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What does efficiency look like at cement plant’s loading bay?

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The expansion of Indian cement industry over the last two decades has been remarkable and the prospects for demand and growth are exceptional. While the industry is focusing on modernisation and sustainability; one area that needs a bit more focus is the packing, loading and dispatch operations. Many plants still operate a semi or even wholly manual packing and loading process and the use of non-laminated HDPE bags is widespread.

Of course, it doesn?? have to be this way. The technology exists to totally modernise the packing, loading and dispatch process. It is already being used in factories around the world. Automation is giving cement plants an opportunity to eliminate bottlenecks in the loading bay. Increase the throughput in the packing plant and, in short, get more high-quality product out to customers. That is the potential of an efficient cement dispatch unit.

FLSmidth has been operating in India for a very long time. We know the market very well and we have had a lot of success here, but we??e also faced some challenges. The biggest of these is the lack of uniformity among empty bag manufacturers and the variation in truck dimensions. Automated truck loaders are typically designed to work within the scope of the dimensions provided by manufacturers, but they rely on those dimensions staying within the established range.

We are big believers in building solutions ??not products. Providing great technology is not enough. It has to work for you, now. So having talked with our Indian cement plant customers, we set about developing a more flexible automatic truck loading equipment.

Indian trucks are a thing of beauty ??not homogeny. Lengths range from 6 to 14 m. Internal widths vary from 2 to 2.5 m. Some have high fixed lateral sides that cannot be removed. All of this poses an interesting challenge to automated truck loading. Add to that the fact that customers wish to keep the same straight bag loading pattern used with manual loading to avoid extra unloading costs. And then the difficulties that come with the (currently extensive) use of HDPE non-laminated bags, which do not typically work so well with automated loading machines as the more internationally used paper and WPP glued valve bags.

Increasing efficiency in packaging and loading operations

In practice, an efficient dispatch operation comprises:

  • A degree of automation that allows you to significantly optimise human intervention and create a safer and more productive working conditions.

  • Optimisation of every piece of equipment in terms of output, weighing accuracy and reliability, reducing both the downtime required for maintenance and the number of spare parts needed.

  • Reduced dust emissions and a cleaner working environment and bag quality.

  • Optimum bag handling to ensure product is protected.

  • Ability to satisfy market demand, both in terms of quantity and the preferred means of delivery ??i.e. truck or rail ??with flexibility built in.

  • Best possible configuration of the loading plant and packing area for the utmost safety, productivity and flexibility.

Intelligent bag loading technology

Using the traditional top bag-loading principle, the CARICATECH??forms the bag layer above the truck and then transfers the layer onto the truck platform. What differentiates the CARICATECH??is that bag layers are formed on a special roller bed and then picked up and positioned on the truck by forks. With the CARICATECH SB model, the loading pattern is adjusted to the truck dimensions automatically to match with manual loading pattern.

Setting loading parameters is easy and intuitive. It is possible to make changes to the loading parameters in real time. But the biggest benefit is the diversity of automatic loading capabilities. It?? possible to handle different bag sizes, pattern configurations (interlocked or not, Fig 1), and loading modes (flat and/or pyramidal loading) with a different number of bags per layer, layer by layer, completely automatically.

The CARICATECH??model for loading interlocked or straight bag layers has already been implemented, where loading bay space is limited and therefore needs to be highly efficient to avoid a bottleneck. This design version can handle up to 3300 bags per hour and is flexible enough to cope with a range of bag types and truck dimensions in use. The loading operation is now completely automated and is controlled remotely with cameras and monitors to supervise, avoiding the need to put an operator in a high-risk condition.

This technology has the ability to revolutionise truck loading in India, enabling higher capacities and faster loading operations than ever before. Moreover, the CARICATECH??is future-proof and will be equally efficient ??in fact, more efficient ??if the market moves away from HDPE non-laminated bags.

For more details:

Ashish Kumar Srivastava

Email: Ashishkumar.Srivastava@Flsmidth.com

Vikesh Singh

Email: Vikesh.Singh@flsmidth.com

Satyender Sehgal

Email: Satyender.sehgal@flsmidth.com

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Concrete

Cement Makers’ Margins To Fall Rs 50-75 Per Tonne Amid West Asia Conflict

Crisil Sees Margins Easing Despite Steady Demand

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Crisil said operating margins of Indian cement manufacturers are expected to decline by Rs 50-75 per tonne (t) this fiscal to Rs 925-950 per t due to higher input costs triggered by the West Asia conflict. The analysis covered 18 cement companies accounting for nearly 90 per cent of India’s domestic cement capacity and noted margins had improved sharply to around Rs 1,000 per t in fiscal 2026.

