Technology

Technology for alternative fuel firing

Published

5 years ago

July 1, 2021

admin

Use of low-grade alternative fuels such as waste coal, tyres, sewage sludge, and biomass fuels (such as wood products, agricultural waste, etc.) in pre-calciners is a feasible option since combustion in pre-calciner takes place at a lower temperature.

India is the second largest cement producer in the world and accounted for over 8 per cent of the global installed capacity as of 2019 with an overall cement production capacity of around 545 MT in FY20. The Indian cement industry is swiftly developing due to the increasing demand of construction sectors, be it housing, commercial, industrial, etc.

Cement manufacturing being a high energy consuming and heavy polluting process accounts for at least 8 per cent of the total emission of greenhouse gases. At the same time, energy-related expenses in the cement sector, mostly on fossil fuels and electricity, account for 30 to 40 per cent of the industry?? cash costs.

Historically, the primary fuel used in cement industry is coal. Recent increases of coal prices in the Indian market again made the cement industry vulnerable to fuel cost. Since then, petroleum coke has been successfully used as fuel and the use alternative fuels in cement kilns is now common and increasing. Although fossil fuels such as coal, petroleum, natural gas, etc. can provide all the energy the world needs for the time being, their finite nature, high prices and most importantly, their damaging effect on the environment underscore the need to develop alternative fuels.

Today?? cement industry becomes more challenging for the following main factors: the lowest production cost and minimum environmental impact. Beyond the cost-reduction benefits of alternative fuels, use of these fuels can contribute greatly to the environmentally sound disposal of waste and to the mitigation of greenhouse-gas emissions (GHG). Therefore, key cement players have started to consider alternative fuels as a lever to improve their contribution to sustainable development and as a key component of corporate social responsibility.

This is certainly a win-win option for both cement industry and the society at large. There is, hence, an urgent need to implement appropriate policies and practices in favor of co-processing in the country so that it can contribute reasonably towards the waste management needs of the country and help industry in substituting alternative resources in the cement manufacturing process. This would require substantial capacity building in the relevant stakeholder community ??particularly the policy makers, authorities, waste generators, facility providers and the cement plants.

Alternative Fuel options available

The range of alternative fuels is extremely wide. Use of low-grade alternative fuels such as waste coal, tyres, sewage sludge, and biomass fuels (such as wood products, agricultural waste, etc.) in pre-calciners is a feasible option since combustion in pre-calciner takes place at a lower temperature. The major Alternative Fuel available to use in India would be MSW (Municipal Solid Waste).

Sewage sludge: In several countries, sewage sludge is used in cement production. The sludge is usually co-fired with coal in pre-dried form. Pre-dried sludge is easier to store, transport and feed. However, it has a high content of SiO2, Al2O3 and Fe2O3 which could affect the quality of cement if excess amounts are used.

Used Tyres: Combustion of whole tyres requires long residence times to obtain complete conversion. In some cement installations, tyres are fired whole, mostly in the rotary kiln. More commonly, they are shredded in a slashing process, producing tyre chunks or chips, and co-fired with coal in the precalciner. They cannot, however, be finely comminuted economically. FLSmidth offers HOTDISC? Combustion Device for high efficient firing of used tyres.

Agricultural Biomass- A largely untapped renewable energy source: The type of biomass utilized by cement plants is highly variable, and is based on the crops that are locally grown/available. For e.g., rice husk, hazelnut shells, coconut husks, corn stover, coffee pods, and palm nut shells are among the many varieties of biomass currently being burned in cement kilns. Biomass fuels are considered carbon neutral because the carbon released during combustion is taken out of the atmosphere by the species during the growth phase.

Major challenges of using agricultural biomass residues include the relatively low calorific value which can cause flame instability, and availability since most of the agricultural residues are seasonal (not available all year round). The flame instability problems could be overcome with lower substitution rates and ability to adjust air flow and flame shape.

Other major Alternative Fuels include waste oil, liquid waste, Plastic, Meat and bone meal, etc.

Benefits of using Alternative Fuels in Cement Production

Cement producers are striving to lower their production costs. One effective method of achieving this end is the use of alternative fuels.

The reduction in emissions to the atmosphere and the positive environmental impact it holds is a major benefit of Alternative Fuel firing. In pre-calciners where kiln exhaust gases pass through, the NOx emissions are much reduced due to reburn reactions. Also, there is an increased net global reduction in CO2 emissions when waste is combusted in the cement kiln systems as opposed to dedicated incinerators, resulting a reduction in penalties.

