Concrete

Transforming perception

Published

5 years ago

July 1, 2021

admin

We are witnessing the journey of cement from commodity to brand, and there have been several facets of this journey. One important aspect is packaging. The primary objective of packaging is to contain, protect and preserve a product as well as support its handling and final presentation. It is an integral part of product planning and promotion. Packaging refers to the process and design, evaluation and production of packages.

Functions of Packaging

Promotion and selling of the product: To create a brand identity the packaging needs to be attractive, colourful, and visually appealing packages have promotional value. A well designed package is a powerful selling device because it helps the product stand out from the competitors.

Defining product identity: It is sometimes used to promote an image such as prestige, convenience or status. Can be a crucial part of marketing strategy particularly in advertising.
Providing information: Packages give directions for product use, information about guarantees, production related information like week of manufacturing, BIS Specification number, dos and don??s, etc. It also provides place and address of the manufacturer. Few of the marketing professionals are of the view that the bag not only should be attractive in looks but also should communicate with the customer. The colour and design should be disruptive, yet should reflect positivity.
Protecting the product: For cement it is important that the packaging should be durable and strong enough so that there is no tampering or spoiling during shipping and delivery of the packages. Being a hygroscopic material, it can easily attract moisture.

It is interesting to see the cement bag?? journey from plant to the end user; it reveals some areas of stress. Like oozing bags, due to iron hooks used by loaders, it has been a chronic problem in handling a cement bag consignment. At majority of places in our country like railway yards, truck loading bays and unloading in ware houses, at the consumption points, iron hooks are rampantly used by the labourers doing the job manually. Due to political interference in the job, the practice is continuing unabated. The quality of bags is another issue for bag bursting. The problem can be eased only by automating the process.

Cement packaging is conventionally done in bags and sacks. These bags and sacks can be made out of paper or plastic, jute. In India for long time we were using jute bag in spite the consumer disliked it but in order to support the jute industry a decision was taken to use jute bags. Then came the age of HDPE and PP bags. Paper as a packaging material was too expensive for us. But paper as a packaging material is favoured in European countries. In few micro markets of our country, paper bags are preferred. Paper bags are usually heavy-duty bags and sacks that are manufactured using multiple layers of paper and can be coated with layers of plastic films to provide a barrier against moisture. Paper bags did not get popular in our country mainly due to the methodology used in handling of paper bags.

The bag handlers always charge more rates for paper bags. However, woven and nonwoven plastic bags can also be employed for cement packaging. These bags can hold up to 50 kg of cement without damage. Bags and sacks used for cement packaging also offer printing area on its surface for branding and promotion of the product. Cement producers never thought of producing bags for their use until the recent past because it has been very convenient to source such a low cost material from outside as and when required. Normal PP bag costs around Rs 9 to 11 per piece and a laminated PP bag costs nearly Rs 15 per piece.

For cement companies, it is backward integration to produce bags for captive use. We suggest our readers to go through the interview of M Ravinder Reddy, Head of Marketing ??Vicat Group (India) and Director Marketing of Bharathi Cement, in the same issue for more information.

Starlinger from Austria in Europe is one of the notable companies in production of machinery for sacks, packaging fabrics and technical textiles woven from plastic tapes. The company has a strong presence in India. Its product AD*STAR cement packaging is a well-known sack concept which has been adopted across the world. The main advantage of using AD*STAR cement sacks is reduction in the bag breakage/ bursting.

What is AD*STAR?

??D*STAR ??is a trademark that can be used as a packaging solution only for the bags manufactured by Starlinger’s end-to-end machinery. Off late many cement manufacturers in India have been using AD*STAR packaging solutions for packing of premium cements in order to differentiate from normal cement.

Since it involves use of technology few cement companies thought that it would be advisable to produce the bags rather than to source these from outside. Considering the quantum of usage it has been felt necessary to produce the bags close to the cement manufacturing unit. Some ingredients of the bags are occasionally imported if not locally available. Various studies show that the use of high-grade virgin polypropylene for fabric production and the tight sealing of the sack bottom and top ensure low breakage even during rough handling, dropping, or after contact with water.

