Concrete

SPECTRAFLOW, now in India

Published

5 years ago

July 1, 2021

admin

Cross belt analysers have been gaining popularity over years especially for the raw material analysis that goes for raw meal preparations. This leads to consistency of raw meal before clinkerisation takes place.

Ramco Cements, an independent Indian group, ordered a Crossbelt and Airslide analyzer from SpectraFlow analytics, for their new integrated plant at Kalvatala, to optimize the stability of their raw meal.

Ramco Cements Limited, founded in 1961, is a reputed cement manufacturer in India, headquartered in Chennai. Ramco Cements produces superior quality cement at their state-of-the art facilities including integrated cement plants and grinding units. The company is the fifth largest cement manufacturer in India and also produces Ready Mix Concrete and Dry Mortar products and operates one of the largest wind farms in the country.

About Ramco Cements Limited, Kalvatala plant:

Greenfield integrated cement plant is being setup at Kalvatala, Kolimigundla Mandal, Kurnool District. The foundation stone was laid in December 2018 and the plant shall be operational in first quarter of 2021. The project will include a Waste Heat Recovery System and a Thermal Power Plant.

FLS was chosen as the main equipment supplier and Ramco Project Team looked after specialized components themselves and choose SpectraFlow Analytics Crossbelt Analyzer for their stockpile and pre-blending management and SpectraFlow Airslide Analyzer for the raw meal optimization of their two raw mills.

SpectraFlow Installation for Quarry/Stockpile Optimization:

The SpectraFlow Crossbelt Analyzer is the online analyzer to be able to measure raw materials on belt conveyors. As raw materials from the quarry are processed through a crusher the raw material on the conveyor belt is statistically homogeneous and therefore the analytical results of the SpectraFlow Crossbelt Analyzer are accurate.

By using SpectraFlow Crossbelt analyzer and a site specific blending strategy at Kavalatala the high variation in the local raw materials shall be balanced out to increase consistency of the stockpile quality.

Summarized benefits are:

– No need of sampling. Sampling from conveyor belts is unrepresentative and slow for process optimization. Additionally, sampling is very work intensive regarding operation and maintenance.

– The analyzer together with a Pre-Blending control software from RAMCO SYSTEMS is fully automating the feed from the hoppers. The analyzer delivers the analytical results and according the setpoint the software is adjusting the feeders into the mixing stage

– The analyzer together with a Pre-Blending control software is informing the quarry/crusher operators of the current composition of the stockpile and accordingly the trucks can be coordinated to reach the setpoint of the stockpile.

– Stockpile quality will be homogeneous and on setpoint. That results in stable and low additive consumption at the raw mill.

– Stable feed from the stockpile leads to stable raw mill operation and fine raw meal/clinker quality.

SpectraFlow Installation for Raw Mill Optimization:

The SpectraFlow Airslide Analyzer is the online analyzer to be able to measure raw materials in airslides. As raw materials in airslides are very homogeneous and dry the analytical results of the SpectraFlow Airslide Analyzer are very accurate and based on these accurate results the raw mix control software can optimize the weight feeders before the raw mill in real time every minute. This results in very low LSF STDEV without the need of extensive sampling and laboratory efforts.

Kalvatala operates 2 Roller Press raw. The raw meal will feed to a joint airslide where the SpectraFlow Airslide analyzer will measure.

For the control of the weight feeders at the 2 raw mills Ramco will use control software from RAMCO SYSTEMS.

By using SpectraFlow an increase in the raw meal homogeneity will be achieved.

Summarized benefits are:

– Two raw mills can be controlled by one online analyzer.

– No need of intensive sampling. No automated sample transport system, no automated laboratory required.

– High cost reduction due to reduced laboratory usage (CAPEX, OPEX, man power,??

– The analyzer together with the control software is fully automating the raw material grinding. The analyzer delivers the analytical results and according the setpoint the software is adjusting the weight feeders of the additive bins.

– Adjustment of the weight feeders in real time every minute. No time delay due to sampling, sample preparation, ??/p>

– Lower LSF STDEV/better and more consistent raw mill quality

RAMCO SYSTEMS

SpectraFlow order

This SpectraFlow order is the 39^th order for the Cement Industry and the 1^st installation in India. This order raises the installed based in India to 2 analyzers (1 Crossbelt & 1 Airslide) and worldwide to 56 analyzers (31 Crossbelt & 25 Airslide).

SpectraFlow Analytics Ltd. Switzerland are the experts in providing online analysis for the cement and minerals industry without any radioactive sources nor neutron generators. The NIR technology used for the SpectraFlow Analyzers is not requiring any permits or licenses and there are no restrictions in buying, importing or maintaining the analyzers. This results in very low operating costs and high availability of the analyzers combined with highly accurate measurement results.

