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Getting the last mile connectivity with Indian railway network is an extremely …

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The process of obtaining design and engineering clearances from the railways is very cumbersome and takes lot of time. Though the liberalised siding policy of 31 January 2012 stipulates a time frame of four months for engineering scale plan clearance, there is poor compliance with these timelines, says Arvind Pathak, Chief Executive Officer, Reliance Cement.

Excerpts from the interview.

What are the challenges in supply chain management as faced by the cement industry?

Logistics cost account for almost 25 to 30 per cent of the total delivered cost of cement. Recent hikes in rail freight rates and diesel prices have put an enormous burden on the industry. On the other hand, service level expectations of the customers have risen significantly in recent years. Customers are insisting on on-time deliveries, smaller loads and fresh material. The key challenge faced by the industry today is to strike a balance between cost and services.

How is your supply chain cost divided on different fronts such as inbound and outbound transportation, warehousing, inventory, transit loss, etc?

Essentially depends on plant location, distance from market / mines, mode of transport for inward and outward traffic, etc. On an average, inbound transportation costs account for 25 per cent and outbound for 70 per cent of the total transportation costs. The balance 5 per cent is accounted for by warehousing, inventory, transit loss, etc.

Are you considering automating the cement loading and unloading process?

Yes, because there are key benefits to automating cement loading and unloading process like faster turnaround time for transportation assets, efficient and pollution free loading / unloading along with minimal damage to cement bags.

Why has cement transport via BCCW not picked up that well in our country?

There are several reasons for this. Primarily, it has not picked-up due to: Cost of building infrastructure: Heavy investment required in building up the necessary rail infrastructure both at the loading and at the unloading end.

Insufficient asset utilisation:

High investment cost of BCCW rakes is another deterrent. Fifteen per cent of the freight rebate available under the Liberalised Wagon Investment Scheme is not sufficient to cover the fixed cost of rake on account of low average speed of goods trains in India (~40 km/hr). This leads to increased turnaround time consequently to poor asset utilisation.

Lack of incentives for bulk transport:

The government has not provided any additional freight incentive for transporting cement in bulk. The rail freight rate is the same for both bagged and bulk cement.

How do you deal with product loss in transit or during storage?

Shortages resulting out of pilferage, if any, are debited to the warehouse operator. Shortages that occur as a result of transit losses, if any, are debited to the concerned transporter. However, these issues continue to be a challenge for the industry.

Are you planning to build a terminal in the near future?

We are building private rail sidings / terminals at all our upcoming integrated cement units. There are few hindrances in the process, like:

Obtaining design and engineering clearances: The process of obtaining design and engineering clearances from railways is very cumbersome and takes a lot of time. Though the liberalised siding policy of 31 January 2012 stipulates a time frame of four months for Engineering Scale Plan Clearance, there is poor compliance with these timelines.

Unavailability of land:

Existing stations along the Indian railway network are very congested. Limited availability of land in the vicinity of the connecting station makes getting the last mile connectivity with the Indian railway network an extremely tedious task. To make the matters worse, the railways, of late , has been very reluctant to give railway land to private parties for last mile connectivity.

Lack of station infrastructure: Rail yard and signalling infrastructure at the existing stations is generally very poor. Due to the financial crunch faced by the railways, they are unwilling to invest in the connecting station infrastructure. Thus, the private party not only has to bear the cost of rail terminal but also the cost of augmenting the infrastructure at the connecting station. This raises the investment cost of setting up a private rail sidings / terminal very high.

What are the advantages / disadvantages of employing carry and forward agents?

Having carry forwarding agents has both pros and cons to it. Advantages: The act as your business developer for new /existing markets. They play the role of an influencer. They are a means of secured payments. They provide the necessary additional manpower when required. Disadvantages:There is always a high risk of the CFA leaving the organisation. Additional discounts. Low market control.

Are you open to collaborate with other cement companies for setting up a terminal?

Yes, we are. But the decision about collaboration will be made on a case- to- case basis. Customers are insisting on on-time deliveries, smaller loads and fresh material.

Reliance Cement

Reliance Cement, set up in 2007, is a hundred per cent subsidiary of Reliance Infrastructure Limited. The company has two projects located at Madhya Pradesh and Maharashtra with a combined capacity of 10 MTPA. The Madhya Pradesh project has an integrated unit at Maihar, a blending unit at Gondavali and a grinding unit at Rae Bareilly in Uttar Pradesh. The Maharashtra project has an integrated unit at Yavatmal and a grinding unit at Butibori. Phase I of the Butibori unit was commissioned in 2012 and is currently catering to the markets in Vidharbaha region. The Maihar unit is on a fast track and slated to be commissioned in 2013. The company aspires to build a capacity of 50 MTPA and be counted amongst the top five cement companies in India. Being a growth focused company; process optimisation for sustainable business is one of the core values for the company.

