will also ultimately protect the mine’s impact on the environment. Mining companies sometimes overlook the importance of replenishing the environment. This simple act can go a long way towards increasing the environmental sustainability of mining.
It has simple solutions like replenishing native soils and grasses, cleaning excess waste, proper waste removal, site inspections, replanting trees and natural forestry. By restoring the environment around the mine, the mining companies are contributing to positive environmental change, rather than making the environment more difficult to live in. The entire mine reclamation process should combine removal of hazardous materials, reshaping land, restoring topsoil, and planting native grasses, trees or ground cover natural to the site.
The New Mineral Policy emphasized that all mining shall be undertaken within the parameters of a comprehensive Sustainable Development Framework which will ensure that environmental, economic and social considerations are integrated effectively in all decisions of mines and mineral issues. The Guiding principal shall be that a miner shall leave the mining area in an ecological shape which is as good as it was before the commencement of mining or better with least impact on flora and fauna of the area.
Improving environmental performance
It is well known fact that mining activity impacts the environment in unnatural ways, which not only disrupts its natural decaying process, but also does more damage long-term than natural erosion processes. With exorbitant numbers of materials excavated and used daily, it is important to see that this destruction is actually going towards productive use.
This step is basically emphasised on adopting new measures useful in mitigating these environmental impacts. Let’s push for a systematic framework that will help us monitor the environmental performance.
We have to adopt practice of systematically examining environmental impacts and adopting measures to mitigate these impacts, it is possible to make mining less destructive to the environment. Incremental efficiency gains will not do the job.
Instead, an imaginative remaking of the industrial world-one that aligns economies with the natural environment that supports them is the sustainable way forward. The New Mineral Policy has given thrust on the Sustainable Development
Concrete
Reimagining Logistics: Spatial AI and Digital Twins
Published
2 days agoon
April 13, 2026By
admin
Digital twins and spatial AI are transforming cement logistics by enabling real-time visibility, predictive decision-making, and smarter multi-modal operations across the supply chain. Dijam Panigrahi highlights how immersive AR/VR training is bridging workforce skill gaps, helping companies build faster, more efficient, and future-ready logistics systems.
As India accelerates infrastructure investment under flagship programs such as PM GatiShakti and the National Infrastructure Pipeline, the pressure on cement manufacturers to deliver reliably, efficiently, and cost-effectively has never been greater. Yet for all the modernisation that has taken place on the production side, the end-to-end logistics chain, from clinker dispatch to the last-mile delivery of bagged cement to construction sites, remains a domain riddled with inefficiencies, opacity and manual decision-making.
The good news is that a new generation of spatial computing technologies is now mature enough to transform this reality. Digital twins, spatial artificial intelligence (AI) and immersive augmented and virtual reality (AR/VR) training platforms are converging to offer cement producers something they have long sought: real-time visibility, autonomous decision-making at the operational edge, and a scalable solution to the persistent skills gap that hampers workforce performance.
Advancing logistics with digital twins
The cement supply chain is uniquely complex. A single integrated plant may manage limestone quarrying, kiln operations, grinding, packing and despatch simultaneously, with finished product flowing through rail, road, and waterway networks to reach hundreds of regional depots and distribution points. Coordinating this network using spreadsheets, siloed ERP data, and phone calls is not merely inefficient; it is a structural liability in a competitive market where delivery reliability is a key differentiator.
Digital twin technology offers a way out. A cement logistics digital twin is a continuously updated, three-dimensional virtual replica of the entire supply chain, from the truck loading bays at the plant to the inventory levels at district depots. By ingesting data from IoT sensors on conveyor belts and packing machines, GPS trackers on road and rail fleets, weighbridge records, and weather feeds, the digital twin provides planners with a single, authoritative picture of where every ton of cement is, in real time.
The value, however, goes well beyond visibility. Because the digital twin mirrors the physical system in dynamic detail, it can run scenario simulations before decisions are executed. If a primary rail corridor is disrupted, logistics managers can model alternative routing options, shifting volumes to road or coastal shipping, and assess the cost and time implications within minutes rather than days. If a packing line at the plant is running below capacity, the twin can automatically recalculate dispatch schedules downstream and alert depot managers to adjust receiving resources accordingly.
