The transportation and logistics landscape in the Indian cement industry is witnessing significant evolution, driven by technological advancements and sustainability considerations. From the integration of electric vehicles to the adoption of advanced technologies like IoT and AI, cement companies are embracing innovation. ICR explores the transformative trends shaping the future of transportation and logistics.

The second-largest road transportation network in the world is in India. From one place to another, a transportation system moves both people and things. Machines rule the transportation industry nowadays, while transportation routes or channels serve as the key arteries of our economy.
The logistics industry is crucial to both enterprises and the economy. In today’s interconnected world, shipping and logistics are at the heart of the economy, acting as vital gateways for international trade and business. More than 95 per cent of the nation’s traffic is transported by roads and railways, which are the main modes of transportation. The railways and roads would continue to rule the transportation scene in the near future, even though other modes including coastal shipping and inland water transport would play a larger role.
According to Statista Market Insights 2024, the value added in the transportation market is projected to amount to Rs.7.88tn in 2024, the transportation intensity in India is projected to amount to 1.1200TKM/GDP and the volume of goods transported in the transportation market is projected to amount to 4,583.00bn TKM in 2024.
Pushpank Kaushik, CEO, Jassper Shipping, says, “The shipping and logistics industry is an essential component of the global supply chain and the rise of e-commerce, globalisation, and ever-increasing customer demands for faster delivery times have pushed the boundaries of traditional shipping methods. As a result, the sector is undergoing a significant revolution owing to the use of automation and technology. Automation is a key factor that facilitates the accuracy and efficiency of processes involved in shipping and logistics. Technology has also improved the safety and security of shipping and logistics operations with minimised communication gaps through mobile applications, cloud servers, etc. Real-time tracking and management of inventory through automation help in the identification of errors and delays in the delivery process. It enables logistics companies to have access to their operations and look for drawbacks that may demand improvements, leading to cost reduction.”

