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Brand War

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Branding matters. From a product’s characteristic-specific branding to concepts like ‘enduring relations,’ ‘trust’ and ‘reliability’; from the so- called dry commercials to humorous TVCs, from stagnant frames to animated 3D frames; and from general concepts to niche concepts like green and sustainable development, branding in cement industry has come a long way. Indian Cement Review trains its thought on the current trends in branding, with a specific focus on whether major players are more into the greening of branding.

MAYBE the brand war started in the late 1990s or the early 2000s, a period where the cement industry was split into two groups, one vociferously supporting the use of mineral additives such as fly ash, slag, rice husk, etc, and the other determined to block the inevitable change. The latter lot harped on the OPC brand and strength as the only criteria of determining the quality of cement. And there was even a period when branding just based on these concepts and was witness to branding campaigns such as `zero per cent ash,` which ultimately had to be recalled.

Of course, it all happened for the good. Today, when we talk about branding, even a commodity like cement has followed the major trends; be it celebrity endorsement, aligning with sports, introducing a streak of humour, animation technology, and choreography, the trend is towards branding it green.

As the competition space has drastically changed with the entry of global players into the cement industry, innovative branding and marketing exercises have become imperatives. It is no wonder that many major cement companies have started aligning their selling strategies with branding campaigns and celebrity endorsements with the clear- cut objective of not only differentiating the product but creating different sets of values. They too have realised that in order to retain customer loyalty, they need to create a distinct brand identity.

According to Kumar Pillay, Vice-President, Head-Marketing Services, UltraTech, brand is a key differentiator for cement. The success lies in creating a proper connect with the customer to increase brand recall supported by good visibility and to create brand recognition at the outlets. He says, "A powerful brand reinforces trust and instills confidence in the buyer, increasing his willingness to pay a premium for the product. A good brand has a strong consumer pull and gains the acceptance of the trade as he needs to put in less effort in selling the same. More and more people are then willing to stock the brand and it becomes the most stocked brand. A powerful brand increases customer loyalty and also gets recommended to others. The brand becomes the preferred brand, resulting in increase in sales volume. This combined with the premium, helps in an increase in turnover."

Brand it green

Today, there is greater focus not only on optimising fuel/energy efficiency during various processes of cement manufacturing, storage and its distribution, there is also a renewed focus on making the cement industry greener and more sustainable. The Indian cement industry is probably one of the most energy efficient ones in the world today. Some of the plants have thermal and electrical specific energy consumption (SECs) comparable to the best cement plants in the world, resulting in low emission intensities. The industry which is on the top in the Certified Emission Reductions Projects list registered with the Clean Development Mechanism (CDM) of the Kyoto Protocol, has contributed significantly to the eco-friendly use of industrial wastes and thereby has succeeded in reducing its carbon footprint. But has this concept of green and sustainable ever got due recognition in branding exercises?

Kumar Pillay had this to say: "Environmental sustainability is a global phenomenon and there is a major concern for the depleting natural resources. The Indian construction industry has realised the importance of green buildings and is wholeheartedly supporting the revolution. The ratings provided by IGBC in India for LEED certification has become popular and more builders are aiming for a higher rating. This has led to an increase in demand for green products. The industry has taken upon itself the onus of providing healthy living conditions. Manufacturers on their part are also chipping in by producing environment- friendly products. They have realised that green is a powerful platform to gain a heartshare amongst consumers. Hence, more and more brands are taking steps to make their products environment- friendly and also initiating campaigns to popularise their products as green products."

According to BK Singh, Senior Executive Director – Group Marketing & Corporate Communication, Dalmia Bharat, sustainability is one of biggest agendas discussed at world fora, governments, scientists, industry, and people at large. The responsibility of addressing this mega challenge lies both with the government and industries to a large extent. It will need both mitigation and adaptation routes. In the near future, adoption of sustainability initiatives will become the license to operate. Increasingly funds and technology will become costlier for those who fail to adopt credible sustainability programmes, rendering their products uncompetitive and face extinction. Many products have started carrying green declarations (Environment Product Declarations: EPDs) and people are ready to pay a premium for such products. A simple example is organic foods. Then why not cement?"