For cement companies operating multi-plant networks across geographies as varied as Rajasthan and the North-East, this kind of end-to-end situational awareness is transformative. It collapses information latency from hours to seconds, enables proactive rather than reactive logistics management, and creates the data foundation upon which AI-driven decision-making can be built. Companies that have deployed logistics digital twins in comparable heavy-industry contexts have reported reductions in transit time variability of up to 20 per cent and meaningful decreases in demurrage and detention costs, savings that flow directly to the bottom line.
Smart logistics operations
A digital twin is only as powerful as the intelligence layer that sits on top of it. This is where Spatial AI becomes the critical differentiator for cement logistics.
Traditional logistics management systems are reactive. They record what has happened and flag exceptions after the fact. Spatial AI systems, by contrast, are proactive. They continuously analyse the state of the logistics network as represented in the digital twin, identify emerging bottlenecks before they crystallise into delays, and recommend corrective actions.
At the plant gate, AI-powered visual inspection systems using spatial depth-sensing cameras can assess truck conditions, verify load integrity and confirm seal tamper status in seconds, replacing the manual checks that currently slow throughput. At the depot level, Spatial AI can monitor stock drawdown rates in real time, cross-reference them against pending customer orders and inbound shipment ETAs, and automatically trigger replenishment orders when safety thresholds are approached. In transit, AI systems processing GPS and telematics data can detect anomalous vehicle behaviour, including extended stops, route deviations, speed irregularities and alert fleet managers instantly.
Perhaps most significantly for Indian cement logistics, Spatial AI can optimise the complex multi-modal routing decisions that are central to competitive cost management. Given the variability in road quality, seasonal accessibility, rail rake availability, and regional demand patterns across India’s vast geography, the combinatorial complexity of routing optimisation is beyond human planners working with conventional tools. AI systems can process this complexity continuously and adapt routing recommendations as conditions change, reducing empty running, improving vehicle utilisation and cutting fuel costs.
The agentic dimension of modern AI is particularly relevant here. Agentic AI systems do not merely analyse and recommend; they act. In a cement logistics context, this means an AI system that can, within pre-authorised boundaries, directly communicate revised dispatch instructions to plant teams, update booking confirmations with freight forwarders and reallocate available rail rakes across plant locations, all without waiting for a human to process a recommendation and make a call. For logistics executives, this represents a genuine shift from managing a workforce to setting the rules of engagement and reviewing outcomes. The operational tempo achievable with agentic AI simply cannot be matched by human-in-the-loop systems working at the pace of emails and phone calls.
Bridging the skills gap
Technology investments in digital twins and spatial AI will deliver diminishing returns if the human workforce cannot operate effectively within the new systems they create. This is a challenge that India’s cement industry cannot afford to underestimate. The sector relies on a large, geographically dispersed workforce, including truck drivers, depot managers, despatch supervisors, fleet maintenance technicians, many of whom have been trained on paper-based processes and manual workflows. Retraining this workforce for a digitised, AI-augmented environment is a substantial undertaking, and conventional classroom or on-the-job training methods are poorly suited to the scale and pace required.
Immersive AR and VR training platforms offer a fundamentally different approach. By creating photorealistic, interactive simulations of logistics environments, such as a plant dispatch bay, a depot yard, the interior of a cement truck cab, allow workers to practice complex procedures and decision-making scenarios in a safe, consequence-free virtual environment. A depot manager can work through a simulated rail rake delay scenario, making decisions about customer allocation and communication
without the pressure of real orders being affected. A truck driver can practice the correct procedure for securing a load of bagged cement without the risk of a road incident.
The learning science case for immersive training is compelling. Studies consistently show that experiential, simulation-based learning produces faster skill acquisition and higher retention rates than didactic instruction, with some research indicating retention rates three to four times higher for VR-based training compared to classroom methods. For complex operational procedures where muscle memory and situational awareness matter as much as conceptual knowledge, the advantage of immersive simulation is even more pronounced.
