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Wish list Budget 2013

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Indian Cement Industry has a total capacity of around 340 million tonne and ranks second in the world, producing quality cement that matches the world’s best and has its footprints in around 30 countries of the world through cement exports. The Working Group on Cement Industry for the XI Five Year Plan (2007-12) had set a target of cement production at 269 mnt and the capacity needed at 298 mnt at the end of the Plan i.e. 2011-12. Against this, the Cement Industry surpassed the target and created an installed capacity of over 340 mnt by the terminal year of the 11th Plan resulting in surplus capacity situation.

Though cement is the most essential infrastructure input, the tax on cement continues to be the highest among the items required for building infrastructure. The levies and taxes on cement in India are far higher compared to those in countries of the Asia Pacific Region. Average tax on cement in the Asia Pacific Region is just 11.4 per cent with the highest levy of 20 per cent being in Sri Lanka.

In this backdrop, the cement industry would like to submit the following suggestions in order to help the industry sustain a healthy growth:

1. Uniform and specific rate of excise duty

Till 28-2-2007, specific rate of excise duty was applicable on cement; and thereafter, up to 28.2.2011 different rates of Excise duty based on Retail Sale Price were levied for cement. However, in the Union Budget 2011-12 the Excise Duty Rates on cement were replaced with composite rates having a 10 per cent ad valorem and specific component of Rs 80 and Rs 160 per tonne, based on Retail Sale Price. In the Union Budget 2012-13 the excise duty on cement increased from 10 to 12 per cent ad valorem whereas specific duty was at Rs.120/- per tonne of cement. Cement has also been notified under Section 4A of the C.E. Act. Accordingly, the value for the purpose of charging duty on packaged cement is determined on the basis of the Retail Sale Price (RSP). Abatement of 30 per cent from the RSP has also been notified. The existing rates of excise duty on cement are as under:

It is clear from the above that the incidence of excise duty on cement is still on the higher side for consumers other than industrial/institutional as an additional specific rate of duty of Rs.120/- per tonne is payable by them. Also the basis of levying Excise Duty is different i.e. 12 per cent on RSP less 30 per cent of RSP (as abatement) and 12 per cent on Transaction Value for sale to industrial/institutional consumers. Thus, the current regime makes for different sets of duties per tonne of cement payable by a producer on any given day.

Excise duty rates on cement are one of the highest and next only to luxury goods such as cars. Other core industries such as coal steel attract duty at around 5 per cent. Cement is one of the core infrastructure industries and it requires large-scale investments and capacity additions in view of the expected GDP growth and projected demand for cement over the medium to long term.

It is well-known that today the industry suffers from excess of surplus capacity of cement in the country and cement market is on bearish trend. Therefore, for growth of cement industry Government may kindly reduce excise duty on cement and clinker.

To encourage cement industry and to bring it at par with other core and infrastructure industries, the excise duty rate be rationalized from 12 per cent to 6-8 per cent and a holistic view may be taken to scrap the specific rate of duty of Rs.120/- per tonne in the interest of common man’s housing needs. Also, the duty structure be simplified to be either on specific rate per MT or on advalorem basis and without relating to MRP etc.

2.Excise Duty on Coal, Lignite, Coke, Fly Ash etc.

In the Budget for the year 2011-12, 1 per cent excise duty was levied on various items including items like coal, lignite, coke, flyash etc which are important for the industry. The aforesaid duty was increased to 2 per cent (except on coal, on which 1 per cent duty continued) in the budget for the year 2012-13. As no Cenvat Credit is available for aforesaid + per cent Excise duty paid, it has increased the cost for the manufacturers. It is also worthwhile to mention that the prices of coal have increased sharply and the industry is already absorbing oClean Energy Cessö levied earlier.

It is suggested that levy of aforesaid duty may be withdrawn or Cenvat credit be made available for the duty paid.