TECHNOLOGY OF TRANSPORT
The role of technology in transportation and logistics within the cement industry is paramount, revolutionising traditional practices and ushering in unprecedented efficiency and cost-effectiveness. Technology plays a crucial role in optimising various aspects of the transportation process, from route planning to fleet management. Utilising advanced algorithms, companies can analyse factors such as traffic patterns, road conditions, and delivery schedules to optimise routes, minimising transit time and
fuel consumption.
“The integration of new technology and digitalisation has significantly enhanced both the efficiency and cost-effectiveness of our plant operations. By leveraging advanced analytics, real-time monitoring and automation solutions, we have been able to optimise resource utilisation, minimise downtime and reduce overhead costs. Additionally, digitalisation has improved decision-making processes, enabling us to respond swiftly to changing market dynamics and customer demands,” says Vinod Agarwal, Logistics Head, Wonder Cement.
Moreover, the integration of cutting-edge technologies such as Internet of Things (IoT), GPS, and telematics has enabled real-time tracking and monitoring of vehicles and shipments. IoT sensors installed in trucks and cargo containers provide valuable data on location, temperature, humidity, and other relevant parameters. This real-time visibility enhances transparency and accountability throughout the transportation chain, allowing for proactive decision-making and timely interventions to address any issues that may arise.
Dhriti Prasanna Mahanta, Vice President & Business Head, TeamLease Degree Apprenticeship says, “The global integration of AI into the logistics, transportation, and supply chain sectors is experiencing remarkable growth, with projections soaring from $412 million to an astounding $13,948 million by 2032, reflecting an impressive CAGR of 43.5 per cent. However, amidst this global surge, India emerges as a promising market poised for significant expansion. Reports suggest that the logistics industry in India is poised and expected to create 10 million jobs by 2027. Furthermore, the Indian freight and logistics market is projected to grow at an annual rate of 8.8 per cent, reaching $484.43 billion by 2029,
up from $317.26 billion in 2024. This underscores the critical need for skilled professionals
proficient in AI technologies to meet the industry’s evolving demands.”
Furthermore, GPS and telematics systems facilitate effective fleet management by enabling remote monitoring of vehicle performance, fuel consumption and driver behaviour. This data-driven approach allows companies to identify inefficiencies, optimise routes and reduce operational costs. Additionally, predictive maintenance algorithms help minimise downtime by alerting maintenance teams to potential issues before they escalate into costly breakdowns.
Prashant Jha, Chief Ready-Mix Concrete and Modern Building Materials Officer, Nuvoco Vista, says, “Our implementation of a Vehicle Tracking System (VTS) in our transit mixers, coupled with Drum Rotation Sensors and GPS integration, has revolutionised our operational efficiency. This advanced technology empowers our plant to monitor transit mixers in real-time, facilitating agile planning for subsequent deliveries and enabling us to provide customers with precise updates on delivery status. Moreover, by leveraging GPS data, we ensure fair variable cost payments based on accurate kilometres travelled, optimising cost management. In addition to enhancing financial transparency, the VTS enables our plant teams to track driver behaviour, allowing us to provide timely feedback and targeted training on safe work practices. This hands-on approach not only improves the safety of concrete transportation but also fosters a culture of continuous improvement within our workforce.”
Automation technologies, ranging from autonomous vehicles to robotic warehouses, are revolutionising traditional logistics operations. In the context of transportation, autonomous vehicles, including trucks and drones, are being increasingly deployed to transport raw materials and finished products. These vehicles leverage advanced sensors, artificial intelligence, and machine learning algorithms to navigate roads safely and efficiently, reducing the need for human intervention and minimising the risk of accidents.
“A major challenge in the cement industry is the logistics cost and time for delivery. This can only be resolved with faster turnaround time, complete visibility of shipments, delivery lead time and process control to adhere to compliance,” explains Haresh Calcuttawala, CEO and Co-Founder, Trezix.
Furthermore, automation plays a significant role in warehouse operations, where robotic systems are employed for tasks, such as loading and unloading cargo, sorting materials, and managing inventory. These automated solutions not only improve operational efficiency but also optimise space utilisation and enhance inventory accuracy, ultimately leading to cost savings and improved customer satisfaction.
Additionally, automation enables the integration of predictive analytics and real-time data processing, allowing logistics companies to anticipate demand, optimise routes, and mitigate disruptions proactively. By harnessing the power of data-driven insights, companies can make informed decisions and adapt quickly to changing market dynamics, thereby gaining a competitive edge in the industry.
Guru Prasad, Assistant Vice President, CSSR and Electronics, Robotics and Discrete, ABB India, elaborates, “ABB Robotics can help cement plants find a balance between volume, speed, accuracy and flexibility through their automation solutions for logistics applications. Automating cement plants can provide various benefits such as supporting the workforce. If the cement plant is to achieve the speed, efficiency and resilience required by today’s complex world, companies must integrate automation, digital connectivity and edge technologies such as artificial intelligence and robotics. The successful integration of these technologies is critical to keep the plant operational in both normal and emergency situations. There are likely to be more operations that run entirely autonomously. Robotic automation is increasingly being used to tackle monotonous, hazardous and challenging tasks that can increase productivity, boost operational efficiency and generate a higher return on investment for businesses. This makes the plant safer for human workers and allows them to focus on more skilled and fulfilling tasks.”