For further information, contact: Vijay Kumar Vemuri, Managing Partner, SPV Engineers, 2242, BHEL MIG,

Phase-I, Serilingampally, Hyderabad – 502032

M no. +91 8885744161, Email:vk.vemuri@spvengineers.com

Concrete

Jammu Division Begins First Cement Rail Traffic to Anantnag

Cement Loading From Kathua for Anantnag to Begin on September 14

Published

2 days ago

September 21, 2026

admin

Jammu Railway Division has placed an indent for the first movement of cement by rail within the division, linking Shaheed Captain Sunil Kumar Choudhary Kathua Railway Station with Anantnag Railway Station. Loading for the consignment is scheduled to begin on September 14.

Concrete

Hard Worker Wins Three Honours at Kyoorius Design Awards

Ramco Cements’ brand secures Grand Prix and two Blue Elephant honours.

Published

2 days ago

September 21, 2026

admin

The Ramco Cements Limited’s construction chemicals brand, Hard Worker, has won three honours at the Kyoorius Design Awards 2026, including the Grand Prix – Grey Elephant in the Design in Action category.

The brand also secured two Blue Elephant honours, one for Design in Action and another for Packaging, recognising the design approach behind its brand identity and packaging.

Launched in 2025, Hard Worker entered the construction chemicals segment with the brand promise, “Hard-working products for hardworking people.” Its visual identity uses animals and birds to represent product benefits. The camel represents the water-retention capability of Hard Worker Eco Plaster, while the cheetah represents the speed and performance of Hard Worker Block Fix.

The visual language has been extended across packaging, retail, communication, literature, digital platforms and other brand touchpoints. Hard Worker uses bold colours, distinctive animal illustrations and simple visual storytelling to communicate product benefits across markets and audiences, including construction workers and applicators.

“For Hard Worker, design was never an afterthought. It was fundamental to how we wanted to build the brand. In a category that is largely functional, we wanted to create a brand that people could recognise, understand and remember instantly. The Kyoorius recognition is a wonderful validation of this design-led approach,” said Mr. AV Dharmakrishnan, CEO, The Ramco Cements Limited.

Mr. Balaji K. Moorthy, Executive Director – Marketing, Ramco Cements said “In a category where communication has traditionally been product-led and functional, we wanted Hard Worker to stand apart by making design an integral part of the brand experience. From the distinctive animal-led packaging to our communication across consumer and trade touchpoints, every element was designed to make the brand more memorable and the product benefits easier to understand.”

Within its first 12 months, Hard Worker crossed Rs 3.5 bn in sales. The latest recognition follows six honours secured by the brand’s campaign at the Kyoorius Creative Awards earlier in 2026, including the Grey Elephant Grand Prix for its Eco Plaster film.

The Kyoorius Design Awards recognise outstanding design work in India’s visual communications sector across multiple categories and platforms. The 2026 awards were announced on 12 September in Goa.

The Ramco Cements Limited is part of the Ramco Group and operates across cement and allied building-material solutions. Hard Worker is its construction chemicals brand, offering solutions across key construction applications.

Concrete

Cement Firms to Invest Rs. 130 bn in Green Energy by FY28

Cement companies plan to expand clean energy capacity to 6 GW by FY28

Published

6 days ago

September 17, 2026

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India’s major cement companies are set to raise their clean energy capacity to 6 GW by March 2028 from around 4 GW at the end of March 2026, according to ratings agency ICRA. The planned expansion is expected to involve investments of Rs. 130 bn over the next two years.

The additional capacity could generate annual savings of Rs. 62 bn to Rs. 67 bn, resulting in an estimated payback period of 1.8 to 2.2 years. Cement is an emission-intensive industry, and leading producers have established net-zero roadmaps covering the next 15 to 20 years.

The calcination process accounts for 57 to 60 per cent of the sector’s total emissions, while fuel combustion contributes 27 to 30 per cent and electricity consumption accounts for 10 to 13 per cent. ICRA said the figures highlighted the need for a broad decarbonisation strategy involving green power, blended cement, alternative fuels and improvements in clinker efficiency.

Green energy is considered one of the most commercially attractive decarbonisation options because it can reduce emissions while lowering operating costs. Every 5 per cent increase in green power replacement can reduce power and fuel costs by Rs. 15 to Rs. 16 per tonne. A 25 per cent replacement level could therefore save Rs. 75 to Rs. 80 per tonne and expand operating margins by 140 to 160 basis points.

Cement producers are also assessing carbon capture, utilisation and storage, although high implementation costs, energy requirements and limited transport and storage infrastructure are expected to slow commercial adoption. The government has proposed Rs. 200 bn over five years to support deployment across key sectors. Meanwhile, companies are targeting thermal substitution rates of 10 to 15 per cent over the next three to five years, compared with the current industry level of around 6 per cent.