Key considerations and challenges for co-processing Alternative Fuels

The potential benefits of burning alternative fuels at cement plants are numerous. However, the contrary is possible where poor planning results in higher emissions or when they are not put to their best use with best practices.

Alternative fuels used in cement manufacturing have different characteristics compared to the conventional fuels. Switching fuels present several challenges that must be addressed in-order to achieve successful application. The type of fuel used can introduce some material components which can interfere with the chemistry of the cement materials as well as affect the operation of the system. The use of a type of fuel is hence subject to the constraints imposed by any effect on cement quality, refractory life, gas and material flow or potential emissions to the atmosphere.

Poor heat distribution, unstable pre-calciner operation, blockages in the preheater cyclones, build-ups in the kiln riser ducts, higher emissions and dusty kilns are some of the major challenges.

FLSmidth Alternative Fuel Firing Technology

Introducing alternative fuels has an impact across the plant. The materials can have totally different characteristics from fossil fuels. They can be sticky, fluffy, moist, and fluctuating in size and quality or you may need to switch between different types of fuel with very different characteristic due to governed by availability. They will burn differently, have a different reaction in the kiln and may require you to take other actions to ensure consistent clinker quality. There are a lot of variables at play ??which is why you need an experienced partner on your side.

With over 25 years of direct alternative fuels experience and more than 130 years in the cement industry, FLSmidth? offers a range of products to enable Cement Manufacturers to increase their substitution of Alternative Fuels.

JETFLEX? Burner

Cement kilns have several characteristics which make them ideal installations for disposal of waste through co-processing in an environmentally sound manner:

– High temperatures

– Long residence time

– Oxidizing atmosphere

– High thermal inertia

– Alkaline environment

– Ash retention in clinker

FLSmidth?? JETFLEX? Burner is a highly flexible kiln burner, designed to produce the best flame shape and lowest NOx emissions for various fuel types and operating conditions. It fires rotary kilns with pulverized coal or coke, oil, natural gas, or any mixture of these fuels. Alternative fuel firing of plastic chips, wood chips and sewage sludge can also occur through the same common fuel channel to improve heat and power consumption and minimize cold airflow entering from the fuel transport.

JETFLEX? PLUS Burner

For optimum combustion flexibility, our JETFLEX PLUS Burner offers superior combustion of cost-effective grade fuels, complete flame-forming control and increased fuel retention time. The two design features that characterize the JETFLEX PLUS Burner model are individually rotatable jet air nozzles and a retractable center pipe for alternative fuel firing.

The individual rotatable nozzles also enable fuel lift configuration. This is used with solid alternative fuels to increase fuel retention time in the flame. The result is less fuel drop-out, improved combustion, and improved clinker quality. The swirler is the main mechanism for shaping the flame during start-up and daily operation.

The JETFLEX PLUS burner offers retraction of the swirler and central duct. In combination with the axial air nozzles, this enables a significant drop in fuel velocity in front of the burner. This feature strongly increases the fuel retention time in the flame and enables early ignition of low grade fuels. In combination with the fuel lift configuration as noted above, spillage to the charge is minimised. This allows the burner to contribute to superior flame and clinker quality control as well as a high alternative fuel substitution.

HOTDISC? Combustion Device

The HOTDISC solution allows cement producers to substitute coal or other fossil fuels with a wide range of alternative fuels. The HOTDISC is a flagship solution for FLSmidth?? MissionZero that helps cement producers take an important step toward zero-emission cement plants by 2030. Launched in 2004 and over 35 installations worldwide, the HOTDISC Combustion Devices has already firmly established itself as an attractive technology to accelerate cement plants??transition toward alternative fuels.

From wet powders to solid waste up to 1.2 metres in diameter, our HOTDISC Combustion Device can burn them all. The waste to energy process eliminates the need for expensive shredding and gives you the flexibility to select the most economical choice from a wide range of alternative fuel options. The HOTDISC Combustion Device is designed to achieve a calciner fuel substitution rate of up to 80%, although results vary significantly depending on specific plant conditions.

As an integrated part of your kiln system, the HOTDISC Combustion Device is added onto the calciner and functions as a slow-moving disc furnace. When alternative fuel, preheated raw meal and tertiary air are fed into the HOTDISC, it produces combustion gases, partly calcined meal and combustion residues. These are then processed in the calciner alongside the other streams entering it. The result is calcined meal ready for the kiln and well-controlled emissions.