The studies in terms of global warming in use of bags show different results in different countries. E.g. the production phase of AD*STAR sacks have less impact on global warming than paper bags in Saudi Arabia because transportation contributes more to the global warming since the raw materials for the paper sacks have to be shipped which is not the case with AD*STAR bags. In short AD*STAR sacks show that it is environmentally friendlier packaging in terms of acidification potential (acid rain), ozone depletion potential, photochemical ozone creation potential (causes summer smog), as well as energy and fresh water consumption.

Regional preference

The geographical analysis of the cement packaging market has revealed that demand for cement packaging solutions is likely to be fueled by developing countries of the Asia Pacific and the Middle East & Africa. In countries such as India and China, polypropylene cement packaging is used most prominently. The material used for making cement bags is usually recycled, and bags are sewn by hand operated machines at large factories. Furthermore, China is one of the leading manufacturers of cement and has a high impact on the dynamics of the cement packaging industry.

Also, the Middle East region has witnessed the establishment of several new cement plants and revamped the existing ones, to cater to the growing demand for construction material. Hence, the sales of cement packaging solutions are growing at present. The market in the Middle East is turning to PP laminated bags from paper.

Paper v/s plastic

For years, there has been a debate on whether paper packaging is better for the environment than plastic. While the general belief is that paper products are more environmentally friendly because they are made from a renewable source, but the argument that paper is more sustainable than plastic is not so straight forward. Some of these misconceptions are due to not considering the entire life cycle of the bag. It is not a simple case of looking at how bags are being disposed of or how long they take to degrade; other aspects also have an impact on the environment.

While plastic packaging can have a bad reputation, banning them and moving solely to paper products could have other adverse effects. In the end, we need to remember the way we use these products to make the greatest difference, not just the bag itself! The most important decision we can make is to choose packaging that doesn?? end in landfills when it doesn?? have to and to select biodegradable options when recyclable options don?? exist.

HDPE and PP

HDPE stands for high-density polyethylene, is a versatile plastic known for its unique benefits. It is commonly used to create containers like milk and water jugs, water tanks etc. However, HDPE can remain flexible as well. For example, plastic bags. Long-lasting, weather resistant, and capable of carrying weight ??whether rigid or flexible.

PP, which stands for polypropylene plastic, is a type of plastic that is specifically known for its semi-crystalline nature. Additionally, PP is a lighter material compared to other types of plastic like HDPE. This makes it an ideal alternative across a variety of commercial applications. Polypropylene plastic is found in everything from ropes to carpets and clothing. It?? relatively affordable commercial material. Presently cement industry uses PP bags.

Additionally, PP is a lighter material compared to other types of plastic. This makes it an ideal alternative across a variety of commercial applications.

Cement packaging market: Key players

Apart from Starlinger from Austria the other key players operating in the global cement packaging market are Mondi Plc, LC Packaging International BV, Gascogne SA, Bischof + Klein SE & Co. KG, Uflex, Taurus Packaging, Unisun packaging, Gempack, Volgopromtrans LLC, ToolAsian Polysacks, Edna Group, and Rosenflex UK.

Concrete

JSW Cement Begins Production At Nagaur Rajasthan Plant

Greenfield integrated cement plant begins operations in Rajasthan

Published

16 hours ago

March 23, 2026

admin

JSW Cement has started production at a new greenfield integrated cement plant in Nagaur, Rajasthan, marking its first integrated facility in north India. The commissioning advances its national expansion and raises cement grinding capacity to 24.1 million tonnes per annum (MTPA) and clinker manufacturing capacity to nine point seven four MTPA including joint venture capacity. The plant is strategically located to serve high growth markets in Rajasthan, Haryana, Punjab and the National Capital Region.