ELECTRIC VEHICLES
According to the report Electric Vehicles: Revving Up Despite Roadblocks by CareEdge Ratings, January 2024, the sales volume of electric vehicles in CY23 surpassed 1.5 million, a 50 per cent increase compared to CY22. Total EV volume sold was recorded at 1.53 million in CY23 compared to 1.02 in CY22. Growth was driven by the increasing adoption of EVs and several exciting new EV models across segments giving better options. CY24 looks promising with the industry expecting to surpass sales volume of 2 million in CY24, underpinned by surging demand and sustained government support through incentives. However, investments in the
EV ecosystem remain crucial for fostering EVs’ massive adoption.
The growth momentum is expected to continue in CY24, driven by the government’s increased focus on electrification at both the Central and state levels, the potential extension of FAME II, the improving EV ecosystem with a significant increase in charging stations, the envisaged reduction in battery costs leading to the lower total cost of ownership (TCO) compared to ICE, and the development of new models across categories, thus continuing to drive demand for EVs. An increase in the number of EVs will promote sustainability and reduce carbon emissions, contributing to the government’s environmental goals. The massive adoption of EVs can boost battery technology and infrastructure, further enhancing the EV ecosystem. These incentives reduce the upfront cost of vehicles, making them more attractive to consumers.
In cement transportation, electric vehicles (EVs) present a promising avenue for achieving sustainability goals while addressing the industry’s unique challenges. However, along with immense opportunities, several hurdles must be overcome to realise the full potential of EV adoption. One of the primary challenges is the need to address infrastructure limitations. This includes the establishment of a robust charging infrastructure network capable of supporting the widespread deployment of EVs for cement transportation. Investing in charging stations along transportation routes and at key logistical hubs will be essential to ensure uninterrupted operations and facilitate the transition to electric fleets.
Raman Bhatia, Founder and Managing Director, Servotech Power Systems, asserts, “Shifting industrial transportation fleets to EVs can lead to reduced greenhouse gas emissions. Transportation is a major contributor to greenhouse gas emissions, particularly CO2. An EV produces zero tailpipe emissions, significantly reducing emissions and mitigating climate change. Petrol and diesel trucks emit harmful pollutants like nitrogen oxides and particulate matter. Replacing these vehicles with EVs can significantly improve air quality, especially in urban areas with high traffic congestion. Lastly, widespread EV adoption can lessen dependence on fossil fuels, particularly imported oil. This can enhance energy security and reduce geopolitical vulnerability.”
Moreover, the upfront cost of EVs and associated infrastructure investments may pose financial challenges for cement companies, especially smaller players. However, opportunities exist for innovation and investment in EV technology tailored to meet the specific needs of the cement industry. This includes the development of specialised EV models designed for heavy-duty applications, such as transporting bulk materials like cement and aggregates over
long distances.
Furthermore, advancements in battery technology and energy storage solutions offer promising opportunities to overcome range limitations and improve the overall efficiency of electric transportation in the cement industry. Research and development efforts focused on enhancing battery performance, reducing charging times, and increasing energy density will be crucial in driving the widespread adoption of EVs.

TRANSPORTATION AND SUSTAINABILITY
Sustainability has become a core focus for the cement industry, extending beyond production processes to encompass transportation and logistics operations. Recognising the environmental impact associated with transportation, cement companies are implementing various sustainability initiatives and practices to reduce carbon emissions, minimise resource consumption and enhance overall environmental stewardship.
“Making sustainable practices a priority in the shipping and logistics sector is crucial to ensure a significant impact on the environment and the industry. Companies can turn cost effective and save money by investing in green technologies such as hybrid or electric ships, alternative fuels, and automated route optimisation systems. By investing in sustainable practices, companies can ensure compliance with government regulations, avoiding fines and other consequences that could affect their bottom line. With growing consumer awareness of environmentally friendly practices, companies adopting sustainable policies can differentiate themselves from their competitors and attract more customers, ultimately boosting the revenue charts,” says Kaushik.
One key sustainability initiative in transportation and logistics is the adoption of alternative fuels and energy-efficient vehicles. Cement companies are increasingly incorporating biofuels, natural gas, and electric vehicles into their fleets to reduce reliance on fossil fuels and lower greenhouse gas emissions. By investing in energy-efficient vehicles and alternative fuels, companies can significantly decrease their carbon footprint while also reducing fuel costs over the long term.
Cement manufacturers today are prioritising route optimisation and logistics planning to minimise transportation distances and reduce fuel consumption. Advanced data analytics and logistics software are being utilised to optimise delivery routes, consolidate shipments, and maximise vehicle capacity utilisation. These efforts not only reduce emissions but also enhance operational efficiency and reduce transportation costs.
Shrivats Singhania, Director and CEO of Udaipur Cement Works (UWCL), states, “As cement production grows, so does the demand for efficient logistics and transportation. At UCWL, we recognise this link. Increased production volume necessitates a robust and adaptable logistics network to ensure timely and efficient product delivery. We are continuously evaluating and optimising our logistics network to meet this growing demand. Beyond simply scaling our operations, we are committed to sustainable practices across the supply chain. We have implemented innovative strategies like CNG-powered truck distribution to reduce our carbon footprint during transportation. These initiatives not only optimise logistics and distribution but also demonstrate UCWL’s unwavering commitment to environmental responsibility. We believe that sustainable practices and efficient operations go hand-in-hand, and we are actively working to achieve both.”
In addition to improving vehicle efficiency and logistics optimisation, cement companies are implementing sustainable packaging solutions to minimise waste and reduce environmental impact. Innovative packaging materials, such as recyclable and biodegradable materials, are being explored to replace traditional packaging materials like plastic and cardboard. Furthermore, companies are investing in returnable packaging systems to minimize waste and promote circularity within the supply chain.