Today’s leading cloud-based spatial computing platforms enable high-fidelity AR and VR training experiences to be delivered on standard mobile devices, removing the hardware barrier that has historically made immersive training impractical for large, distributed workforces. This is particularly relevant for cement companies with depots and logistics operations in tier-two and tier-three locations, where access to specialised training hardware cannot be assumed.
The integration of AR into live operations also creates ongoing learning opportunities beyond formal training programs. As an example, maintenance technicians equipped with AR overlays can receive step-by-step guidance for equipment procedures directly in their field of view, reducing error rates and service times for critical plant and fleet assets.
New strategy, new horizons
India’s cement industry is entering a period of intensifying competition, rising logistics costs, and demanding customers with shrinking tolerance for delivery variability. The companies that will lead over the next decade will be those that treat logistics not as a cost centre to be minimised, but as a strategic capability to be built.
Digital twins, spatial AI and immersive AR/VR training are not distant future technologies, they are deployable today on infrastructure that Indian cement companies already operate. The question is not whether to adopt them, but how quickly to do so and where to begin.
About the author:
Dijam Panigrahi is Co-Founder and COO of GridRaster Inc., a provider of cloud-based spatial computing platforms that power high-quality digital twin and immersive AR/VR experiences on mobile devices for enterprises. GridRaster’s technology is deployed across manufacturing, logistics and infrastructure sectors globally.
Concrete
Beyond Despatch: Building a Strategic Supply Chain Process
Published
2 days agoon
April 13, 2026By
admin
Dr SB Hegde, Global Cement Industry Leader discusses the imperative need for modern cement plants to recognise packaging and bag traceability as critical components of quality assurance and supply chain management.
In cement manufacturing, considerable attention is given to clinker quality, kiln operation, grinding efficiency and laboratory control. Yet the final stage of the process, cement packaging and despatch, often receives less strategic focus. The cement bag leaving the plant gate represents the final interface between the manufacturer and the customer. Even if clinker chemistry, fineness and strength development are well controlled, weaknesses in packaging, handling, or distribution can affect product quality before it reaches the construction site.
Operational experience from cement plants across different regions shows that packaging efficiency and bag traceability have a significant influence on product reliability, logistics performance and brand credibility. In modern cement plants, packaging systems are no longer viewed merely as despatch equipment. They are increasingly recognised as an important part of quality assurance, supply chain management and customer confidence.
Operational importance of packaging
Cement packaging systems must operate with high speed, accuracy and reliability to support efficient despatch operations. Rotary packers equipped with electronic weighing systems have improved packing accuracy and productivity in many plants.
However, maintaining operational discipline remains essential. Regular calibration of weighing systems, maintenance of packer spouts and proper bag application are important for maintaining consistent bag weights and preventing cement loss.
Operational benchmarks observed in many cement plants are summarised in Table 1.
Plants that improved calibration discipline and equipment maintenance have reported packing loss reductions of about 1 per cent to 1.5 per cent, which represents significant annual savings.
Quality assurance beyond the plant gate
Quality control in cement plants traditionally focuses on laboratory parameters such as fineness, compressive strength and chemical composition. However, the condition of cement when it reaches the customer is equally important.
Cement bags may travel through several stages including plant storage, transport vehicles, dealer warehouses and retail outlets before reaching the construction site. During this journey, cement may be exposed to humidity, rough handling and improper storage conditions.
Table 2 shows common factors that may affect cement quality during distribution.
Studies indicate that cement stored under humid conditions for long periods may experience 10 per cent to 20 per cent reduction in early strength. Therefore, maintaining proper packaging integrity and traceability is essential.
Role of cement bag traceability systems
Traceability systems allow manufacturers to identify when and where cement was produced and despatched. These systems connect packaging operations with production records and logistics data.
