Product Development
Ensuring sustainable management of municipal solid waste
Published
6 years agoon
By
admin
With rapid urbanisation taking place in our country, tackling of municipal solid waste especially in the metro cities has reached a dead end when land fill areas are no more available. The world over situation is no different, yet the problem gets solved, explains Ulhas Parlikar.
Current level of municipal solid waste (MSW) generation in the country is about 70 million TPA. The sustainable management of MSW demands that each constituent present in it is gainfully utilised and same is achievable by having proper segregation processes. This workable approach provides landfill free towns is depicted in Fig 1.
Towns of Madukkarai in Tamil Nadu, Vengurla in Maharastra, Ambukapur in Chattisgarh, etc. are the demonstrated examples of this concept of sustainable management of MSW in which each fraction of the segregated fraction of MSW gets gainfully utilised and there is no dump yard or landfill in the process in these towns. The SWM Rules, 2016 have included following provisions to achieve the desired level of segregation.
Segregation of dry, wet and domestic hazardous waste at source
Door-to-door collection
Setting up Material Recovery Facility (MRF) facilities to achieve following:
- Segregation of compostable material for sending it to composting facility or converting it into biogas
- Segregation of recyclables such as metals, plastics and glass for sending it to recycling facilities
- Segregation of inert materials to send it for filling in low lying areas/embankments etc.
Segregating the non-recyclable combustiblematerial called segregated combustible fraction (SCF) and sending it for use in following applications:
- Co-processing in cement kilns as alternative fuel and raw material or
- replacement of fossil fuel used by power plants or other applications within utilise
- fossil fuel in their operations or
- sending it to waste-to-energy (WTE) plant for generating electricity.
The municipal corporations of different towns and cities are moving towards implementing the above provisions in the rules appropriately. The management of compostable, recyclables and inert materials is pretty easy and has no difficulty in implementing.
In the sustainable management approach defined in Fig 1 the real challenge is with the management of SCF. This SCF is a mix of multi-layer Packaging (MLP) material, thin and single use plastics, rexin pieces, tyre and tube pieces, rubber pieces, thermocol, old or damaged shoes, chappals, old and torn clothes, contaminated paper, etc. As there are no takers for this material in the market market place, the same needs to be used for electricity generation in WTE plant or needs to be sent to cement kiln or power plant for co-processing.
Options of WTE and power plants
The option of waste to energy for this SCF fraction is difficult to implement in most of the towns and cities because the minimum implementable size of the WTE plant is 300 TPD and the cost of such a WTE plant is about Rs 100 crore. To generate 300 TPD of SCF, the population of the town has to be more than 50 lakh, SCF content in MSW should be around 15 per cent and the MSW generation rate should be 0.4 kg/capita/day. Barring a few metro cities, none of the towns and cities can meet these criteria. Therefore, the option of waste to energy is difficult to implement unless the SCF is pooled up from different adjacently located towns.
The utilisation of SCF in the power plant is not yet getting implemented and has concerns due to presence of >0.5 per cent chlorine in it. These concerns are on account of the likelihood of dioxins/furans and hydrogen chloride in the stack gases. There is need therefore to have some co-processing trials carried out in some of the power plants in the country to work out an appropriate protocol.
Capability of cement industry
The best option therefore is cement kiln co-processing and is substantially workable on account of following features.
- The cement plant is already existing.
- Most of the cement plants have co-processing facility already set up on their kiln system.
Hence most of such cement plants are ready to utilise the refused derived fuel (RDF) meeting their acceptability criteria. From the 70 million TPA of MSW, appropriately 10 million TPA of SCF can get generated. This can be suitably converted into cement grade RDF and can be sustainably utilised in the cement kiln as alternative fuel and raw material through co-processing.
The current clinker production is at a level of about 250 million TPA, the TSR achievable by the industry with this RDF would range in between 12 to 15 per cent, which is easily feasible without getting into concerns of chlorine saturation.
Acceptable RDF grade to cement industry
The expert committee constituted by the Ministry of Housing and Urban Affairs (MoHUA) has proposed three grades of RDF for use in cement industry. Grade – I and Grade – II can be utilised by cement industry as such and Grade – III can be utilised by it after blending it with some other AFR materials. These RDF grades can be manufactured from the non-recyclable segregated combustible fraction (SCF) that gets generated from MSW.