FUTURE AND INNOVATION OF TRANSPORTATION
Ankit Kumar, Co-Founder and CEO, Skye Air, affirms, “In the foreseeable future, the incorporation of drone deliveries holds promise for integration within the cement industry, presenting efficient and swift transportation solutions for materials. The sophisticated drone technology prevalent in logistics stands poised to collaborate seamlessly with cement companies, optimising their supply chain operations. Drones offer the potential to ferry small batches of cement or other construction materials to remote or challenging-to-access locations, thereby diminishing reliance on conventional transportation modes such as trucks and mitigating logistical complexities. Through the strategic utilisation of drones, the cement industry stands to bolster its efficiency, curtail costs and elevate overall operational efficacy.”
The future of transportation and logistics in the Indian cement industry is set to undergo significant transformation, driven by technological advancements and sustainability imperatives. Expectations include a rapid uptake of electric vehicles to cut carbon emissions and meet stringent environmental regulations. Further, advanced technologies like IoT and AI will revolutionise operations, optimising route planning and enhancing supply chain visibility. Sustainable packaging solutions are anticipated to gain traction, while collaboration across the supply chain will drive innovation and efficiency. Emphasis on optimisation and cost reduction will remain paramount, with data analytics and automation playing pivotal roles. Overall, the industry’s future outlook promises a greener, more efficient and collaborative approach to cement transportation and logistics.

• –Kanika Mathur

Niranjan Kirloskar, Managing Director, Fleetguard Filters, elaborates on the importance of filtration and its profound impact on efficiency, longevity and environmental sustainability.

Tell us about the core principle of filtration.
Filtration is segregation/separation of matter by density, colour, particle size, material property etc. Filtration is of four basic types:

• Separation of solids from gas
• Separation of solids from liquids
• Separation of liquids from liquids
• Separation of Solids from solids.

As applied to engines/equipment, the main objective of filtration is to purify the impurities and provide the desired fluid or air for enhanced engine/equipment performance in turn optimising their performance and life.

Can better filtration bring productivity to the work process? How?
Better filtration can improve the quality of application performance in multiple ways. Filtration improves engine performance as it filters and prevents dirt, dust, and debris from entering into the engine. This ensures that the quality of air or fluid that reaches the combustion chamber is as per the specific requirements of optimal performance of the engine. It also extends engine life by filtering out contaminants. Efficient filtration ensures optimal performance of the engine/equipment over its entire operating life. Filtration also improves fuel efficiency as a clean filter allows for a better air-fuel mixture in the engine, thus improving combustion efficiency, which in turn results in better fuel economy. It keeps emissions under control as fuels burn more efficiently leading to lesser harmful residue in the environment. Thus, to sum up, an optimal filtration solution ensures better performance, prolonged engine life and less hazardous waste in the environment.