Customs Duty on pet coke, gypsum and other inputs

Cement Industry has been subject to perennial shortages of coal, the main fuel. Approx, only 39 per cent of linked coal is received by the member cos. against their total fuel requirement for kiln under the coal linkage Scheme. This adversely impacts the Cement Industry through increased fuel cost, as the balance requirement of fuel has to be necessarily procured from open market/e-auction, import of coal and use of alternative fuel like Pet coke at a substantially higher rate than linked coal.

In the Union Budget 2012-13, steam coal was fully exempted from the basic custom duty. This provided some much-needed relief to the cement industry on import of coal. However, this relief alone cannot fully meet the fuel shortage for the cement industry. Pet coke is an important material as fuel, which is used in the cement industry. In view of the reducing availability of coal, the cement industry has been resorting to increased usage of pet coke. The indigenous availability of pet coke being short, more and more pet coke is imported to make up shortage of coal.

Gypsum is another important input. Because of the limited availability of indigenous Gypsum, the industry is depends on imports.

Pet-coke and Gypsum attract 2.5 per cent duty, if imported, while there is no import duty on cement import. This leads to an anomaly situation that "Import Duty on inputs is higher than a finished product".

Therefore, it is requested that government may kindly scrap import duty on pet coke, gypsum. Levy of customs duty on imports.

Presently, import of cement into India is freely allowed without having to pay basic customs duty. However, all the major inputs for manufacturing cement such as limestone, gypsum, pet coke, packing bags etc attract customs duty. In this situation duty-free imports cause further hardship to the Indian cement industry apart from the security concerns that are caused by import of cement from Pakistan.

Therefore, it is requested that to provide a level- playing field, basic customs duty be levied on cement imports into India.

Alternatively, Import duties on goods required for manufacture of cement be abolished and freely allowed without levy of duty.

Withdrawal of excise duty on flyash

Excise duty has been levied on fly ash, which is a waste product generated on burning of coal in the boiler of power plant vide notification no. 1/2011 – CE and 2/2011 – CE.

In this regard the decision of the Hon’ble Supreme Court in case of Union of India Vs. Ahmadabad Electricity Co. Ltd., in 2003 (158) ELT 3 (SC) has settled the issue that use of coal as fuel to produce steam resulting in fly ash as a byproduct cannot amount to manufacture.

There is no change in the process generation of fly ash viz. a waste generated on burning coal in the boiler, therefore, the above judgment still holds good & hence fly ash generation should not be treated as manufacture and no Excise Duty on fly ash be levied.

Treatment of waste heat recovery as renewable energy

Energy cost is a very substantial part of the cost of producing cement, as indeed, it is for many other industries. The prices of conventional energy resources are rising higher and higher and further, greater use of these is adversely affecting the environment. Also, various Government are imposing renewable energy obligations on the industry. Looking at all the above, the cement industry has been putting up Waste Heat Recovery plants so as to derive more energy from the same energy resource. In a way, this is akin to green energy. All of this requires further substantial capital investments.

To help the industry in its endeavor to produce more such environment-friendly energy, it is requested that such energy generation be treated as Renewable Energy Source.

Abolition of Import Duty on Tyre Chips

Cement industry is an energy-intensive industry and requires huge amounts of energy resources. However, it does not get adequate supplies of domestic coal and hence has to resort to expensive imported coal.

To meet its requirements, the industry has been developing alternative energy sources like tyre chips etc. However, tyre-chips is presently put under the "negative list" of imports, whereby the same cannot be imported into India. To increase supply of energy sources as well as for conserving the domestic energy sources it is necessary, in the National Interest, that tyre chips be allowed to be imported by removing it from the Negative list and by reducing import duty on the same to ZERO.

Classifying Cement as "Declared Goods"

Cement industry is one of the basic and core infrastructure industries. However, unlike other similar industries/goods, cement is subject to higher rates of taxation. It is requested that Cement be stipulated as "Declared Goods" under Section 14 of Central Sales Tax Act, so that it is put on an equal footing with other core sector goods like coal and steel.

Tax exemption to Certified Emission Reduction (CER) credits under Clean Development Mechanism

The Clean Development Mechanism (CDM) allows industrialised countries to meet their emission reduction commitments under the Kyoto Protocol by purchasing carbon credits from developing countries.