The entry of global brands has really added new facets to the brand war. Branding here is no more characteristic, specific of a product such as strength of cement or durability of a structure, nor concepts like ‘enduring relation’, or ‘trust’ or ‘ever-dependant’ that we hitherto have been accustomed to. The context is rather holistic, propelled by two major trends – one, an intensely competitive space that made the cement manufactures think out of the box and come out with an array of product solutions, other than just offering simple solutions. So branding here happens on a higher plane. For example, Lafarge India’s new baseline reads – ‘Building Better Cities.’ Lafarge India recently unveiled the Group’s new positioning to build better cities marking company’s current presence in the Indian market. The new brand baseline ‘Building Better Cities’ demonstrates Lafarge’s position as a company offering innovative products and construction solutions to all its customers and stakeholders.

Says Martin Kriegner, Country Chief Executive Officer, Lafarge India, "Our commitment towards building better cities encompasses our overall ambition. Although our work in this area isn’t new, we believe that by explicitly stating our purpose, we will be in a stronger position to work even more closely with our customers and stakeholders to the benefit of the living environments that surround us all. And it will further differentiate us from our competitors." Kriegner further adds, "We want to play a part in the improvement of towns and cities, helping people access better quality housing at a cost they can afford and better quality infrastructure, with a lesser impact on nature, thanks to innovative products and solutions to support our customer needs."

Jacques Van Niekerk, Head-Supply Chain, Ambuja Cement, says, "What customers in the future will be demanding from the industry, will be increasingly complicated products, more complicated solutions to cater to their specific needs and requirements. Cement manufacturers need to come out with tailor-made solutions pertaining to the specific needs of the customer that calls for more capital and a shift in the thinking.”

The second school of thought is on the green and sustainability factor. Here, branding per se does not talk about a product, nor about the company’s credentials. Rather, it projects a concept that is nobler and more inclusive and sustainable, a potent tool trying to change the current faceless development agenda into a more inclusive development. Again, Lafarge scores there with its baseline of ‘building bettercities.’

Holcim is another major brand that is hell-bent on creating a different set of values through its SustainableForum. Mind you, it`s another powerful tool of brand positioning. An example is the recent three-day symposium at the Indian Institute of Technology (IIT Bombay) in Mumbai, organised by Hoclim. Experts from all continents met in Mumbai at the 4th International Holcim Forum for Sustainable Construction in April 2013. The conference for academics and professionals from architecture, civil engineering, urban planning, natural and social sciences and deliberated on the paradigm shift associated with growing awareness of the considerable economic potential of sustainable development. Taking an array of disciplines into consideration, the focus of the Holcim Forum was on knowledge mining and dissemination, material and product life-cycle assessment, CO2 emissions and energy efficiency, considered deployment of means and economic resources, as well as social welfare and equity. And that way, branding happens on a totally different plane.

Film branding

We had our hearts in our mouths when Vidya Sharma, the skipper of the Indian hockey team positioned her hockey stick in the movie ‘Chak De India’ The moment the skipper played her stroke, the ball landed in the net, which led the Indian team to win the Hockey World Cup. These scenes can never be forgotten as they have a special place in the archives of our memory. Also with this started the tale of cement companies, opting for in-film advertising; the trend was started by UltraTech. The company had demonstrated the power of subtle, seamless and integrated in-film brand placement with Yashraj Films’ blockbuster hit, ‘Chak De India’ starring Bollywood superstar, Shah Rukh Khan. UltraTech’s in-film brand placement with ‘Chak De India’ is a first-of-its-kind pure branding initiative in the history of the cement industry. Talking about the strategy of associating the brand with sports like cricket and hockey, Kumar Pillay, Vice- President, Head – Marketing Services, UltraTech, says, "Cricket is next to religion in India. Forget the youth, the elders are also glued to cricket and hockey. Our presence in cricket gives us enough brand exposure which is important, especially in the case of house builders as their purchase is guided by brand familiarity. Our presence in cricket also acts as a motivator for the trade and they take pride in associating themselves with a company which is connected with popular sports like cricket." He further explains that UltraTech is a corporate brand which is proud to play a part in nation- building and creating long lasting relationships. "As a corporate brand, we have always been proud of the part we play in nation- building and creating lasting relationships. This pride is reflected in our corporate TVCs, as well as our sponsorship of cricket, the pride of India’s sporting activities."