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Process

Price hikes, drop in input costs help cement industry to post positive margins: Care Ratings

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Region-wise,the southern region comprises 35% of the total cement capacity, followed by thenorthern, eastern, western and central region comprising 20%, 18%, 14% and 13%of the capacity, respectively.

The cement industry is expected to post positive margins on decent price hikes over the months, falling raw material prices and marked drop in overall production costs, said an analysis of Care Ratings.

Wholesale and retail prices of cement have increased 11.9% and 12.4%, respectively, in the current financial year. As whole prices have remained elevated in most of the markets in the months of FY20, against the corresponding period of the previous year.

Similarly, electricity and fuel cost have declined 11.9% during 9M FY20 due to drop in crude oil prices. Logistics costs, the biggest cost for cement industry, has also dropped 7.7% (selling and distribution) as the Railways extended the benefit of exemption from busy season surcharge. Moreover, the cost of raw materials, too, declined 5.1% given the price of limestone had fallen 11.3% in the same aforementioned period, the analysis said.

According to Care Ratings, though the overall sales revenue has increased only 1.3%, against 16% growth in the year-ago period, the overall expenditure has declined 3.2% which has benefited the industry largely given the moderation in sales.

Even though FY20 has been subdued in terms of production and demand, the fall in cost of production has still supported the cement industry by clocking in positive margins, the rating agency said.

Cement demand is closely linked to the overall economic growth, particularly the housing and infrastructure sector. The cement sector will be seeing a sharp growth in volumes mainly due to increasing demand from affordable housing and other government infrastructure projects like roads, metros, airports, irrigation.

The government’s newly introduced National Infrastructure Pipeline (NIP), with its target of becoming a $5-trillion economy by 2025, is a detailed road map focused on economic revival through infrastructure development.

The NIP covers a gamut of sectors; rural and urban infrastructure and entails investments of Rs.102 lakh crore to be undertaken by the central government, state governments and the private sector. Of the total projects of the NIP, 42% are under implementation while 19% are under development, 31% are at the conceptual stage and 8% are yet to be classified.

The sectors that will be of focus will be roads, railways, power (renewable and conventional), irrigation and urban infrastructure. These sectors together account for 79% of the proposed investments in six years to 2025. Given the government’s thrust on infrastructure creation, it is likely to benefit the cement industry going forward.

Similarly, the Pradhan Mantri Awaas Yojana, aimed at providing affordable housing, will be a strong driver to lift cement demand. Prices have started correcting Q4 FY20 onwards due to revival in demand of the commodity, the agency said in its analysis.

Industry’s sales revenue has grown at a CAGR of 7.3% during FY15-19 but has grown only 1.3% in the current financial year. Tepid demand throughout the country in the first half of the year has led to the contraction of sales revenue. Fall in the total expenditure of cement firms had aided in improving the operating profit and net profit margins of the industry (OPM was 15.2 during 9M FY19 and NPM was 3.1 during 9M FY19). Interest coverage ratio, too, has improved on an overall basis (ICR was 3.3 during 9M FY19).

According to Cement Manufacturers Association, India accounts for over 8% of the overall global installed capacity. Region-wise, the southern region comprises 35% of the total cement capacity, followed by the northern, eastern, western and central region comprising 20%, 18%, 14% and 13% of the capacity, respectively.

Installed capacity of domestic cement makers has increased at a CAGR of 4.9% during FY16-20. Manufacturers have been able to maintain a capacity utilisation rate above 65% in the past quinquennium. In the current financial year due to the prolonged rains in many parts of the country, the capacity utilisation rate has fallen from 70% during FY19 to 66% currently (YTD).

Source:moneycontrol.com

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Wonder Cement shows journey of cement with new campaign

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The campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV…

ETBrandEquity

Cement manufacturing company Wonder Cement, has announced the launch of a digital campaign ‘Har Raah Mein Wonder Hai’. The campaign has been designed specifically to run on platforms such as Instagram, Facebook and YouTube.