India does not have any carbon emission obligations under Kyoto Protocol. However, Indian enterprises are entitled to earn carbon credits.

As per proviso (ii) to Sec-28(va), any sum received as compensation, from the multilateral fund of Montreal Protocol on substances that deplete the Ozone Layer under United Nations Environment Program, in accordance with the terms of agreement entered into with the Govt. of India, is not taxable.

To motivate the corporate sector for reduction in carbon emission, receipt from CER credit should be exempted from tax.

Exemption to Cement Industry u/s 80-1A

As per provision of Sec. 80-IA(4), deduction is allowed on income derived by any enterprise carrying on the business of (i) developing, or (ii) operating and maintaining or, (iii) developing, operating and maintaining any infrastructure facility.

Since for developing infrastructure facility, cement Industry plays a major role by providing basic material i.e. cement, 80-IA benefit should also be extended to cement Industry.

It is also justifiable for the survival of cement sector which is adversely affected due to increase in cost of production and surplus of capacity as compared to demand, resulting in prices being under pressure.

Exemption to Power Plants U/S 80-IA Power is the critical infrastructure on which the socio-economic development of the country depends. The growth of the economy and its global competitiveness hinges on the availability of reliable and quality power. The demand of power in India is enormous and is growing steadily. India is the world’s sixth largest energy consumer, accounting for about 3.5 per cent of the world’s total annual energy consumption.

In view of the emphasis by Planning Commission to increase the power generation in India, it would be in line with the vision of Planning Commission to continue the exemption to power plants till the demand-supply gap gets bridged.

As per provision of Sec. 80-IA (4) (iv), profit earned by an undertaking which is set-up for generation or generation and distribution of power, if it begins to generate power up to 31st Mar-2012, is exempted.

In view of the scarcity of power & to promote the Power Plants, it is suggested to continue the exemption if the power plants are commissioned by 31st Mar-2015.

Goods & Service Tax (GST)

Central Government is seriously considering introducing GST w.e.f. 1.4.2013. In this regard, the following suggestions may kindly be considered before introduction of the new tax regime:

a) Single Rate of Tax: Central Government has made a proposal to State Government for dual rate under GST which would be brought to single rate over a period of 3 years. However, it is suggested that single rate may kindly be introduced from the first year itself, so that all disputes/litigation towards classification can be avoided from the first year itself.

b) Common Law & enforcement: The Basic purpose behind introduction of GST is simplicity and uniformity of the tax law throughout India. Though the Empowered committee of State Finance Ministers (EC) has agreed to introduce Dual GST with separate Act for SGST to be levied by each state, it may be ensured that there is uniformity in the law to be enacted by various states and process/procedures of different states are similar, as otherwise, the basic purpose behind the introduction of GST would get defeated.

In this regard, it is suggested that any change in the statute of any state, after introduction of GST, be made only with the concurrence of all states.

c) Cenvat/Input tax Credit: Input Tax Credit of tax paid is available under present Excise/Service Tax/VAT laws and the same is presumed to be continued under GST regime. However, this area attracts most of the litigation and hence the criteria/process for availing Input tax credit be simple and unambiguous. To achieve this purpose, the following suggestions are submitted:

i) Input tax credit may be made available for all the inputs and capital goods in or in relation to manufacturing and business activities.

ii) No condition be imposed for availing Input tax credit as long as it relates to the business or industrial activity.

iii) Exclusion (negative list) for availment of Input Tax Credit in respect of items used for or in relation to manufacture be abolished.

iv) 100 per cent input tax credit may be allowed on Capital Goods in the year of purchase itself and conditions like capitalisation/put to use not be imposed.

d) Common dispute resolution mechanism: To reap the full benefit of GST, it is suggested that the mechanism for dispute resolution prescribed may be common throughout all the states.