Alternative fuels are introduced onto the slowly rotating disc and they start to burn in fully-oxidising conditions when they meet the hot tertiary air. The burning fuel is transported approximately 270? on the disc until it reaches the scraper, where the remaining ash and partly calcined materials are discharged into the riser duct. Heavy combustion residues fall into the kiln inlet, while lighter fragments and combustion gases move up into the calciner.

HOTDISC-S? is a recently developed version of HOTDISC specifically to cater the needs of customers with SLC type calciners, hence enabling them to achieve Alternative Fuel firing. Two of these devices have been commissioned globally and running successfully.

Low NOx Calciner

With a goal to optimise production costs, FLSmidth?? Low NOx Calciner has been enhanced for operational stability, availability and combustion efficiency.

NOX regulations are continuously being tightened around the world. Meeting NOx emissions limits is therefore a key demand for cement producers, not only because NOx-related issues, such as smog pollution, have a direct impact on the local society, but also because your plant?? license to operate is directly linked to its NOx emissions.

Multiple fuel inlets are given to ensure optimal distribution between the kiln gases and the fuel. To achieve the best distribution between the kiln gases and the fuel, there are multiple inlets (four or six, depending on plant size). Better fuel distribution provides optimal mixing, which gives the highest average cross-sectional temperature without any build-up problems.

The Low NOX Calciner has the flexibility to burn almost any type of fuel. This includes traditional fuels, including coal and natural gas, more difficult-to-burn fuels, such as petcoke, and most solid and liquid waste fuels. These fuel types are burned while achieving low NOx and CO emissions.Primary Mitigation

Another simple solution FLSmidth? provides for reducing the NOx emissions in the existing plants is the Primary mitigation NOx reduction through calciner design changes. These are basically layout changes to create one firing location, one meal split, one air stream entering tangentially to the calciner and creating “hot zone??and ??eduction zone?? The plant system is studied and appropriate modifications are recommended. For even lower NOx emissions, FLSmidth? provides SNCR system as an add-on solution.

Kiln Gas By-pass System

Kiln gas bypass systems have traditionally only been used in regions where the local raw materials are naturally high in chloride, sulfur or alkalis. The growing use of alternative fuels and other materials is also increasing the input of chloride to kiln systems to the point that may require a bypass to maintain process stability or product quality. FLSmidth has extensive experience with the design and use of kiln bypass systems.

Main features:

– Quench chamber with dual layer dip tube

– Quench air inlet flap valve

– Control scheme for maximum stability

– Special lining design in transition pipe section

– Constant force support system

– Multiple layout possibilities

While the fundamental principles of a bypass system have not changed, state-of-the-art technology and design tools have been incorporated to improve bypass efficiency and maximise reliability. Most projects today will at least have the space for a future small chloride bypass (less than 10%) with respect to use of alternative fuels and materials.

Conclusion

The co-processing of waste as AFR disposes the waste completely and thereby eliminates the societal concerns associated with it. In Indian cement industry, if these initiatives could increase thermal substitution to the level of European countries, the cement industry can reduce its GHG emission by a significant amount, impacting the overall country?? GHG emission.

The type of fuel used in cement production is subject to the constraints imposed by its effects on cement quality, refractory life, emissions to the atmosphere, etc. and hence requires proper study and planning by specialists before implementation.

To reduce fuel cost in cement industry, globally, waste materials and low-grade fuels are co processed extensively as alternative fuels or energy sources. India still has a long way to go in ensuring greater substitution of AFRs, resulting in sizable conservation of natural materials and fossil fuels and to make the most out of the technology available for the same.

Author:

Gopika Krishnakumar

Product Line Manager

Cement Industry/Pyro Technology

FLSmidth

Concrete

Reimagining Logistics: Spatial AI and Digital Twins

Published

15 hours ago

April 13, 2026

admin

Digital twins and spatial AI are transforming cement logistics by enabling real-time visibility, predictive decision-making, and smarter multi-modal operations across the supply chain. Dijam Panigrahi highlights how immersive AR/VR training is bridging workforce skill gaps, helping companies build faster, more efficient, and future-ready logistics systems.