When customer complaints occur, traceability enables manufacturers to identify:
- Production batch
- Packing date and time
- Plant location
- Laboratory test results
Several technologies are used to implement bag traceability, as shown in Table 3.
Among these technologies, QR code authentication systems are becoming popular because customers can verify product authenticity through smartphones.
Digital transformation
Digital technologies are transforming cement packaging operations. Modern packing lines now integrate:
- automated rotary packers
- electronic bag counting systems
- robotic palletising systems
- ERP-based despatch management
- digital supply chain monitoring
These technologies improve operational efficiency and transparency across the supply chain.
Such systems help manufacturers track cement movement across the distribution network and respond quickly to quality concerns.
Case Study: Digital Cement Bag Authentication
Several cement manufacturers in Asia and the Middle East have implemented QR code-based bag authentication systems to improve supply chain transparency.
In one integrated cement plant, QR codes were integrated into the rotary packing machine. Each cement bag received a unique digital identity linked to the production database.
The QR code contained information such as:
• plant location
• manufacturing date and time
• product type
• batch number
Customers and dealers could scan the code using a mobile application to verify product authenticity.
After implementation, the company reported:
• reduction in counterfeit bag circulation
• improved despatch data accuracy
• faster resolution of customer complaints
• better visibility of distribution networks
The system was also integrated with the company’s ERP platform, enabling real-time monitoring of production and despatch activities.
Future-Smart Packaging Systems
The future of cement packaging lies in the integration of Industry 4.0 technologies with logistics and supply chain management.
Packaging lines will increasingly become part of connected digital ecosystems linking production, quality control, despatch and market distribution.
Artificial intelligence and data analytics may also help detect abnormalities in bag weight variations, equipment performance and despatch patterns.
Global benchmark indicators
Global benchmarking of cement packaging operations highlights the increasing importance of efficiency, automation and digital traceability in modern cement supply chains. Leading cement plants are now focusing on key performance indicators such as packer availability, bag weight accuracy, packing losses, truck turnaround time and digital traceability coverage. Studies show that overall equipment effectiveness (OEE) in many industrial operations is still around 65 per cent to 70 per cent, whereas world-class plants aim for levels above 85 per cent, indicating significant scope for improvement in operational efficiency.
At the same time, the global cement packaging sector is expanding steadily, supported by growing infrastructure demand and increased emphasis on reliable and moisture-resistant packaging solutions. The cement packaging market is projected to grow steadily in the coming decade as companies adopt automation, smart packaging technologies and integrated logistics systems to improve despatch efficiency and supply chain transparency. In this context, benchmarking against global indicators helps cement plants identify performance gaps and adopt best practices such as automated bagging systems, QR-based traceability, ERP-linked despatch monitoring, and predictive maintenance of packing equipment.
Strategic Recommendations
To fully benefit from packaging and traceability systems, cement manufacturers should consider the following approaches.
• Packaging systems should be treated as an integral part of the manufacturing value chain rather than simply despatching equipment.
• Investments in modern packers, automated loading systems and digital traceability technologies should be encouraged.
• Industry associations may also promote standard traceability practices to reduce counterfeit products and improve transparency in the cement market.
Finally, continuous training of plant personnel in packaging operations and maintenance practices is essential for sustaining operational efficiency.
Conclusion
Cement packaging has evolved from a routine mechanical operation into a strategic component of modern cement manufacturing. Efficient packaging systems ensure that the quality achieved within the plant is preserved during transportation and distribution. Traceability technologies allow manufacturers to track cement movement, investigate complaints and prevent counterfeit products.
As the cement industry moves toward digitalisation and integrated supply chains, packaging and bag traceability will play an increasingly important role in quality assurance, operational efficiency and customer confidence. Ultimately, the cement bag leaving the plant carries not only cement but also the reputation and responsibility of the manufacturer.
References
- Hewlett, P.C., & Liska, M. (2019). Lea’s Chemistry of Cement and Concrete. Butterworth-Heinemann.
- Schneider, M., Romer, M., Tschudin, M., & Bolio, H. (2011). Sustainable cement production. Cement and Concrete Research, 41(7), 642–650.