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Concrete

Grinding aids help in reducing the agglomeration of particles

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Lokesh Chandra Lohar, General Manager – Technical and Executive Cell, Wonder Cement, shares insights on overcoming challenges, leveraging innovations and the crucial role of R&D in maintaining high standards in cement production.

Can you provide an overview of the grinding process in your cement manufacturing plant and its significance in the overall production process?
Cement grinding unit is used to grind clinker and gypsum into a fine powder, known as cement. The process of grinding involves grinding of the clinker to a fine powder, which is then mixed with gypsum, fly ash and other additives to produce cement.
At Wonder Cement, our grinding processes are pivotal in ensuring high-quality cement production by utilising state of art technologies ex. Vertical Roller Mill (VRM), roller press with ball mill in combi circuit and finish mode grinding and high-efficiency classifier, have achieved optimal particle size distribution and energy efficiency.
Our commitment to sustainability is evident with usage of energy-efficient equipment, eco-friendly grinding aids and renewable energy sources. Continuous research and development efforts ensure we stay at the forefront of innovations, optimising our grinding operations and minimising impact on the environment.

The main processes involved in a cement grinding unit are:

  • Clinker grinding: This is the main process in a cement grinding unit, where the clinker is ground into a fine powder using a ball mill or combi mills (RP+ Ball Mill) or vertical roller mill circuit. The grinding process is controlled to achieve the desired fineness of the cement.
  • Gypsum and other additives: Gypsum is added to the clinker during the grinding process to regulate the setting time of the cement. Other additives such as fly ash, BF slag and pozzolana may also be added to improve the performance of the cement.
  • Packaging: Once the grinding process is complete, the cement is stored in silos before being packed in bags or loaded into bulk trucks for transportation.
  • Quality control: Quality control measures are in place throughout the grinding process to ensure that the final product meets the required specifications, including strength, setting time, and consistency.What are the main challenges you face in the grinding process, and how do you address these challenges to maintain efficiency and product quality?
    The main challenges in the grinding process include high energy consumption, frequent wear and maintenance, variability in clinker properties, environment impact and ensuring consistent product quality. To address these challenges, we have implemented several strategies:
  • High energy consumption: Clinker grinding is energy-intensive, and high energy costs can significantly impact the overall production costs of cement.
    This is one of the primary challenges in the grinding process.
  • Use of high-efficiency equipment: We have state-of-the-art energy-efficient grinding equipment, such as vertical roller mills (VRM), Combi Circuit (roller press with ball mill), which consume significantly less energy consumption.
  • Process optimisation: Real time monitoring and optimisation of the grinding process to minimise energy consumption.
  • Frequent wear and maintenance: The grinding equipment, such as mills and crushers, is subjected to wear over time. Frequent maintenance and downtime can affect production efficiency.
  • Regular maintenance: Implement a proactive maintenance schedule to address wear and tear promptly, ensuring the equipment remains in optimal condition.
  • Proper lubrication: Adequate lubrication of moving parts can extend the lifespan of grinding equipment.
    Use of wear-resistant materials for components, which are prone to wear and abrasion.
  • Variability in clinker properties: Clinker properties can vary from one batch to another, leading to inconsistencies in the grinding process and the quality of the final cement product.
  • Clinker sources: At Wonder we have one clinker source, which is our mother plant at Nimbahera, Rajasthan and we distribute clinker to various split GU’s from Nimbahera. This helps us to maintain uniform clinker quality across each location.
  • Quality control: Rigorous quality control measures help us identify and address variations in clinker properties. Adjust grinding parameters as needed to compensate for these variations. (ex. use of cross belt analyser and on-line particle size distribution)
  • Environmental impact: Energy-intensive grinding processes can have environmental repercussions due to high dust emissions and energy consumption.
    Use of high efficiency dust collection and suppression system to keep emissions below statutory norms
  • Sustainable grinding aids: Consider using eco-friendly grinding aids that enhance grinding efficiency without compromising cement quality and environmental standards.
  • Alternative fuels: Use alternative and more sustainable fuels in the cement kiln and hot gas generated to reduce carbon emissions.
  • Use of clean energy in logistics:
    To reduce carbon emissions, sustainable alternatives are also sought for inland transport. We have involved neutral internal transports (electric powered trucks).
  • Automation and digitalisation of production:
  • Wonder Cement has already initiated the process to implement Smart Cement Industry 4.0.
  • With Industry 4.0, the automation and digitalisation of operations, including the use of sensors, remote diagnosis, analysis of big data (including the artificial intelligence analysis of unstructured data such as images and video), equipment, virtual facilities, and intelligent control systems will be done automatically (based first on ‘knowledge capture’ and then on machine learning). For Process optimisation we are using the FLS Process expert system (PXP) system. This allows for system optimisation and increased efficiency gains in production.