The manufacture of these RDF grades can be done after setting up the required facility. These include facilities for quality assessment, blending, shredding, bailing, storage, etc. It is desired that RDF producers interact with cement plants to produce the material having desired quality and enter into a suitable long term techno-commercial agreement with them. This facility can be set up near the SCF generation site or at the cement plant. It can be set up and operated by a third party waste processor or also by the cement plant as depicted in Fig 2.
Win-win considerations in the sustainable management of SCF For having ensuring a successful business model, it is important to have a win-win consideration in case of each of the stakeholder. There are three stakeholders in the process. They are municipal corporation, waste processor and cement plant. Fig 3 provides the cost and benefits associate with each of these stakeholders.
Following win-win considerations should be noted from Fig 3:
- Cement plant: The price of RDF should be reasonably lower than the cost of coal after accounting for higher fuel consumption and production loss.
- Waste processor: Sum of the (i) tipping fee earned from municipal corporation and (ii) RDF price received from cement plant should be reasonably more than sum of (i) processing cost of converting SCF to RDF, (ii) transportation cost of SCF from Municipal Corporation to its facility and (iii) transportation cost of RDF from its facility to cement plant.
- Municipal corporation: The SCF should get sustainably managed without the need to build dump yard or land fill for the same. Further, the proportionate portion of the taxes collected by it for management of MSW should be more than or equal to the tipping fee paid to the waste processor for the sustainable management of SCF.
Challenges and feasible solutions
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A justifiable consideration of the administration towards this solution. Currently, the major consideration of the administration is revolving around the WTE solution which is unlikely to get implemented due to the techno-commercial constraints mentioned above. The co-processing solution is more attractive from both technical and commercial considerations.
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Cost involved in setting up RDF processing facilities and extending some of the relevant fiscal policies towards this solution. The central government and state governments extend grants in setting up the projects for management of MSW. It is desired that these grants should also get extended to setting up the facilities for production of cement grade RDF.
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Cost of transportation of SCF from Municipal Corporation to waste processor and cost of RDF from the waste processor to cement plant. Considering that the overall SCF generation in the country will be about 10 Million TPA and average transportation cost of transporting SCF from municipal corporation to SCF processing facility is Rs 400/t, the overall cost of transportation works out to Rs 400 crore per year. Considering that RDF produced from SCF will be 7 million TPA and the average cost of transportation of RDF from processing facility to cement plant is Rs 1,500 per tonne, the total transportation cost works out to Rs 1,050 crore. Hence, put together the amount works out to Rs 1,450 crore.
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This figure of Rs. 1450 Crores per year is for the management of the entire non-recyclable combustible fraction getting generated in the country and avoids dump yards and landfill implementation country-wide.
Recommendations
It is suggested therefore that following actions be taken up by the Government to solve this huge problem of SCF waste management and dump yard creation faced in the country.
-
Formulate a RDF mission to directly coordinate the required actions through municipal corporations, MSW management companies, RDF manufacturing companies and cement plants.
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Extend the existing fiscal benefits of MSW projects to RDF production projects also.
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Encourage use of RDF in cement kilns through feasible fiscal policies.
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Encourage setting up of RDF facilities across the towns and cities of the country by including them in the tendering process.
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Establish mechanism to deal with the transportation cost management of SCF and RDF as elaborated above through an appropriate central and state level budgeting process.
Conclusion
The current status of RDF usage is same as that of fly ash usage in the cement manufacture in the 90s. The cement industry has grown mature over past decades and is utilising now about 50 million TPA of fly ash. This is because of the win-win policy that the fly ash mission had promoted during the initial days. It is clear from the fly ash example that if RDF is seen as an accessible and acceptable material from the techno-commercial angle, the entire cement industry would implement the required facilities at its plant and would undertake co-processing of RDF to its maximum levels.
This RDF use in cement plant will facilitate following.
- Reduction in land filling/dump yard space
- Reduced GHG emissions
- Eliminating the dump yards and associated environmental issues and
- Conservation of reasonable quantum of fossil resources such as coal, limestone, iron ore, bauxite and silica that are being utilised currently in the cement manufacture.
ABOUT THE AUTHOR:
The article is authored by Ulhas Parlikar. He can be contacted at: Mob: +91 99675 81975 or Email: ulhas@parlikar.com
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Economy & Market
Power Build’s Core Gear Series
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4 days agoon
February 19, 2026By
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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 agoon
June 16, 2025By
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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.
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.
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