What is the role of technology in the process of filtration?
Innovation, research and development as well as technology play a pivotal role in catering to the ever-evolving environmental norms and growing market demands. At FFPL we have NABL Accredited labs for testing, we have ALD Labs for design, and a team of R&D experts constantly working on providing advanced solutions to cater to the evolving market needs. We have robust systems and advanced technologies that make high-quality, high-precision products. Our state-of-the-art manufacturing facilities use advanced technologies, automation, robotics and also Industry 4.0 as applicable to provide the best products to our customers. To ensure each product delivered to market is of utmost precision, advanced quality equipment such as CMM, scanning systems and automated inspection technologies for real-time monitoring and quality control during the manufacturing of filtration systems and to comply with standard quality requirements are used.

Tell us about the impact of good filtration on health and the environment.
Good filtration of equipment is to the environment what a good respiratory system is to the body. There are various benefits of an efficient air filtration system as it improves the air quality by ensuring optimum combustion of fuel thereby reducing/controlling emissions to the environment. Efficient lube filtration ensures low wear and tear of the engine thereby extending life of the engines and maintaining optimal performance over the entire operating life of the engine. Efficient fuel filtration ensures low wear and tear of expensive and sensitive fuel injection thereby ensuring perfect fuel metering resulting in best fuel efficiency and saving of precious natural resources. This efficient filtration can help to control climate change as it reduces the carbon footprint due to combustion in the environment.

Can your products be customised and integrated with other machinery?
Fleetguard Filters have been known as a leading solutions provider for decades. With relevant experience and close customer relations, we understand the market/applications requirements and develop solutions to address the pressing technical challenges our customers face concerning filtration solutions. Filters can be customised in terms of size, shape and configuration to fit specific requirements. Customised filters can be designed to meet critical performance requirements. Filtration systems can be designed to integrate seamlessly with any auto and non-auto application requirements.

What are the major challenges in filtration solutions?
Major challenges faced in filtration solutions are:

• With every emission regulation change, filtration requirements also keep changing.
• Engines are being upgraded for higher power ratings.
• Space for mounting filtration solutions on vehicles/equipment is shrinking.
• For fuel injection systems, the water separation efficiencies are becoming more and more stringent, so are particle separation efficiencies.
• Due to next level filtration technologies,filtration systems and filter elements are becoming expensive, thereby increasing TCO for customers.
• Customers prefer higher uptimes and longer service intervals to ensure lower maintenance and operating costs.

We, at Fleetguard, strive continuously to ensure that all the pains experienced by our customers are addressed with the fit to market solutions. Balancing the cost of filtration solutions with their performance and durability can be challenging, especially where the requirements of high filtration standards are required. Also, wrong disposal methods for used filters can have environmental impact.

• –Kanika Mathur

Shrivats Singhania, Director and CEO of Udaipur Cement Works (UWCL), shares how the company has embraced cutting-edge technologies and sustainable practices to strengthen its logistics and minimise its carbon footprint.

What is your current production capacity and what are your plans for expansion?
Udaipur Cement Works Limited (UCWL) recently achieved a significant milestone with the inauguration of the newly installed cement grinding and packaging section at our Dabok Plant in Udaipur, Rajasthan. This state-of-the-art facility has nearly doubled our production capacity, from 2.2 million metric tonnes (MT) per annum to an impressive 4.7 million MT per annum.
This expansion wasn’t just about volume – it was a strategic move aligned with catering to the growing demand for high-quality cement in the region. It also allows us to enhance our efficiency and overall competitiveness in the market.
UCWL is committed to continuous improvement and growth within the cement industry. We are constantly looking for ways to expand our operations and better serve our customers.

With the growing production of cement industry wide, how is the cement industry managing its carbon footprint?
The growing production in the cement industry necessitates addressing our collective carbon footprint. At UCWL, we recognise this responsibility and are actively implementing several strategies to minimise our environmental impact. One key approach is embracing advanced technologies. Our recent expansion with the newly installed cement grinding and packaging section incorporates cutting-edge features that enhance efficiency and reduce energy consumption.
Additionally, we have commissioned a Waste Heat Recovery System (WHRS) that utilises waste heat of the pyro-process for power generation. This along with our Captive Solar Power Plants significantly increases our Green Energy share, exceeding 50 per cent of our total electrical consumption.
Furthermore, we recently doubled our Clinker Capacity. While clinker production can be energy-intensive, this expansion allows us to explore alternative fuels and optimise the overall production process, reducing our environmental impact per unit of cement produced.
These initiatives exemplify UCWL’s dedication to environmental stewardship. We are committed to continuous improvement and believe that innovation, coupled with responsible practices, can lead to a more sustainable future for the cement industry.