Celebrity endorsements

The cement companies as a part of the marketing strategy, have roped in various celebrities as brand ambassadors. It makes sense for a celebrity to endorse a cement brand when it is new in a particular market and needs a credible vehicle to build confidence in the minds of consumers and channel partners. Anjani Cement has the Big B as the brand ambassador, JK cements roped in Virender Sehwag; Jaypee Cement has the cricketing god, Sachin Tendulkar, Bharathi Cement roped in south Indian film star Surya, and the latest to join the bandwagon is Dalmia Cement who took an unusual or rather a bold step by roping in a female brand ambassador for a commodity like cement. The move from Dalmia to rope in Mary Kom has jelled well, with the company acquiring two cement companies, Adhunik and Calcom Cement in the north-east. Elaborating on this move, BK Singh, says, "As a brand with a national presence, we wanted our brand to be symbolised as national and yet local. Mary Kom fitted the slot perfectly and the timing was just right, after her Olympic win. Both the Dalmia brand and Mary Kom stand for the core values of perseverance, breaking of tradition and above all, of commitment. Our entry into this region is a serious step; we are committed to the people of the north- east. Hence, for us the right personality mattered."

Logos and taglines

A logo is no more a mere graphic image, it reflects the identity of the company and helps the consumer with the brand. The colours and the design chosen as for the logo, speak volumes about the company. Emphasising the importance of the logo, Pillay says, "The logo is a strong graphical representation of the company. It is the face of the company/brand for the customer. The goal is to create brand recognition. The cement industry is dotted with several players. Your logo must inspire trust, admiration, and loyalty and should be memorable, timeless, versatile and appropriate. It should be distinct. The tagline defines the company. It sums up what you do or offer or how do you want a customer to perceive your product. The tagline should be a strong, short description of your product or company. The tagline should be memorable and should be the guiding force to create interest in your company, product or service." The logo of Dalmia Cement gives an impression of continuous flow. Explaining the core concept conveyed through the logo, Singh says, "The identity and logo of the Dalmia brand is a very thoughtprovoking representation of the various facets of this organisation, like expertise built over 70 years, its Indian core, traditional yet modern. It is a response to the new India, the young India. The colourful windmill represents the tricolour of our nation, a fresh and progressive spirit. The italics fonts depict dynamism." Similarly the tagline, ‘New think’, the tagline of Dalmia Bharat, signifies new hope, new ideas, and new direction.

There have been a few examples where the company tries to highlight a person’s name in the logo for the masses to identify with the brand. One such example is KJS Cement, a company based in Madhya Pradesh. Explaining the core concept conveyed through the logo, Pawan Ahluwalia, Managing Director, KJS Cement says, "We wanted to project Kamal Jeet Singh Ahluwalia, our Chairman’s, name in the logo. Since he is one of the highest tax payers in India and a tycoon in the steel industry, we decided to put his initials in the logo, due to which people could connect to it."

The logo is also be designed keeping in mind the target audiences. The focus of NCL Industries has been on the rural areas as the company has registered its presence in the five major districts of Andhra Pradesh. Highlighting the importance of the logo in the rural areas, Gopal Verma, VP Marketing, NCL Industries, says, "We have engaged an agency called IPD which does all our campaigns. If you see our logo, we have a mason standing tall. If you need to build a house in a rural area, you do not have sophisticated engineers and architects; all you have is a mason, who is the most reliable person. Thus, our product is recommended by the most reliable people in rural areas. The tagline is ‘Nagarjuna Cement monagadu cement. ‘Monagadu means the person with cementing strength."

Kumar Pillai sums it up: With more and more players entering the fray and regional players becoming national, branding will play a crucial role. Branding speaks volumes about the quality of a product. It builds credibility for a product. India is witnessing a glut of brands in the cement industry and it is important to be a recognised brand and have a fair voice. There will be a dearth of shelf space at counters and you need to be a truly big brand to gain better and more space. With a sizeable increase in multi- brand outlets, branding will emerge as a powerful tool to be recognised at outlets. At the technocrat level, more brands will make decisions difficult. A brand with top- of- mind recall will have a competitive edge. The digital media will also play a key role in branding especially in B2B businesses."

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Concrete

The primary high-power applications are fans and mills

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Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.

As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.

How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.

What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.

Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.

Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.

How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.

What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.

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Concrete

We conduct regular internal energy audits

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Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.

In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.

How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.

What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.

How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.

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Concrete

Digitalisation is pivotal in driving energy efficiency

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As energy costs continue to dominate the cement industry, efficiency and sustainability are proving to be vital components. MM Rathi, Joint President, Power Management, Shree Cement, explains the company’s long-term strategy is focused on cutting emissions while powering growth with renewable energy solutions.