- International Cement Review. (2023). Advances in cement packaging and logistics systems.
- World Business Council for Sustainable Development (2021). Cement Industry Supply Chain Innovation Report.
- Gartner, E., & Hirao, H. (2015). Reducing CO2 emissions in cement production. Cement and Concrete Research.
- ScienceDirect Industry Studies. (2024). Operational efficiency benchmarks and overall equipment effectiveness in industrial manufacturing systems.
- World Cement Association. (2022). Digital Transformation in Cement Manufacturing and Logistics. London.
- Towards Packaging Research. (2024). Global cement
packaging market trends and technology outlook. Industry Market Analysis Report. - Towards Packaging Research. (2024). Global cement
packaging market trends and technology outlook. Industry Market Analysis Report.
About the author:
Dr SB Hegde is a Professor at Jain College of Engineering, Karnataka, and Visiting Professor at Pennsylvania State University, USA. With 248 publications and 10 patents, he specialises in low-carbon cement, Industry 4.0, and sustainability, consulting with cement companies to support India’s net-zero goals.
Table 1. Key Operational Parameters for Cement Packaging Systems
Parameter Typical Industry Range Recommended Target Operational Significance
Rotary packer capacity 2400–3600 bags/hr 3000–4000 bags/hr Improves despatch efficiency
Bag weight tolerance ±0.5 kg ±0.25 kg Reduces customer complaints
Bag leakage rate 1 per cent to 2 per cent <0.5 per cent Minimises cement loss Packing accuracy 98 per cent to 99 per cent >99.5 per cent Ensure compliance with standards
Truck loading time 30–45 minutes 20–30 minutes Improves logistics efficiency
Table 2. Causes of Cement Quality Degradation During Distribution
Factor Typical Cause Impact on Cement
Moisture exposure Poor storage or rain exposure Lump formation
Long storage duration Slow inventory turnover Loss of early strength
Bag damage Rough handling Cement loss
Improper stacking Excessive loading Bag rupture
Counterfeit bag reuse Refilling of empty bags Brand damage
Table 3. Comparison of Cement Bag Traceability Technologies
Technology Advantages Limitations
Printed batch code Low cost and simple Limited traceability
Barcode Fast scanning Requires equipment
QR code Smartphone verification Requires digital platform
RFID tagging Automated tracking Higher cost
Blockchain systems High transparency Complex implementation
Economy & Market
SEW-EURODRIVE India Opens Drive Technology Centre in Chennai
Published
3 weeks agoon
March 25, 2026By
admin
The new facility strengthens SEW-EURODRIVE India’s manufacturing, assembly and service capabilities
SEW-EURODRIVE India has inaugurated a new Drive Technology Centre (DTC) in Chennai, marking a significant expansion of its manufacturing and service infrastructure in South India. The facility is positioned to enhance the company’s responsiveness and long-term support capabilities for customers across southern and eastern regions of the country.
Built across 12.27 acres, the facility includes a 21,350-square-metre assembly and service setup designed to support future industrial growth, evolving application requirements and capacity expansion. The centre reflects the company’s long-term strategy in India, combining global engineering practices with local manufacturing and service capabilities.
The new facility has been developed in line with green building standards and incorporates sustainable features such as natural daylight utilisation, solar power generation and rainwater harvesting systems. The company has also implemented energy-efficient construction and advanced climate control systems that help reduce shopfloor temperatures by up to 3°C, improving production stability, product quality and working conditions.
A key highlight of the centre is the 15,000-square-metre assembly shop, which features digitisation-ready assembly cells based on a single-piece flow manufacturing concept. The facility also houses SEW-EURODRIVE India’s first semi-automated painting booth, aimed at ensuring uniform surface finish and improving production throughput.
With the commissioning of the Chennai Drive Technology Centre, SEW-EURODRIVE India continues to strengthen its manufacturing footprint and reinforces its long-term commitment to supporting industrial growth and automation development in India.
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