How do grinding aids contribute to the efficiency of the grinding process in your plant? What types of grinding aids do you use?
Grinding aids help in reducing the agglomeration of particles, thus improving the overall grinding efficiency and ensuring a smoother and more efficient grinding process without having adverse effect on any of the properties of the resulting cement. In cement manufacturing, various types of grinding aids are used to improve the efficiency of the grinding process. These include:

Glycol-based grinding aids

  • Composition: Ethylene glycol and diethylene glycol.
  • Usage: Commonly used in to improve the grinding efficiency and reduce energy consumption.

Amine-based grinding aids

  • Composition: Triethanolamine (TEA) and Triisopropanolamine (TIPA).
  • Usage: Effective in improving the grindability of clinker and other raw materials, enhancing cement strength and performance.

Polyol-based grinding aids
Composition: Polyethylene glycol and other polyol compounds.
Usage: Used to improve the flowability of the material and reduce the tendency of particles
to agglomerate.

Acid-based grinding aids
Composition: Various organic acids.
Usage: Used to modify the surface properties of the particles, improving the grinding efficiency and final product quality.

Specialty grinding aids

  • Composition: Proprietary blends of various chemicals tailored for specific materials and grinding conditions.
  • Usage: Customised to address challenges in the grinding process, such as the use of alternative raw materials or specific performance requirements.

Can you discuss any recent innovations or improvements in grinding technology that have been implemented in your plant?
Recent innovations and improvements in grinding technology:

  • Selection of state-of-the-art vertical roller mills along with high efficiency classifier (VRMs): VRMs are more energy-efficient and have lower power consumption, leading to significant energy savings. They also provide a more consistent product quality and require less maintenance. For raw meal grinding, we have both VRM and roller press.
  • Wear-resistant materials and components: Upgrading grinding media, liners and other components with wear-resistant materials. These materials extend the lifespan of the equipment, reduce downtime, and lower maintenance costs. Examples include ceramic liners and high chrome grinding media.
  • Intelligent monitoring and predictive maintenance: Utilising IoT sensors and predictive analytics to monitor equipment health. Predictive maintenance helps identify potential issues before they lead to equipment failure, reducing unplanned downtime and maintenance costs. It ensures optimal performance and prolongs equipment life.
  • Optimisation software and simulation tools: Using simulation software to model and optimise the grinding process. These tools help in understanding the process dynamics, identifying bottlenecks, and testing different scenarios for process improvement. This leads to better process control and efficiency.

How do you ensure that your grinding equipment is energy-efficient and environmentally sustainable?

  • Energy-efficient grinding technologies such as VRMs: VRMs are more energy-efficient than traditional ball mills due to their ability to grind materials using less energy.
  • Benefits: Up to 30 per cent to 40 per cent reduction in energy consumption.
    Use of renewable energy sources (solar power integration): Utilising solar power for grinding operations
  • Implementation: Signing of long-term open access power purchase agreements (PPA) with renewable energy developers
  • Benefits: Reduces reliance on fossil fuels, decreases greenhouse gas emissions.