#HarRaahMeinWonderHai is a one-minute video, designed and conceptualised by its digital media partner Triature Digital Marketing and Technologies Pvt Ltd. The entire journey of the cement brand from leaving the factory, going through various weather conditions and witnessing the beauty of nature and wonders through the way until it reaches the destination i.e., to the consumer is very intriguing and the brand has tried to showcase the same with the film.

Sanjay Joshi, executive director, Wonder Cement, said, "Cement as a product poses a unique marketing challenge. Most consumers will build their homes once and therefore buy cement once in a lifetime. It is critical for a cement company to connect with their consumers emotionally. As a part of our communication strategy, it is our endeavor to reach out to a large audience of this country through digital. Wonder Cement always a pioneer in digital, with the launch of our IGTV campaign #HarRahMeinWonderHai, is the first brand in the cement category to venture into this space. Through this campaign, we have captured the emotional journey of a cement bag through its own perspective and depicted what it takes to lay the foundation of one’s dreams and turn them into reality."

The story begins with a family performing the bhoomi poojan of their new plot. It is the place where they are investing their life-long earnings; and planning to build a dream house for the family and children. The family believes in the tradition of having a ‘perfect shuruaat’ (perfect beginning) for their future dream house. The video later highlights the process of construction and in sequence it is emphasising the value of ‘Perfect Shuruaat’ through the eyes of a cement bag.

Tarun Singh Chauhan, management advisor and brand consultant, Wonder Cement, said, "Our objective with this campaign was to show that the cement produced at the Wonder Cement plant speaks for itself, its quality, trust and most of all perfection. The only way this was possible was to take the perspective of a cement bag and showing its journey of perfection from beginning till the end."

According to the company, the campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV. No other brand in this category has created content specific to the platform.

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In spite of company’s optimism, demand weakness in cement is seen in the 4% y-o-y drop in sales volume. (Reuters)

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Cost cuts and better realizations save? the ?day ?for ?UltraTech Cement, Updated: 27 Jan 2020, Vatsala Kamat from Live Mint

Lower cost of energy and logistics helped Ebitda per tonne rise by about 29% in Q3
Premiumization of acquired brands, synergistic?operations hold promise for future profit growth Topics

UltraTech Cement
India’s largest cement producer UltraTech Cement Ltd turned out a bittersweet show in the December quarter. A sharp drop in fuel costs and higher realizations helped drive profit growth. But the inherent demand weakness was evident in the sales volumes drop during the quarter.

Better realizations during the December quarter, in spite of the 4% year-on-year volume decline, minimized the pain. Net stand-alone revenue fell by 2.6% to ?9,981.8 crore.

But as pointed out earlier, lower costs on most fronts helped profitability. The chart alongside shows the sharp drop in energy costs led by lower petcoke prices, lower fuel consumption and higher use of green power. Logistics costs, too, fell due to lower railway freight charges and synergies from the acquired assets. These savings helped offset the increase in raw material costs.

The upshot: Q3 Ebitda (earnings before interest, tax, depreciation and amortization) of about ?990 per tonne was 29% higher from a year ago. The jump in profit on a per tonne basis was more or less along expected lines, given the increase in realizations. "Besides, the reduction in net debt by about ?2,000 crore is a key positive," said Binod Modi, analyst at Reliance Securities Ltd.

Graphic by Santosh Sharma/Mint
What also impressed analysts is the nimble-footed integration of the recently merged cement assets of Nathdwara and Century, which was a concern on the Street.

Kunal Shah, analyst (institutional equities) at Yes Securities (India) Ltd, said: "The company has proved its ability of asset integration. Century’s cement assets were ramped up to 79% capacity utilization in December, even as they operated Nathdwara generating an Ebitda of ?1,500 per tonne."

Looks like the demand weakness mirrored in weak sales during the quarter was masked by the deft integration and synergies derived from these acquired assets. This drove UltraTech’s stock up by 2.6% to ?4,643 after the Q3 results were declared on Friday.

Brand transition from Century to UltraTech, which is 55% complete, is likely to touch 80% by September 2020. A report by Jefferies India Pvt. Ltd highlights that the Ebitda per tonne for premium brands is about ?5-10 higher per bag than the average (A cement bag weighs 50kg). Of course, with competition increasing in the arena, it remains to be seen how brand premiumization in the cement industry will pan out. UltraTech Cement scores well among peers here.

However, there are road bumps ahead for the cement sector and for UltraTech. Falling gross domestic product growth, fiscal slippages and lower budgetary allocation to infrastructure sector are making industry houses jittery on growth. Although UltraTech’s management is confident that cement demand is looking up, sustainability and pricing power remains a worry for the near term.

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