As India accelerates infrastructure investment under flagship programs such as PM GatiShakti and the National Infrastructure Pipeline, the pressure on cement manufacturers to deliver reliably, efficiently, and cost-effectively has never been greater. Yet for all the modernisation that has taken place on the production side, the end-to-end logistics chain, from clinker dispatch to the last-mile delivery of bagged cement to construction sites, remains a domain riddled with inefficiencies, opacity and manual decision-making.
The good news is that a new generation of spatial computing technologies is now mature enough to transform this reality. Digital twins, spatial artificial intelligence (AI) and immersive augmented and virtual reality (AR/VR) training platforms are converging to offer cement producers something they have long sought: real-time visibility, autonomous decision-making at the operational edge, and a scalable solution to the persistent skills gap that hampers workforce performance.

Advancing logistics with digital twins
The cement supply chain is uniquely complex. A single integrated plant may manage limestone quarrying, kiln operations, grinding, packing and despatch simultaneously, with finished product flowing through rail, road, and waterway networks to reach hundreds of regional depots and distribution points. Coordinating this network using spreadsheets, siloed ERP data, and phone calls is not merely inefficient; it is a structural liability in a competitive market where delivery reliability is a key differentiator.
Digital twin technology offers a way out. A cement logistics digital twin is a continuously updated, three-dimensional virtual replica of the entire supply chain, from the truck loading bays at the plant to the inventory levels at district depots. By ingesting data from IoT sensors on conveyor belts and packing machines, GPS trackers on road and rail fleets, weighbridge records, and weather feeds, the digital twin provides planners with a single, authoritative picture of where every ton of cement is, in real time.
The value, however, goes well beyond visibility. Because the digital twin mirrors the physical system in dynamic detail, it can run scenario simulations before decisions are executed. If a primary rail corridor is disrupted, logistics managers can model alternative routing options, shifting volumes to road or coastal shipping, and assess the cost and time implications within minutes rather than days. If a packing line at the plant is running below capacity, the twin can automatically recalculate dispatch schedules downstream and alert depot managers to adjust receiving resources accordingly.
For cement companies operating multi-plant networks across geographies as varied as Rajasthan and the North-East, this kind of end-to-end situational awareness is transformative. It collapses information latency from hours to seconds, enables proactive rather than reactive logistics management, and creates the data foundation upon which AI-driven decision-making can be built. Companies that have deployed logistics digital twins in comparable heavy-industry contexts have reported reductions in transit time variability of up to 20 per cent and meaningful decreases in demurrage and detention costs, savings that flow directly to the bottom line.

Smart logistics operations
A digital twin is only as powerful as the intelligence layer that sits on top of it. This is where Spatial AI becomes the critical differentiator for cement logistics.
Traditional logistics management systems are reactive. They record what has happened and flag exceptions after the fact. Spatial AI systems, by contrast, are proactive. They continuously analyse the state of the logistics network as represented in the digital twin, identify emerging bottlenecks before they crystallise into delays, and recommend corrective actions.
At the plant gate, AI-powered visual inspection systems using spatial depth-sensing cameras can assess truck conditions, verify load integrity and confirm seal tamper status in seconds, replacing the manual checks that currently slow throughput. At the depot level, Spatial AI can monitor stock drawdown rates in real time, cross-reference them against pending customer orders and inbound shipment ETAs, and automatically trigger replenishment orders when safety thresholds are approached. In transit, AI systems processing GPS and telematics data can detect anomalous vehicle behaviour, including extended stops, route deviations, speed irregularities and alert fleet managers instantly.
Perhaps most significantly for Indian cement logistics, Spatial AI can optimise the complex multi-modal routing decisions that are central to competitive cost management. Given the variability in road quality, seasonal accessibility, rail rake availability, and regional demand patterns across India’s vast geography, the combinatorial complexity of routing optimisation is beyond human planners working with conventional tools. AI systems can process this complexity continuously and adapt routing recommendations as conditions change, reducing empty running, improving vehicle utilisation and cutting fuel costs.
The agentic dimension of modern AI is particularly relevant here. Agentic AI systems do not merely analyse and recommend; they act. In a cement logistics context, this means an AI system that can, within pre-authorised boundaries, directly communicate revised dispatch instructions to plant teams, update booking confirmations with freight forwarders and reallocate available rail rakes across plant locations, all without waiting for a human to process a recommendation and make a call. For logistics executives, this represents a genuine shift from managing a workforce to setting the rules of engagement and reviewing outcomes. The operational tempo achievable with agentic AI simply cannot be matched by human-in-the-loop systems working at the pace of emails and phone calls.