Crisil noted that the reduction would be driven mainly by higher power and fuel costs, which account for about 30 per cent of total costs, as petcoke and imported coal prices have surged amid geopolitical uncertainties. Freight costs, which account for about a quarter of total costs, are also expected to remain elevated because of higher diesel prices. The impact on profitability is likely to be more pronounced in the first half of the fiscal year before easing commodity prices moderate cost pressures later.

The rating agency said steady domestic demand and strong balance sheets should keep credit profiles stable despite the moderation in margins. Green energy currently accounts for 35-40 per cent of the sector’s total electricity consumption and is expected to partly cushion higher energy costs. Operating cash flows are likely to remain resilient, supported by projected 6-7 per cent growth in cement demand this fiscal.

Crisil highlighted that demand growth will be driven primarily by infrastructure spending, which meets about one-third of sector consumption, and by a nearly 18 per cent higher budgetary allocation for core ministries that should support project execution. Weaker rural housing demand amid pressure on agricultural incomes from a possible below-average monsoon may be offset by improved urban housing demand supported by favourable home-loan rates and a strong pipeline of Pradhan Mantri Awas Yojana-Urban projects. Ongoing capacity additions will keep capital expenditure elevated and may lift net debt to EBITDA to between 1.2 and 1.4 times from around 1.0 time last fiscal, though ratios are expected to remain healthy.

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Concrete

UltraTech Board Approves Rs 50 bn Fundraise Via NCDs

Company to issue half a million debentures for expansion plan

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UltraTech Cement’s board of directors has approved raising Rs 5,000 crore (Rs 50 bn) through non?convertible debentures issued in rupees.

The finance committee cleared a proposal to issue up to 500,000 fully paid, unsecured, listed, rated, redeemable, rupee?denominated, non?convertible, non?cumulative debentures of Rs 1 lakh each (Rs 0.1 mn each), aggregating to the Rs 5,000 crore programme.

As of June 2026 the firm reported net debt of Rs 15,875 crore (Rs 158.75 bn) and said its capacity expansion projects under execution are backed by capital expenditure of about Rs 17,000 crore (Rs 170 bn) over the next two to two?and?a?half years.

UltraTech spent Rs 9,500 crore (Rs 95 bn) on capital expenditure in financial year 2026 and in April the group crossed 200.1 mn tonnes per annum of domestic grey cement capacity and 205.5 mn tonnes per annum of global capacity.

The chief financial officer indicated the company would take consolidated capacity beyond 242 mn tonnes per annum, with grey cement capacity reaching 212.7 mn tonnes per annum by the end of financial year 2027. He noted the net debt?to?earnings before interest, taxes, depreciation and amortisation ratio stood at 0.87 times as of June 2026 and the company was confident of ending financial year 2027 with the ratio below one time.

In the first quarter of financial year 2026?27 UltraTech’s net profit attributable to owners rose 16.8 per cent year?on?year to Rs 2,599.3 crore (Rs 25.993 bn) and revenue from operations increased 15.9 per cent to Rs 24,648.20 crore (Rs 246.482 bn). The board approval is expected to complement internal cash flows as the company advances its expansion programme.

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Concrete

Lokesh Lays Stone For Rs 31 Billion Cement Unit In Kadapa

Line-2 expansion to make Kadapa a major cement hub

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Andhra Pradesh Education and IT Minister Nara Lokesh on Wednesday laid the foundation stone for the Line-2 expansion of Dalmia Bharat Cement at Chinnakomerla village in Mylavaram Mandal in Kadapa district. The project carries an investment of Rs 31 billion (bn) and is slated for completion by the third quarter of the financial year 2028. The expansion is intended to boost industrial growth and employment generation across the Rayalaseema region.

Once commissioned, the Kadapa facility will become Dalmia Bharat’s largest integrated cement manufacturing ecosystem in southern India, creating over 1,000 direct and indirect jobs and opening new business avenues for regional micro, small and medium enterprises and transport operators. Lokesh said the expansion signalled growing corporate confidence in the state and reflected the practical ease of doing business that secured repeat investment.

He placed the project within the government’s wider economic targets and recalled the Yuvagalam padayatra commitment to generate two million (mn) jobs within five years, noting that the state would cultivate talent while industry created opportunities. Lokesh highlighted Andhra Pradesh’s competitive pursuit of major manufacturing accounts, mentioning past successes and a personal initiative to engage global investors when persuading them to anchor expansion in the state.

The plant will leverage Kadapa’s abundant limestone reserves to scale production and sustainability. Clinker capacity is planned to rise from two point five million tonnes per annum (mn tpa) to six point one mn tpa, while overall cement output will increase from three point six mn tpa to nine point six mn tpa. The unit is designed to operate on over eighty per cent renewable energy and deploy waste heat recovery, zero liquid discharge, water recycling and advanced AI systems to optimise efficiency. Industries Minister TG Bharat, BC Welfare Minister S. Savitha and Jammalamadugu MLA C. Adinarayana Reddy attended the ceremony.

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