The Nagaur plant comprises a three point three MTPA clinkerisation unit and a two point five MTPA cement grinding unit, with an additional one MTPA grinding unit under construction. The facility’s capacity additions enable it to meet regional demand and support infrastructure development. The project was funded by equity and long term debt and the company allocated Rs 8 bn from IPO proceeds to part finance the unit.

Company leadership said commissioning was completed within 21 months and that the expansion advances its aim to become a pan India player, with a mid term target of 41.85 MTPA and a long term vision of 60 MTPA. The plant includes sustainability features such as co processing of alternative fuels and a seven kilometre overland belt conveyor to transport limestone from the mines, reducing road transport impacts. The operation is expected to support economic growth and provide supplies for construction projects across the north.

The site will incorporate a 16 megawatt (MW) Waste Heat Recovery System to capture and reuse process heat, reducing the carbon footprint. JSW Cement’s operations include eight plants in India and a clinker unit in the UAE through a joint venture, providing a presence across the building materials value chain. The company emphasised use of industrial by products in manufacture and focus on producing eco friendly building materials.

Concrete

MAPEI India Celebrates 15 Years of Building Excellence

MAPEI India celebrates 15 years with growth, expansion and CSR impact

Published

16 hours ago

March 23, 2026

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MAPEI India marks its 15th anniversary, celebrating a journey defined by innovation, trust, and continuous growth. Beginning in 2011 with just four employees and a single manufacturing facility in Bengaluru, the company has evolved into a key player in India’s construction chemicals industry, now employing over 380 professionals across the country. Over the past 15 years, MAPEI India has delivered strong performance with a sales CAGR of 31 per cent. From zero production in its early years, the company shipped 1,71,000 metric tonnes of materials in 2025, demonstrating robust operational capabilities and rising market acceptance.

To support expanding demand, MAPEI India has steadily scaled its manufacturing footprint. Following the Bengaluru plant in 2011, new facilities were launched in Vadodara in 2016 and Kosi (Mathura) in 2022. A fourth facility in Kharagpur is set to go live in 2026, strengthening the company’s nationwide supply network.

As part of its commitment to global standards, MAPEI India operates under an Integrated Management System (IMS) certified for ISO 9001 (Quality), ISO 14001 (Environment) and ISO 45001 (Health & Safety). These certifications reinforce its dedication to delivering safe, sustainable, and high quality solutions.

With a diverse portfolio of over 20 product lines, MAPEI India has supported iconic projects such as the Atal Tunnel, the Statue of Unity, and major airport and metro developments. The company has also invested Rs 3.2 crore in CSR initiatives focused on education, women’s empowerment, and rehabilitation. As it steps into the future, MAPEI India remains committed to excellence, sustainability, and customer trust.

Mapei hai to bharosa hai.

Concrete

Material Flow Efficiency

Published

6 days ago

March 18, 2026

admin

We explore how material handling systems are becoming strategic assets in cement plants, enabling efficient movement of raw materials, clinker and finished cement. Advanced conveying, automation and digital technologies are improving plant productivity while supporting energy efficiency and sustainability goals.

Material handling systems form the operational backbone of cement plants, enabling the efficient movement of raw materials, clinker and finished cement across complex production networks. With India’s cement industry producing over 391 million tonnes of cement in FY2024 and possessing an installed capacity of around 668 mtpa, according to the CRISIL Research Industry Report, 2025, efficient material logistics have become critical to maintaining plant productivity and cost competitiveness. At the same time, cement production is highly energy intensive and contributes around 7 per cent to
8 per cent of global CO2 emissions, making efficient material flow and logistics optimisation essential for reducing operational inefficiencies and emissions states the International Energy Agency Cement Technology Roadmap, 2023. As plants scale capacity and integrate digital technologies, modern material handling systems, ranging from automated conveyors to intelligent stockyards, are increasingly recognised as strategic assets that influence plant stability, energy efficiency and environmental performance.