Bridging the skills gap
Technology investments in digital twins and spatial AI will deliver diminishing returns if the human workforce cannot operate effectively within the new systems they create. This is a challenge that India’s cement industry cannot afford to underestimate. The sector relies on a large, geographically dispersed workforce, including truck drivers, depot managers, despatch supervisors, fleet maintenance technicians, many of whom have been trained on paper-based processes and manual workflows. Retraining this workforce for a digitised, AI-augmented environment is a substantial undertaking, and conventional classroom or on-the-job training methods are poorly suited to the scale and pace required.
Immersive AR and VR training platforms offer a fundamentally different approach. By creating photorealistic, interactive simulations of logistics environments, such as a plant dispatch bay, a depot yard, the interior of a cement truck cab, allow workers to practice complex procedures and decision-making scenarios in a safe, consequence-free virtual environment. A depot manager can work through a simulated rail rake delay scenario, making decisions about customer allocation and communication
without the pressure of real orders being affected. A truck driver can practice the correct procedure for securing a load of bagged cement without the risk of a road incident.
The learning science case for immersive training is compelling. Studies consistently show that experiential, simulation-based learning produces faster skill acquisition and higher retention rates than didactic instruction, with some research indicating retention rates three to four times higher for VR-based training compared to classroom methods. For complex operational procedures where muscle memory and situational awareness matter as much as conceptual knowledge, the advantage of immersive simulation is even more pronounced.
Today’s leading cloud-based spatial computing platforms enable high-fidelity AR and VR training experiences to be delivered on standard mobile devices, removing the hardware barrier that has historically made immersive training impractical for large, distributed workforces. This is particularly relevant for cement companies with depots and logistics operations in tier-two and tier-three locations, where access to specialised training hardware cannot be assumed.
The integration of AR into live operations also creates ongoing learning opportunities beyond formal training programs. As an example, maintenance technicians equipped with AR overlays can receive step-by-step guidance for equipment procedures directly in their field of view, reducing error rates and service times for critical plant and fleet assets.

New strategy, new horizons
India’s cement industry is entering a period of intensifying competition, rising logistics costs, and demanding customers with shrinking tolerance for delivery variability. The companies that will lead over the next decade will be those that treat logistics not as a cost centre to be minimised, but as a strategic capability to be built.
Digital twins, spatial AI and immersive AR/VR training are not distant future technologies, they are deployable today on infrastructure that Indian cement companies already operate. The question is not whether to adopt them, but how quickly to do so and where to begin.

About the author:
Dijam Panigrahi is Co-Founder and COO of GridRaster Inc., a provider of cloud-based spatial computing platforms that power high-quality digital twin and immersive AR/VR experiences on mobile devices for enterprises. GridRaster’s technology is deployed across manufacturing, logistics and infrastructure sectors globally.

Concrete

Beyond Despatch: Building a Strategic Supply Chain Process

Published

15 hours ago

April 13, 2026

admin

Dr SB Hegde, Global Cement Industry Leader discusses the imperative need for modern cement plants to recognise packaging and bag traceability as critical components of quality assurance and supply chain management.

In cement manufacturing, considerable attention is given to clinker quality, kiln operation, grinding efficiency and laboratory control. Yet the final stage of the process, cement packaging and despatch, often receives less strategic focus. The cement bag leaving the plant gate represents the final interface between the manufacturer and the customer. Even if clinker chemistry, fineness and strength development are well controlled, weaknesses in packaging, handling, or distribution can affect product quality before it reaches the construction site.
Operational experience from cement plants across different regions shows that packaging efficiency and bag traceability have a significant influence on product reliability, logistics performance and brand credibility. In modern cement plants, packaging systems are no longer viewed merely as despatch equipment. They are increasingly recognised as an important part of quality assurance, supply chain management and customer confidence.

Operational importance of packaging
Cement packaging systems must operate with high speed, accuracy and reliability to support efficient despatch operations. Rotary packers equipped with electronic weighing systems have improved packing accuracy and productivity in many plants.
However, maintaining operational discipline remains essential. Regular calibration of weighing systems, maintenance of packer spouts and proper bag application are important for maintaining consistent bag weights and preventing cement loss.
Operational benchmarks observed in many cement plants are summarised in Table 1.
Plants that improved calibration discipline and equipment maintenance have reported packing loss reductions of about 1 per cent to 1.5 per cent, which represents significant annual savings.

