Economy & Market

The Indian growth story got a temporary jolt but it is bottoming out

Published

4 years ago

October 14, 2021

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Bidyut Bhattacharya, Chief Technical Director, Sinoma International Engg Co India Positive about the potential of the country, Bidyut Bhattacharya, Chief Technical Director, Sinoma International Engg Co India explains that though the Indian industry saw a bad patch on the road to economic growth, the way forward is still exciting. The mature cement industry can definitely make use of some policy changes that will put the industry back on track in 2014. Excerpts from the interview.

Has the economic slowdown impacted production capacity augmentation or the setting up of new cement plants?
There is no denying the fact that there was a serious economic slowdown in India, over the last couple of years, resulting in a dismal GDP growth rate. Consequently, cement consumption has suffered and created a large overcapacity situation. So it is natural that new cement capacity augmentation has not been too encouraging.

Are we in the state of cement production overcapacity?
Yes, we are in a state of overcapacity of cement for the time being. In the backdrop of sub five percent growth rate, rough estimates project a figure of as high as 80 to 100 million tonnes of overcapacity in the country. The situation is even more precarious in the southern belt.

What policy changes can help the cement industry regain momentum from the year 2014 onwards?
The first and foremost requirement would be to boost investor sentiment. Enabling polices and a stable vision for the future is equally mandatory. The low-capacity utilisation of already installed production lines is troubling. To improve cement consumption, the economic growth rate is vital. In this respect, we strongly feel that government spending and regulatory clearances of large infrastructure projects will play an important role to revive not only the cement industry but the overall economy as well. Housing sector is also vital for cement consumption.

One of the major reasons/excuses for the present day reduced level of capex spending on new projects lies in regulatory hurdles and inordinate delays in clearances. This needs to be taken care of.

Higher cost of borrowing is another impediment to new investments in this sector. For a supportive interest rate regime, food inflation specifically, needs to be controlled with particular focus on supply side bottlenecks.

Energy sourcing is another bottleneck for the cement sector. Cement plants are highly energy- intensive and require both thermal energy in form of coal (in the case of India) and electrical power. Quality/quantity and the cost of both these energies seem to be bothering the Indian cement industry. The issue of lower quality coal need to be addressed by blending imported high grade coal. Supply of more washed coal from CIL would help. For power, co-generation (through WHR technology) would give a big relief and should be made mandatory as it is in China. Usage of alternate fuels is also vital.

Which new design trends are we likely to see in cement plants and the supporting systems?
The Indian cement industry, over the years, has employed the best available technology for production. Thanks to a high degree of blended cement utilisation, Indian cement producers are at the forefront of fuel and electrical energy consumption on a per- tonne- of- product basis. An additional benefit in terms of sustainability is lower per tonne CO2 emission. Stricter regulatory requirements are leading increasingly towards greener technologies; and they, in turn, lead to further energy efficiency.

Utilising a Vertical Roller Mill (VRM) or roll press circuit in finish grinding mode for raw material grinding is the industry norm today, and it provides a significant energy cost reduction over the traditional closed circuit ball mill system. Likewise, for coal grinding also, a vertical mill is used. For the energy-intensive finish grinding process, the ball mill plus roll press system is widely popular. In specific cases where slag grinding is involved with high per cent moisture, VRM technology for finish grinding is used. Only in extreme cases today, do we get request for close circuit ball mill for grinding; it is inherently less energy efficient. High efficiency separators are standard today for all milling systems.As regards the pyro-processing area, Indian cement producers continuously strive to achieve the lowest specific fuel consumption along with high power saving. High efficiency fourth generation grate coolers are being utilised widely since they provide high recuperation efficiency along with lower maintenance interventions. As the total cooling air requirement reduces from the earlier 2.2Nm3/kg clinker to say, 1.8Nm3/kg clinker, there is a lot of savings through reduced exhaust air and fans power consumption. To achieve lower fuel consumption, six stage pre-heater systems is the popular choice along with in-line calciners. Advanced low NOx technologies are utilised in many cement plants. For process fans, a static efficiency = 82 per cent and use of variable speed drives reduces power consumption.

Do you see the demand for WHR systems growing in the future?
Waste Heat Recovery is slowly catching up in India. It is imperative to make WHR a mandatory requirement for any new cement plant, as is already the case in some countries. A significant portion of the energy requirement can be sourced through utilisation of waste heat from the pre-heater and cooler. In this context, Indian cement producers/consultants need to do a more specific, case to case basis, cost -benefit analysis for the six-stage vs. Five-stage pre-heater system, specifically when raw material moisture is high or when civil design parameters like wind speed/seismic conditions are not favourable. There is also the need to account for additional time taken for six- stage construction.