Tell us about the role of digitalisation and automation in the cement production process.
Digitalisation and automation play a pivotal role in revolutionising the cement production process by enhancing efficiency, productivity and product quality. UCWL has embraced cutting-edge technologies to optimise operations, improve product quality, reduce energy consumption, and ensure timely maintenance. By leveraging automation and digitalisation, UCWL is at the forefront of innovation in the industry, driving operational excellence and setting new benchmarks for efficiency and sustainability.

As the production of cement grows, how does it impact other processes such as logistics, transportation and distribution?
As cement production grows, so does the demand for efficient logistics and transportation. At UCWL, we recognise this link. Increased production volume necessitates a robust and adaptable logistics network to ensure timely and efficient product delivery. We are continuously evaluating and optimising our logistics network to meet this growing demand.
Beyond simply scaling our operations, we are committed to sustainable practices across the supply chain. We have implemented innovative strategies like CNG-powered truck distribution to reduce our carbon footprint during transportation.
These initiatives not only optimise logistics and distribution but also demonstrate UCWL’s unwavering commitment to environmental responsibility. We believe that sustainable practices and efficient operations go hand-in-hand, and we are actively working to achieve both.

What are the sustainability initiatives undertaken by your organisation?
UCWL prioritises sustainability as a core principle. We have actively embarked on a comprehensive journey to minimise our environmental impact and promote responsible practices across our entire operation. This commitment is evident in several key initiatives.
A pioneering first for the Indian cement industry, UCWL deployed a floating solar power plant, significantly reducing our reliance on fossil fuels and contributing to cleaner energy generation. We are also constantly exploring innovative methods for transporting loose cement, with the goal of minimising environmental impact and dust generation during transportation.
These initiatives, along with many others, exemplify UCWL’s unwavering commitment to sustainability. We strive for energy efficiency throughout our operations and are dedicated to environmental stewardship within the cement industry. We believe these efforts will pave the way for a more sustainable future for our company and the environment.

Tell us about the major challenges that may arise in the cement plant and how they are managed.
The cement industry operates in a dynamic landscape, and UCWL recognises that our plants can face several challenges. These can range from managing energy consumption to minimising environmental impact and maintaining peak operational efficiency.
At UCWL, we take a proactive approach to address these challenges. Energy consumption is a significant concern across the industry. We combat this by embracing cutting-edge technologies like automation and digitalisation. These advancements optimise processes, minimise energy waste, and maximise output, leading to greater efficiency in our production.
Minimising our environmental footprint is another top priority. We are committed to implementing sustainable practices throughout our operations. A prime example is our pioneering deployment of a floating solar power plant, the first of its kind in the Indian cement industry. This significantly reduces our reliance on fossil fuels and contributes to cleaner energy generation. Additionally, we utilise WHRS, which not only reduces our environmental impact but also contributes to energy efficiency.
Finally, maintaining peak operational efficiency is crucial for our success. We believe in continuous improvement and are constantly seeking new solutions to further optimise our operations. By proactively addressing these challenges through a combination of innovative solutions, sustainable practices and a commitment to continuous improvement, UCWL effectively manages its plants. This allows us to deliver high-quality cement while minimising our environmental impact.

Tell us about the future outlook of the organisation
The future outlook of UCWL is characterised by a strong emphasis on sustainability, innovation, and growth. By continuing to invest in green energy, automation, and digitalisation, UCWL is poised to maintain its position as a key player in the cement industry.
The company’s strategic vision focuses on meeting market demands, driving operational efficiency and upholding its commitment to sustainability and quality. With a forward-looking approach, UCWL is well-positioned to navigate industry challenges and capitalise on opportunities for continued success and leadership in the cement sector.

• –Kanika Mathur