Quality assurance beyond the plant gate
Quality control in cement plants traditionally focuses on laboratory parameters such as fineness, compressive strength and chemical composition. However, the condition of cement when it reaches the customer is equally important.
Cement bags may travel through several stages including plant storage, transport vehicles, dealer warehouses and retail outlets before reaching the construction site. During this journey, cement may be exposed to humidity, rough handling and improper storage conditions.
Table 2 shows common factors that may affect cement quality during distribution.
Studies indicate that cement stored under humid conditions for long periods may experience 10 per cent to 20 per cent reduction in early strength. Therefore, maintaining proper packaging integrity and traceability is essential.

Role of cement bag traceability systems
Traceability systems allow manufacturers to identify when and where cement was produced and despatched. These systems connect packaging operations with production records and logistics data.
When customer complaints occur, traceability enables manufacturers to identify:

Production batch
Packing date and time
Plant location
Laboratory test results

Several technologies are used to implement bag traceability, as shown in Table 3.
Among these technologies, QR code authentication systems are becoming popular because customers can verify product authenticity through smartphones.

Digital transformation
Digital technologies are transforming cement packaging operations. Modern packing lines now integrate:

automated rotary packers
electronic bag counting systems
robotic palletising systems
ERP-based despatch management
digital supply chain monitoring

These technologies improve operational efficiency and transparency across the supply chain.
Such systems help manufacturers track cement movement across the distribution network and respond quickly to quality concerns.

Case Study: Digital Cement Bag Authentication
Several cement manufacturers in Asia and the Middle East have implemented QR code-based bag authentication systems to improve supply chain transparency.
In one integrated cement plant, QR codes were integrated into the rotary packing machine. Each cement bag received a unique digital identity linked to the production database.
The QR code contained information such as:
• plant location
• manufacturing date and time
• product type
• batch number

Customers and dealers could scan the code using a mobile application to verify product authenticity.
After implementation, the company reported:
• reduction in counterfeit bag circulation
• improved despatch data accuracy
• faster resolution of customer complaints
• better visibility of distribution networks

The system was also integrated with the company’s ERP platform, enabling real-time monitoring of production and despatch activities.

Future-Smart Packaging Systems
The future of cement packaging lies in the integration of Industry 4.0 technologies with logistics and supply chain management.
Packaging lines will increasingly become part of connected digital ecosystems linking production, quality control, despatch and market distribution.
Artificial intelligence and data analytics may also help detect abnormalities in bag weight variations, equipment performance and despatch patterns.

Global benchmark indicators
Global benchmarking of cement packaging operations highlights the increasing importance of efficiency, automation and digital traceability in modern cement supply chains. Leading cement plants are now focusing on key performance indicators such as packer availability, bag weight accuracy, packing losses, truck turnaround time and digital traceability coverage. Studies show that overall equipment effectiveness (OEE) in many industrial operations is still around 65 per cent to 70 per cent, whereas world-class plants aim for levels above 85 per cent, indicating significant scope for improvement in operational efficiency.
At the same time, the global cement packaging sector is expanding steadily, supported by growing infrastructure demand and increased emphasis on reliable and moisture-resistant packaging solutions. The cement packaging market is projected to grow steadily in the coming decade as companies adopt automation, smart packaging technologies and integrated logistics systems to improve despatch efficiency and supply chain transparency. In this context, benchmarking against global indicators helps cement plants identify performance gaps and adopt best practices such as automated bagging systems, QR-based traceability, ERP-linked despatch monitoring, and predictive maintenance of packing equipment.

Strategic Recommendations
To fully benefit from packaging and traceability systems, cement manufacturers should consider the following approaches.
• Packaging systems should be treated as an integral part of the manufacturing value chain rather than simply despatching equipment.
• Investments in modern packers, automated loading systems and digital traceability technologies should be encouraged.
• Industry associations may also promote standard traceability practices to reduce counterfeit products and improve transparency in the cement market.
Finally, continuous training of plant personnel in packaging operations and maintenance practices is essential for sustaining operational efficiency.

Conclusion
Cement packaging has evolved from a routine mechanical operation into a strategic component of modern cement manufacturing. Efficient packaging systems ensure that the quality achieved within the plant is preserved during transportation and distribution. Traceability technologies allow manufacturers to track cement movement, investigate complaints and prevent counterfeit products.
As the cement industry moves toward digitalisation and integrated supply chains, packaging and bag traceability will play an increasingly important role in quality assurance, operational efficiency and customer confidence. Ultimately, the cement bag leaving the plant carries not only cement but also the reputation and responsibility of the manufacturer.