Strategic role of material handling
Material handling is no longer viewed as a secondary utility within cement plants; it is now recognised as a strategic system that directly influences production efficiency and process stability.
Cement manufacturing involves the continuous movement of large volumes of limestone, clay, additives, clinker and finished cement across multiple production stages. Even minor disruptions in conveying systems or storage infrastructure can lead to kiln feed fluctuations, production delays and significant financial losses. According to Indian Cement Industry Operational Benchmarking Study, 2024, unplanned downtime in large integrated cement plants can cost between Rs.15–20 lakh per hour, highlighting the economic importance of reliable material handling systems.
Modern cement plants are therefore investing in advanced mechanical handling systems designed for high throughput and operational reliability. Large integrated plants can process over 10,000 tonnes per day of clinker, requiring highly efficient conveying systems and automated stockyards to maintain continuous material flow, suggests the International Cement Review Industry Analysis, 2024. Efficient material handling also reduces spillage, minimises dust emissions and improves workplace safety. As cement plants become larger and more technologically advanced, the role of material handling is evolving from simple transport infrastructure to a critical operational system that supports both productivity and sustainability.

From quarry to plant
The transport of raw materials from quarry to processing plant represents one of the most energy-intensive stages of cement production. Traditionally, limestone and other raw materials were transported using diesel-powered trucks, which resulted in high fuel consumption, dust generation and increased operational costs. However, modern plants are increasingly adopting long-distance belt conveyors and pipe conveyors as a more efficient alternative. These systems allow continuous material transport over distances of 10–15 kilometres, significantly reducing fuel consumption and operating costs while improving environmental performance, states the FLSmidth Cement Industry Technology Report, 2024.
Milind Khangan, Marketing Manager, Vertex Market Research & Consulting, says, “Efficient and enclosed handling of fine materials such as cement, fly ash and slag requires modern pneumatic conveying systems. By optimising the air-to-material ratio, these systems can reduce energy consumption by 10 per cent to 15 per cent while ensuring smooth material flow. Closed-loop conveying further minimises dust loading and improves the performance of bag filters, supporting cleaner plant operations. In addition, flow-regulated conveying lines help prevent clogging and maintain reliable dispatch performance. Overall, automation in pneumatic conveying delivers immediate operational benefits, including improved equipment uptime, lower energy use, reduced material spillage and more stable kiln and mill performance.”
Pipe conveyor systems are particularly gaining traction because they provide a completely enclosed transport system that prevents material spillage and dust emissions. According to global cement engineering studies, conveyor-based transport can reduce energy consumption by up to 30 per cent compared to truck haulage, while also improving operational reliability. Several cement plants in India have already implemented such systems to stabilise quarry-to-plant logistics while reducing carbon emissions associated with diesel transport.

Stockyard management and homogenisation
Stockyards play a critical role in maintaining raw material consistency and stabilising kiln feed quality. Modern cement plants use advanced stacker and reclaimer systems to ensure efficient storage and blending of raw materials before they enter the grinding and pyroprocessing stages. Automated stacking methods such as chevron or windrow stacking enable uniform distribution of materials, while bridge-type or portal reclaimers ensure consistent extraction during kiln feed preparation. These systems are essential for maintaining stable chemical composition of raw meal, which directly influences kiln efficiency and clinker quality. The Cement Plant Operations Handbook, 2024 indicates that advanced homogenisation systems can reduce raw mix variability by up to 50 per cent, significantly improving kiln stability and energy efficiency. Integrated stockyard management systems also incorporate sensors for monitoring bulk density, moisture levels and stockpile volumes, enabling real-time control over material blending processes.

