Product Development

Digitalisation in cement industry

Published

6 years ago

January 2, 2020

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A combination of enhanced connectivity, remote monitoring and predictive analytics, machine learning, and 3D printing is already transforming the wider construction sector, says Dr SB Hegde, Sr General Manager ‘ Production and Quality Control at Udaipur Cement Works (UCWL).

Cement is the second most polluting industrial sector, responsible for roughly 8 per cent of global CO2 emissions. Although progress has been made in reducing the emissions-intensity of cement production, this has been eclipsed by a surging demand for cement, as cities rapidly expand, and governments worldwide invest in major infrastructure projects.

Cement sector emissions cannot be reduced simply by changing fuels or increasing the efficiency of plants, but instead require the transformation of cement itself, either by blending it with alternative materials or by developing novel low-carbon cements. Although the cement sector is only in the early stages of digital transformation, there is growing interest in the role that digital tools could play in accelerating deep decarburisation. Many of the barriers to cleaner cement production and use are about optimising processes, matching solutions to local conditions, better coordination, and cooperation and communication ‘ areas where digital technologies have significant advantages.

Digitalisation could help address misinformation, enhance collaboration, disseminate best practice, and reduce asymmetries in access to relevant information at different points along the value chain. Well-known barriers stand in the way of lower-carbon cements and concretes. The raw materials required to produce them are often not readily available at the scale required. The major cement companies that dominate the sector are cautious about rolling out new products that could challenge their current business practices and erode the value of their production facilities. Finally-and perhaps most importantly-consumers are reluctant to use novel building materials.

Role of digital technologies in overcoming the barriers
A combination of enhanced connectivity, remote monitoring and predictive analytics, machine learning, and 3D printing is already transforming the wider construction sector. Such changes could feed back into cleaner cement and concrete consumption. Digital technologies are likely to have four key impacts in the cement sector:

Optimising existing processes may be the most obvious promise of digital disruption is the potential to optimise existing processes through better data gathering, data analysis, and the use of automated process control. This is the area in which industrialised cement producers will already be seeing the impact of digital technologies. Firms are, for example, employing”smart” devices to track and monitor operations, and machine learning to improve process control in their plants. Logistics is another area where this has progressed, with technologies employed to gather data insights for increased efficiency and to improve timing of deliveries to sites. Matching solutions to local conditions Digital technologies can play a key role in finding the right combination of technology solutions for each and every location. The choice of building materials for a project is highly site and application specific. Differences in climate and soil conditions, what the material is going to be used for, and the local availability of a given material will all play into the decision-making process. Belite-rich clinkers, for example, have been used in large concrete dam projects in China, where strength gain after a few days is not as important as it might be on a typical construction project.

The number of factors involved and the need for very fine tuning suggest that this problem is well-suited to machine learning. In combination with the potential increase in data gathering described above, analytics could be used to predict product characteristics, for a given mixture, in a given climate, and for a given use. By finding the right solution for any building or structure, anywhere, digital innovation will unlock new opportunities for deep decarburisation. Ideally, this would allow the user to match the lowest carbon cements to their most viable use-cases and reserve the higher carbon cements for only those applications where they might still be needed.

Enhancing information sharing and collaboration
Improving coordination and communication is an area where digital technologies have significant advantages and could play a key role in transforming how building materials are procured and specified. In this context, there has been a growing interest in tools, such as building information modeling (BIM), which allows users to build a data-rich computer-generated model of a building. Structural engineers and architects are using BIM to collaborate on the optimal design and materials for a structure at the very beginning of a project. BIM also helps to communicate decisions to the client, the contractor, and suppliers in the value chain.

Supporting digitalisation in the sector
Concerns raised over the adoption of digital technologies include the cost, changes in workflow, questions over who owns the data, and the potential for blurred lines of responsibility and liability. The skills and training needed to roll out digital technologies are a particularly important consideration. In Europe, the construction sector is already suffering from a serious skills shortage and is struggling to deliver widespread training, even on simple processes. The importance of digital disruption will also depend on the degree to which it reshapes the largest cement markets ‘China and India.

There are, however, near-term opportunities to overcome these challenges.
Governments can invest in training to address the digital-skills shortage in the construction sector, also with a view to retaining the number and improving the quality of jobs in the sector. They can provide de-risking mechanisms and financial support to encourage the use of new technologies and help to cover their cost. Cement and construction companies can work with digital providers to improve digital tools and technologies, to offer the right kind of services, and to accelerate their uptake. Innovation partners should work together to build the stack of digital assets needed to integrate real-time decision tools, supply chain optimisation, and lesson sharing from experience into the development of new materials and blends.

About the author:
Dr SB Hegde is currently working as Sr. General Manager ‘ Production and Quality Control, Udaipur Cement Works (UCWL). He has more than 25 plus years of experience with a lot of accomplishments in India and Abroad in the areas of plant operation, quality assurance, laboratory automation, new product development both (new) cement formulations, concrete and cement-based products. He had served in senior level positions in the companies like Reliance Cement as Functional Head and Vice President- Quality and Product Development for a plant of 10,000 tpd greenfield plant at Maihar (Madhya Pradesh) and grinding unit of two MTPA and 0.8 MTPA greenfield grinding units at Kundanganj (Uttar Pradesh) and Butibori (Nagpur) respectively.

Dr Hegde was one of the active members of “Research Advisory Committee” of NCCBM from 2013 to 2016. He has published more than 70 research papers both in National and International journals of high repute and presented papers in International seminars held in India and Abroad. Presented papers in International Congress on chemistry of Cement, held in Durban and Toronto (Canada).

He can be contacted on: Email: drshegde@gmail.com | sbhegde@ucwl.jkmail.com

Economy & Market

Power Build’s Core Gear Series

Published

5 days ago

February 19, 2026

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A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

Economy & Market

Conveyor belts are a vital link in the supply chain

Published

8 months ago

June 16, 2025

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Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.

In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.

Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.

How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.

How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.

What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.

How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.

What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.

How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.

What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.

Economy & Market

Impactful Branding

Published

3 years ago

July 17, 2023

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Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.