References

Hewlett, P.C., & Liska, M. (2019). Lea’s Chemistry of Cement and Concrete. Butterworth-Heinemann.
Schneider, M., Romer, M., Tschudin, M., & Bolio, H. (2011). Sustainable cement production. Cement and Concrete Research, 41(7), 642–650.
International Cement Review. (2023). Advances in cement packaging and logistics systems.
World Business Council for Sustainable Development (2021). Cement Industry Supply Chain Innovation Report.
Gartner, E., & Hirao, H. (2015). Reducing CO2 emissions in cement production. Cement and Concrete Research.
ScienceDirect Industry Studies. (2024). Operational efficiency benchmarks and overall equipment effectiveness in industrial manufacturing systems.
World Cement Association. (2022). Digital Transformation in Cement Manufacturing and Logistics. London.
Towards Packaging Research. (2024). Global cement
packaging market trends and technology outlook. Industry Market Analysis Report.
Towards Packaging Research. (2024). Global cement
packaging market trends and technology outlook. Industry Market Analysis Report.

About the author:
Dr SB Hegde is a Professor at Jain College of Engineering, Karnataka, and Visiting Professor at Pennsylvania State University, USA. With 248 publications and 10 patents, he specialises in low-carbon cement, Industry 4.0, and sustainability, consulting with cement companies to support India’s net-zero goals.

Table 1. Key Operational Parameters for Cement Packaging Systems

Parameter Typical Industry Range Recommended Target Operational Significance
Rotary packer capacity 2400–3600 bags/hr 3000–4000 bags/hr Improves despatch efficiency
Bag weight tolerance ±0.5 kg ±0.25 kg Reduces customer complaints
Bag leakage rate 1 per cent to 2 per cent <0.5 per cent Minimises cement loss Packing accuracy 98 per cent to 99 per cent >99.5 per cent Ensure compliance with standards
Truck loading time 30–45 minutes 20–30 minutes Improves logistics efficiency

Table 2. Causes of Cement Quality Degradation During Distribution
Factor Typical Cause Impact on Cement
Moisture exposure Poor storage or rain exposure Lump formation
Long storage duration Slow inventory turnover Loss of early strength
Bag damage Rough handling Cement loss
Improper stacking Excessive loading Bag rupture
Counterfeit bag reuse Refilling of empty bags Brand damage

Table 3. Comparison of Cement Bag Traceability Technologies
Technology Advantages Limitations
Printed batch code Low cost and simple Limited traceability
Barcode Fast scanning Requires equipment
QR code Smartphone verification Requires digital platform
RFID tagging Automated tracking Higher cost
Blockchain systems High transparency Complex implementation

Economy & Market

SEW-EURODRIVE India Opens Drive Technology Centre in Chennai

Published

3 weeks ago

March 25, 2026

admin

The new facility strengthens SEW-EURODRIVE India’s manufacturing, assembly and service capabilities

SEW-EURODRIVE India has inaugurated a new Drive Technology Centre (DTC) in Chennai, marking a significant expansion of its manufacturing and service infrastructure in South India. The facility is positioned to enhance the company’s responsiveness and long-term support capabilities for customers across southern and eastern regions of the country.

Built across 12.27 acres, the facility includes a 21,350-square-metre assembly and service setup designed to support future industrial growth, evolving application requirements and capacity expansion. The centre reflects the company’s long-term strategy in India, combining global engineering practices with local manufacturing and service capabilities.

The new facility has been developed in line with green building standards and incorporates sustainable features such as natural daylight utilisation, solar power generation and rainwater harvesting systems. The company has also implemented energy-efficient construction and advanced climate control systems that help reduce shopfloor temperatures by up to 3°C, improving production stability, product quality and working conditions.

A key highlight of the centre is the 15,000-square-metre assembly shop, which features digitisation-ready assembly cells based on a single-piece flow manufacturing concept. The facility also houses SEW-EURODRIVE India’s first semi-automated painting booth, aimed at ensuring uniform surface finish and improving production throughput.

With the commissioning of the Chennai Drive Technology Centre, SEW-EURODRIVE India continues to strengthen its manufacturing footprint and reinforces its long-term commitment to supporting industrial growth and automation development in India.