Environmental sustainability practices

a. Dust collection and emission control
Description: Using bag filters, and covered material handling system
Implementation: Installing and maintaining high-efficiency dust control equipment.
Benefits: Reduces particulate emissions, improves air quality, complies with environmental regulations.
b. Water conservation
Description: Recycle and reuse water in the grinding process.
Implementation: Installing sewage treatment plant (STP)
Benefits: Reduces water consumption, minimises environmental impact.
c. Use of alternative raw materials
Description: Incorporating industrial by-products like fly ash, BF slag and chemical gypsum in the grinding process.
Implementation: Sourcing and blending alternative materials.
Benefits: Reduces the need for natural resources, lowers carbon footprint, enhances sustainability.
By implementing these practices, the plant ensures that its grinding operations are both energy-efficient and environmentally sustainable, aligning with industry best practices and regulatory requirements.

What role does research and development play in optimising your grinding processes and the selection of grinding aids?
Following is the role of research and development in optimising grinding processes and selecting
grinding aids:

  • Testing and usage of new low-cost cementitious material: Dedicated R&D teams work on developing and new low-cost cementitious material to reduce clinker factor in cement and
    improve efficiency.
  • Process simulation and modelling: Uses simulation and modelling tools to understand the dynamics of the grinding process and identify areas for improvement.
  • Formulation of new grinding aids with reverse engineering: Formulate new grinding aids to enhance the efficiency of the grinding process.
  • Testing and evaluation: Conducting laboratory and plant-scale tests to evaluate the effectiveness of different grinding aids.
  • Collaboration with industry partners: Collaborating with suppliers, universities and research institutions to stay at the forefront of grinding technology advancements.

Research and development play a crucial role in optimising grinding processes and selecting the appropriate grinding aids. By focusing on innovation, process optimisation, sustainability and continuous improvement, R&D ensures that the plant remains competitive, efficient, and environmentally responsible. This commitment to research and development enables the plant to achieve higher productivity, lower costs and produce superior quality cement.

What trends or advancements in grinding processes and grinding aids do you foresee impacting the cement manufacturing industry in the near future?
The trends and advancements in grinding processes and grinding aids that we see coming up in the near future are:

1. Digitalisation and Industry 4.0

  • Advanced process control (APC) and automation
  • Internet of things (IoT) and predictive maintenance
  • Artificial intelligence (AI) and machine learning (ML)

2. Energy efficiency and sustainability

  • Energy-efficient grinding technologies
  • Use of renewable energy

3. Innovations in grinding aids

  • Eco-friendly grinding aids
  • Tailored grinding aids
  • Multifunctional grinding aids

4. Advanced materials and components

  • Wear-resistant materials for liners
  • High-density grinding media

5. Process optimisation and integration

  • Holistic process optimisation

6. Sustainability and circular economy

  • Circular economy practices
  • Carbon capture and utilisation (CCU)

– Kanika Mathur

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Concrete

Shaping the Future

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Jigyasa Kishore, Vice President Enterprise Sales and Solutions, Moglix discusses the critical role of cement capacity expansion in India’s infrastructure development, highlighting the importance of technological advancements, sustainability and strategic investments amid market challenges.

With an installed cement capacity of 600 million tonnes, India is the second-largest cement producer in the world. Cement consumption in India is expected to reach 450.78 million tonnes by the end of FY27, owing to rapid urbanisation and smart city development plans. Infrastructure, typically, receives the most funding from the government which bodes well for the cement industry. At a time when India is urbanising and building infrastructure at breakneck speed, the role of cement capacity expansion is becoming critical. This expansion, today, supports the market demands as well as contribute towards the nation’s economic ambitions.