What is the scope for alternative fuels in cement plants?
Considering the dwindling quality/supply of domestic coal and logistic issues of imported supply, a variety of alternate fuels are being utilised cost-effectively. Not only Pet coke but a host of other materials from tyres to rice husk, plastic, sawdust are all being used. Utilisation of municipal wastes/sludge is still in its infancy in India primarily due to supply-side bottlenecks. It is worthwhile to mention here that cement pyro-processing systems are highly suitable for burning waste material, apart from contributing to the calorific value, due to the very high incineration temperature, close to 1,800 to 2,000deg C at the flame zone, higher residence time like five to six sec in calciners, assimilation of heavy metals in the clinker, negligible dust emission through kiln bag filters and dry dust curtains with high surface area in the pre-heater, etc.

What are your suggestions for improving energy efficiency in cement plants?
In terms of overall energy efficiency, we at Sinoma strongly recommend Waste Heat Recovery (WHR) from both the kiln and grate cooler. For the coolers themselves, we recommend fourth generation walking floor type or moving bar/S-type grate coolers. High efficiency, high momentum burner pipes are a must. Modern design low pressure drop high efficiency pre-heater cyclones also plays an important part. For grinding, we recommend the roll press and vertical mills depending upon the process and materials.

As an EPC service provider and supplier of critical plant and machinery what was 2013 like for you?
In the backdrop of poor growth rate and not much positive investor sentiment, 2013 was not a very encouraging year for the industry overall.

However, we are rather bullish on the India story. India cannot and shall not remain a sub 5 per cent growth rate country for long. The Indian growth story got a temporary jolt but is bottoming out. Already green shoots are visible. If we consider the stock markets reflect, at least to some extent, investor sentiment, clearly the sentiment is positive with indices hovering around all- time highs. Even events like the start of QE tapering made virtually no dent. The Indian currency stabilised rather quickly. Smart moves by the RBI in tackling the CAD issues have fortified confidence further. The expectation of a strong and stable government coming to power in May/June 2014, is boosting the overall outlook. Clearance of some high profile infrastructure projects through the Cabinet Committee is a big positive. With a favourable monsoon and the start of the harvesting season, easing of inflation expectations is widely anticipated.

Considering all this, we anticipate a much more exciting time from the second half of 2014 onwards.

Economy & Market

Fornnax launches world’s biggest secondary/fine shredder for AFR pre-processing

Published

1 week ago

November 7, 2025

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Fornnax has introduced its latest breakthrough – the R-MAX3300, for handling low-density waste streams, offering a powerful solution for cement AFR plants.

Fornnax Technology has launched its latest breakthrough – the R-MAX3300, the biggest secondary shredder in its class. The unveiling took place on 14th October, 2025 at IFAT India 2025 in Mumbai, one of the most prestigious events for environmental technologies, waste management, and sustainable resource innovation.

The launch ceremony was graced by esteemed industry leaders and dignitaries. The guest list included Md Fahim Sopariwala, CEO, GEPIL India; Sridhar Jagannathan, Vice President, Zigma Global; Priyesh Bhatti, CEO, GEPIL India; Shailendra Singh, Deputy General Manager, Prism Johnson (Cement Division); Ulhas Parlikar, Global Consultant, Waste Management, Circular Economy, Policy Advocacy and Co-processing; Saurabh Palsania, Joint President (Strategic Sourcing), Shree Cement; Rajeev Patel, DGM (Process), Mangalam Cement; and Anumodan Kumar Dubey, Mangalam Cement.

This state-of-the-art equipment represents a significant advancement for India’s recycling and waste processing landscape, offering a powerful solution for cement AFR plants and waste-to-energy facilities.

Building on the proven performance and legacy of the R Series secondary shredder, which has long been trusted for high-density materials like tyres and cables, the newly introduced R-MAX3300 is specifically engineered for handling low-density waste streams. These include Municipal Solid Waste (MSW), Commercial and Industrial (C&I) waste, Bulky waste, Legacy waste, Wood waste, and Construction & Demolition (C&D) waste.

By incorporating advanced shredding technology, the R-MAX3300 enables seamless and highly efficient production of Refuse Derived Fuel (RDF) and Solid Recovered Fuel (SRF) within the ideal particle size range of 30 to 50 mm. Its design prioritises versatility, durability and superior performance, directly supporting industrial operations that demand consistency and scale.

“The R-MAX3300 represents a monumental leap forward in our vision to become a global leader by 2030 in recycling technology through innovation,” said Jignesh Kundaria, Director and CEO, Fornnax Technology. “With the rising challenges of waste management in India and globally, this machine is not just a product; it’s a powerful tool for change. We engineered it to handle the most difficult waste streams with unparalleled efficiency, turning what was once considered unusable waste into a valuable resource. It directly addresses the urgent demand for effective, large-scale shredding technology that can support cement kilns and waste-to-energy facilities in achieving the desired output,” he added.

The launch of the R-MAX3300 arrives at a pivotal moment. India currently generates over 160,000 tons of municipal solid waste daily, while government-led initiatives such as Swachh Bharat Mission and Smart Cities are accelerating the demand for RDF and waste-to-energy solutions. Simultaneously, the global industrial shredder market is expected to grow at a 5–6 per cent CAGR, driven by stricter recycling regulations and increasing waste generation.