Energy efficiency has always been a cost-saving lever for the cement industry. Today, it is the backbone of sustainability and competitiveness. Cement manufacturers are under growing pressure to optimise consumption, diversify power sources and align with decarbonisation targets. Shree Cement has been at the forefront of this transformation, significantly scaling up its green power capacity and embedding advanced technologies across operations. In this exclusive conversation, MM Rathi, Joint President – Power Management, Shree Cement, shares insights on the company’s approach to energy efficiency, challenges in brownfield modernisation and long-term strategies for achieving net zero alignment.

What percentage of your total operational cost is attributed to energy consumption?
At Shree Cement, energy is one of the most significant components of production cost, accounting for nearly 30 per cent to 40 per cent of total operational expenses. Within this, thermal energy typically contributes around 20 per cent to 25 per cent, while electrical energy forms about 10 per cent to 15 per cent. The exact share varies depending on factors such as the fuel mix (coal, pet coke or alternative fuels and raw materials), the power source (grid-based or captive like solar, wind or thermal), raw mix quality, and regional fuel and electricity price variations. This makes energy efficiency and the adoption of sustainable power sources a key focus area, both from a cost and sustainability perspective.

How has your company improved energy efficiency over the past five years?
Over the past five years, Shree Cement has consistently invested in enhancing energy efficiency across operations. Our green power capacity, covering wind, solar and Waste Heat Recovery (WHR), has more than doubled from 245 MW in 2020 to 592 MW in 2025. All grinding units are now equipped with biomass firing facilities, reducing dependence on conventional fuels. From the project stage itself, we prioritise efficiency by selecting advanced technologies such as six-stage kilns with integrated WHR, CFD-designed plants, and equipment fitted with VFDs, centrifugal compressors and high-efficiency fans. We also review and upgrade equipment systematically, replacing fans, compressors, blowers, pumps, boilers and turbines with more efficient options. This continuous approach has reduced costs while significantly advancing our sustainability journey.
What technologies or practices have shown the highest energy-saving potential in cement production?
WHR stands out as one of the most effective solutions, offsetting a significant portion of electricity required for clinker production. Hot air recirculation has also proven highly beneficial in reducing heat losses. Additionally, regular energy audits help us identify opportunities for improvement and implement corrective measures in daily operations. Together, these practices play a critical role in optimising energy efficiency and driving sustainable operations.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
The biggest challenge is the significant upfront investment required for upgradation. Retrofitting existing facilities often involves complex civil and structural modifications, which add costs and extend downtime. Integration is another hurdle, as new high-efficiency equipment may not align seamlessly with older kiln systems, fans, mills or automation setups. These factors make the transition in brownfield plants more resource-intensive and time-consuming compared to greenfield projects.

How do you measure and benchmark energy performance across different plants?
We track key performance indicators such as specific heat consumption and specific power consumption for each unit, benchmarking them against internal and external standards. Thermal Substitution Rate (TSR percentage) is another critical metric, measuring the share of alternative fuels in the thermal energy mix. Internally, we benchmark performance across plants to encourage best practice sharing. Externally, we compare against national averages and align with the Bureau of Energy Efficiency’s PAT (Perform, Achieve, Trade) scheme, which sets Specific Energy Consumption (SEC) baselines and targets for cement plants. This multi-layered approach ensures continuous monitoring, improvement, and industry leadership in energy efficiency.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation is pivotal in driving energy efficiency at Shree Cement. IoT sensors integrated with SCADA and DCS systems allow real-time monitoring of parameters like heat consumption and energy use, moving beyond periodic reports. Our digital platforms consolidate plant data, enabling management to compare metrics such as SPC, SHC, kWh per tonne and kcal per kg across units in real time. This visibility supports data-driven decisions, faster corrective actions, and higher operational efficiency.

How do government policies and incentives influence your energy-saving decisions?
Government policies and incentives strongly shape our energy-saving decisions. The Perform, Achieve, Trade (PAT) scheme sets plant-specific SEC targets. Non-compliance incurs penalties, while compliance earns tradable energy-saving certificates. This ensures energy efficiency is both cost-driven and regulatory. Additionally, subsidies and viability gap funding for renewable energy projects in wind, solar and AFR co-processing help reduce payback periods and make energy-saving investments more viable.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
Our long-term strategy aligns energy efficiency with India’s net zero 2070 goals. Key levers include improving efficiency, expanding green electricity, producing more blended cement, and increasing alternative fuel use. Today, more than 60 per cent of our electricity comes from green sources such as solar, wind, and WHR, the highest in India’s cement industry. Our blended cement products, which reduce limestone and fuel consumption, further lower emissions. These products are certified under the GreenPro ecolabel by CII, validating our sustainability practices and environmental standards.

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