Setting a firm foundation
Cement is an essential component in the construction of any nation. Roads and bridges, airports and public buildings all indicate cement’s critical importance in infrastructure development. Urbanisation is fuelled by it through the creation of housing projects aimed at achieving economic growth and development. Here’s why capacity expansion of cement production is critical:
Urbanisation: The demand for cement increases as urbanisation intensifies. This is further evidenced by the budget estimate for the Pradhan Mantri Awas Yojana for affordable housing, which has been pegged at US$ 9.63 billion (Rs.79,590 crore) for the first time, registering an increase of 66 per cent over the previous year’s budget.
Major infrastructure projects: Large infrastructure projects like highways, bridges, and city-development require considerable quantities of cement. Capacity expansion can ensure steady supplies of good-quality cement to these large-scale projects and see their timely and expeditious completion. The National Infrastructure Pipeline (NIP) has been widened to 9,735 projects worth $1,828.48 billion. Many of the upcoming projects will be heavily dependent on the cement industry. In addition, the PM Gati Shakti National Master Plan for infrastructure is further driving up the
cement demand.
Employment Generation: Increased production capacity directly results in job creation in the cement industry. Additionally, a corresponding demand for further employment in complementary sectors such as construction, logistics, and retail is also generated. This bolsters holistic economic development and prosperity.
Regional Economic Growth: New cement plants are often set up in regions with abundant raw materials but stunted industrial development. By setting up new plants in these regions, local resources can be leveraged and the overall growth story of the region can be improved. For instance, Dalmia Bharat recently announced a $10.9 million investment for further expansion of its already existing cement plant in the small town of Banjari in Bihar. The increasing presence of small and mid-size cement players across various regions helps dilute market concentration of industry leaders, leading to a more competitive and diverse market landscape.

Reinforcing the Structure
India’s cement industry is currently experiencing a tough fiscal year and there has been a downturn in pricing. Moderate demand is expected for H1FY25. Temporary setbacks such as labour shortage and heavy monsoons have also caused the demand for cement to take a dip in the past couple of months.
Needless to say, expanding capacity during periods of subdued demand involves risk. Cost implications of such investments can be significant. And firms could fail to recoup their investments if market conditions don’t improve as planned. Over-expansion could also result in an oversupplied market and further impact the prices as well as profit margins. Cement producers are currently under pressure due to reduced prices and slow demand. While this price dip might adversely affect profits in the short term, it could be seen as market adjustment ahead of a surge in anticipated demand during the second half of the fiscal year
Periods of uncertainty can be looked at as opportunities for companies to diversify risks and invest in innovation. Developing and launching new cement products for specific use-cases would contribute to the top line. Targeting export markets for better demand can also ensure the optimal use of additional capacities. At the same time, focusing on operational efficiencies would help the companies keep the cost of production in check.
New investments made in cement production facilities automatically come with the latest technological advancements that can enhance efficiency, minimise environmental impacts, and improve the quality of cement. This leads to construction practices that are more durable and sustainable. JSW, for instance, has initiated research on the integration of supplementary cementitious materials (SCMs) like fly ash, slag, calcined clay, and more. These materials not only improve the durability and strength of cement but also contribute towards reduction of carbon footprint of the cement industry. In order to meet energy demands sustainably, we must look at better industry practices such as usage of waste heat recovery systems, high-efficiency coolers and preheaters, and transition towards clean energy sources like solar or wind power.
There is also a growing need for cement companies to become environmentally conscious. Modern cement plants are increasingly adopting greener technologies owing to the decarbonisation pressure. Capacity expansion while keeping sustainability at its core will help check environmental impact of cement production while also aligning with the challenging global environment-conservation goals. Recently, UltraTech announced that it had received Environmental Product Declaration (EPD) certificates for four of its cement products. Similarly, Dalmia Bharat (Cement) has announced plans to produce 100 per cent low-carbon cement by 2031 and has a US$ 405 million carbon capture and utilisation (CCU) investment plan to achieve this goal. Such efforts are laudable and set a fine example for all industry players.

Shaping a Stronger Nation
Cement capacity expansion is a strategic move for the Indian cement industry. While short-term market fluctuations present challenges, continued investment in capacity expansion reflects a long-term vision for shaping India’s future infrastructure landscape. The current economic climate demands agility and innovation from Indian cement players. The leaders need to lead by example. By adopting industry best-practices, aiming for sustainable development, and working towards continuous growth and advancement, the cement industry is sure to rise like a phoenix from the ashes.

About the author
Jigyasa Kishore comes with 15+ years of experience at building brands, enabling enterprise growth, and transforming organisational performance with a technology-first approach. At Moglix, she leads brand growth as a digital supply chain solutions architect for large manufacturing enterprises.