Clinker and cement conveying technologies
Once clinker is produced in the kiln, it must be efficiently transported to storage silos and subsequently to grinding and packing units. Modern cement plants rely on high-capacity belt conveyors, bucket elevators and pneumatic conveying systems to manage this stage of material flow. Steel-cord belt bucket elevators are now capable of lifting materials to heights exceeding 120 metres with capacities reaching 1,500 tonnes per hour, making them suitable for large-scale clinker production lines, states the European Cement Engineering Association Technical Paper, 2023.
For fine materials such as cement, fly ash and slag, pneumatic conveying systems provide a reliable and dust-free solution. These systems transport powdered materials using controlled airflow, ensuring enclosed and contamination-free movement between grinding units, silos and packing stations. Optimised pneumatic systems can reduce energy consumption by 10 per cent to 15 per cent compared to older conveying technologies, while also improving plant cleanliness and environmental compliance, according to the Global Cement Technology Review, 2024.

Automation and digitalisation
Digitalisation is transforming material handling systems by introducing real-time monitoring, predictive maintenance and automated control. Advanced sensors and Industrial Internet of Things (IIoT) platforms enable plant operators to track conveyor health, stockpile levels and equipment performance in real time. Predictive maintenance systems analyse vibration patterns, temperature fluctuations and equipment load data to detect potential failures before they occur. According to McKinsey’s Industry 4.0 Manufacturing Report, 2023, for heavy industries, digital monitoring and predictive maintenance technologies can reduce equipment downtime by up to 30 per cent and increase productivity by 10 per cent to 15 per cent. Digital control centres also integrate data from conveyors, stacker reclaimers and dispatch systems, enabling centralised management of material flows from quarry to dispatch.

Handling of AFR
The growing adoption of Alternative Fuels and Raw Materials (AFR) has introduced new challenges and opportunities for material handling systems in cement plants. AFR materials such as refuse-derived fuel (RDF), biomass and industrial waste often have irregular particle sizes, variable moisture content and lower bulk density compared to conventional fuels. As a result, specialised storage, dosing and feeding systems are required to ensure consistent kiln combustion. According to the Cement Sector Decarbonisation Roadmap published by NITI Aayog in 2026, increasing the use of AFR could enable India’s cement sector to achieve thermal substitution rates of around 20 per cent in the coming decades. To support this transition, plants are investing in automated receiving stations, shredding units, drying systems and precision dosing equipment to stabilise AFR supply and combustion performance.

Energy efficiency and dust control
Material handling systems also play a crucial role in improving plant energy efficiency and environmental performance. Modern conveyor systems equipped with variable speed drives and energy-efficient motors can significantly reduce electricity consumption. Permanent magnet motors used in conveyor drives can deliver 8 per cent to 12 per cent energy savings compared to conventional induction motors, improving overall plant energy efficiency according to the IEA Industrial Energy Efficiency Study, 2023. Dust control is another major concern in cement plants, particularly during material transfer and storage operations. Enclosed conveyors, dust extraction systems and advanced bag filters are widely used to minimise particulate emissions and improve workplace safety.

Future trends in material handling
The future of material handling in cement plants will be shaped by automation, digitalisation and sustainability considerations. Emerging technologies such as AI-driven logistics optimisation, autonomous mobile equipment and digital twins are expected to further improve plant efficiency and operational visibility. Digital twin models allow engineers to simulate material flow patterns, optimise stockyard operations and predict equipment performance under different operating conditions. According to the International Energy Agency Digitalisation and Energy Report, 2024, the adoption of advanced digital technologies could improve industrial energy efficiency by up to 20 per cent in heavy industries such as cement manufacturing. As cement plants expand capacity and adopt low-carbon technologies, intelligent material handling systems will play a critical role in maintaining productivity and reducing environmental impact.

Conclusion
Material handling systems have evolved from basic transport infrastructure into strategic operational systems that directly influence plant efficiency, reliability and sustainability. From quarry transport and automated stockyards to digital dispatch platforms and advanced conveying technologies, modern material handling solutions enable cement plants to manage large production volumes while maintaining process stability.
As India’s cement industry continues to expand to meet infrastructure and urban development demands, investments in advanced material handling technologies will become increasingly important. By integrating automation, digital monitoring and energy-efficient systems, cement manufacturers can improve operational performance while supporting the industry’s long-term sustainability and decarbonisation goals.