Kundaria further emphasised, “Our commitment goes beyond just selling machinery; it’s about empowering our customers to achieve lasting efficiency, sustainability, and growth. We see ourselves as a trusted partner who stands beside them at every step – from technology deployment to ongoing support, ensuring they can rely on Fornnax not only for performance but also for consistency, dependability, and long-term value.”

The R-MAX3300 is equipped to handle high-throughput processing of pre-shredded or coarse materials, making it ideal for SRF/RDF production, composting pre-treatment, and volume reduction for logistics optimisation. It is expected to play a crucial role in Integrated Waste Management Projects (IWMP) and bio-mining operations both within India and globally.

With this grand launch, Fornnax continues to set global benchmark and move decisively towards the vision of becoming global leader in recycling technology by 2030 that is state-of-the-art, innovative, economical, efficient reliable and eco-friendly.

Concrete

Fornnax wins Top Domestic Sales Award 2024-25 by AIRIA

Published

1 week ago

November 7, 2025

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Fornnax bags the Excellence in Top Domestic Sales Award 2024–25 by the All India Rubber Industries Association (AIRIA).

The company has been honoured with the Excellence in Top Domestic Sales Award 2024–25 by the All India Rubber Industries Association (AIRIA) under the Rubber Machineries and Equipment category. The award recognises Fornnax’s exceptional market leadership, strong sales performance and continued commitment to sustainable innovation.

With over a decade of specialised expertise, Fornnax has emerged as a transformative force in India’s tyre recycling sector, commanding nearly 90 per cent of the domestic market while steadily expanding across Europe, Australia, the GCC, and other global regions.

Fornnax’s advanced recycling systems—comprising the SR-Series Primary Shredders, R-Series Secondary Shredders, and TR-Series Granulators—are engineered for durability, efficiency, and high-output performance. These technologies are widely deployed in end-of-life tyre (ELT) processing and other waste management applications, reinforcing Fornnax’s reputation as a trusted industry partner.

Expressing his gratitude, Jignesh Kundaria, Director & CEO, Fornnax, said, “We are incredibly proud to receive this recognition from AIRIA. This award validates the trust that our customers and partners have placed in us over the years. I would like to extend my heartfelt gratitude to all our clients and partners who have been an integral part of this journey and our continued success. At Fornnax, our goal has always been to empower the recycling industry with innovative, high-performance solutions that make sustainability both achievable and profitable.”

The award also underscores Fornnax’s pivotal role in promoting circular economy practices by enabling the conversion of end-of-life tyres and rubber waste into reusable raw materials. Through ongoing R&D, new product innovation, and a solutions-driven approach, the company continues to help industries worldwide adopt eco-conscious, scalable recycling models.

As India’s recycling landscape evolves to meet global sustainability benchmarks, Fornnax stands at the forefront with internationally certified technology, a proven track record, and a clear vision for environmentally responsible growth.

Concrete

Pacific Avenue Completes Acquisition of FLSmidth Cement; Rebrands as Fuller Technologies

Published

2 weeks ago

November 4, 2025

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The acquisition of FLSmidth Cement by Pacific Avenue Capital Partners marks a new phase of focused growth and innovation.
Rebranded as Fuller® Technologies, the company will continue delivering world-class solutions with renewed investment and direction.

Pacific Avenue Capital Partners (“Pacific Avenue”), a global private equity firm, has completed its acquisition of FLSmidth Cement following the fulfillment of all customary closing conditions and regulatory approvals. The transaction includes all of FLSmidth Cement’s intellectual property, technology, employees, manufacturing facilities, and global sales and service organizations.

As Fuller Technologies, the company will continue to seamlessly support its customers while advancing its robust portfolio of capital equipment, digital solutions, and service offerings. With a sharpened focus on Pyro and Grinding technologies, alongside core brands such as PFISTER®, Ventomatic®, Pneumatic Conveying, and Automation, Fuller Technologies aims to deliver enhanced value and reliability across the cement and industrial sectors.

Under Pacific Avenue’s ownership, Fuller Technologies will benefit from increased investment in people, products, and innovation. The dedicated management team will work to optimize operations and strengthen customer relationships, ensuring continuity and excellence during this exciting transition.

“We are proud to be the new owner of FLSmidth Cement, now Fuller Technologies, a global leader with a rich history of providing mission-critical equipment and aftermarket solutions in the cement and industrial sectors. We will continue to build upon the Company’s legacy of being at the forefront of technological innovation, service delivery, and product quality as we support our customers’ operations,” says Chris Sznewajs, Managing Partner and Founder of Pacific Avenue Capital Partners.

Pacific Avenue’s deep experience in executing complex industrial carve-outs and guiding standalone businesses into their next growth phase will be instrumental in shaping Fuller Technologies’ future. With a proven track record in building products and capital equipment industries, Pacific Avenue is poised to help Fuller Technologies optimize performance, accelerate growth, and create long-term value for its customers and stakeholders worldwide.