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

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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.

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Concrete

Adani’s Strategic Emergence in India’s Cement Landscape

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Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.

India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.

Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:

  • September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
  • December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
  • August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
  • April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
  • Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
  • Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
  • Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
  • Orient Cement: It would serve as a principal manufacturing facility following the merger.

Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:

  • By FY 2026: Reach 118 MTPA
  • By FY 2028: Target 140 MTPA

These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).

Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.

Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.

Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.

Challenges potentially include:

  • Integration challenges across systems, corporate cultures, and plant operations
  • Regulatory sanctions for pending mergers and new capacity additions
  • Environmental clearances in environmentally sensitive areas and debt management with input price volatility

When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.

Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.

About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.

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Concrete

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

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PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.

Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

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Concrete

Driving Measurable Gains

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Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.

Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.

Beyond energy efficiency, the retrofit significantly improved operational parameters:

  • Lower thermal stress on equipment
  • Extended lubricant drain intervals
  • Reduction in CO2 emissions and operational costs

These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.

Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:

  • Enhanced component protection
  • Extended oil life under high loads
  • Stable performance across fluctuating temperatures

By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.

Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.

A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

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