She is an alumnus of the Indian

School of Business, Hyderabad, and Bangalore University.

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Concrete

Filtration can help to control climate change

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Niranjan Kirloskar, Managing Director, Fleetguard Filters, elaborates on the importance of filtration and its profound impact on efficiency, longevity and environmental sustainability.

Tell us about the core principle of filtration.
Filtration is segregation/separation of matter by density, colour, particle size, material property etc. Filtration is of four basic types:

  • Separation of solids from gas
  • Separation of solids from liquids
  • Separation of liquids from liquids
  • Separation of Solids from solids.

As applied to engines/equipment, the main objective of filtration is to purify the impurities and provide the desired fluid or air for enhanced engine/equipment performance in turn optimising their performance and life.

Can better filtration bring productivity to the work process? How?
Better filtration can improve the quality of application performance in multiple ways. Filtration improves engine performance as it filters and prevents dirt, dust, and debris from entering into the engine. This ensures that the quality of air or fluid that reaches the combustion chamber is as per the specific requirements of optimal performance of the engine. It also extends engine life by filtering out contaminants. Efficient filtration ensures optimal performance of the engine/equipment over its entire operating life. Filtration also improves fuel efficiency as a clean filter allows for a better air-fuel mixture in the engine, thus improving combustion efficiency, which in turn results in better fuel economy. It keeps emissions under control as fuels burn more efficiently leading to lesser harmful residue in the environment. Thus, to sum up, an optimal filtration solution ensures better performance, prolonged engine life and less hazardous waste in the environment.

What is the role of technology in the process of filtration?
Innovation, research and development as well as technology play a pivotal role in catering to the ever-evolving environmental norms and growing market demands. At FFPL we have NABL Accredited labs for testing, we have ALD Labs for design, and a team of R&D experts constantly working on providing advanced solutions to cater to the evolving market needs. We have robust systems and advanced technologies that make high-quality, high-precision products. Our state-of-the-art manufacturing facilities use advanced technologies, automation, robotics and also Industry 4.0 as applicable to provide the best products to our customers. To ensure each product delivered to market is of utmost precision, advanced quality equipment such as CMM, scanning systems and automated inspection technologies for real-time monitoring and quality control during the manufacturing of filtration systems and to comply with standard quality requirements are used.

Tell us about the impact of good filtration on health and the environment.
Good filtration of equipment is to the environment what a good respiratory system is to the body. There are various benefits of an efficient air filtration system as it improves the air quality by ensuring optimum combustion of fuel thereby reducing/controlling emissions to the environment. Efficient lube filtration ensures low wear and tear of the engine thereby extending life of the engines and maintaining optimal performance over the entire operating life of the engine. Efficient fuel filtration ensures low wear and tear of expensive and sensitive fuel injection thereby ensuring perfect fuel metering resulting in best fuel efficiency and saving of precious natural resources. This efficient filtration can help to control climate change as it reduces the carbon footprint due to combustion in the environment.

Can your products be customised and integrated with other machinery?
Fleetguard Filters have been known as a leading solutions provider for decades. With relevant experience and close customer relations, we understand the market/applications requirements and develop solutions to address the pressing technical challenges our customers face concerning filtration solutions. Filters can be customised in terms of size, shape and configuration to fit specific requirements. Customised filters can be designed to meet critical performance requirements. Filtration systems can be designed to integrate seamlessly with any auto and non-auto application requirements.

What are the major challenges in filtration solutions?
Major challenges faced in filtration solutions are:

  • With every emission regulation change, filtration requirements also keep changing.
  • Engines are being upgraded for higher power ratings.
  • Space for mounting filtration solutions on vehicles/equipment is shrinking.
  • For fuel injection systems, the water separation efficiencies are becoming more and more stringent, so are particle separation efficiencies.
  • Due to next level filtration technologies,filtration systems and filter elements are becoming expensive, thereby increasing TCO for customers.
  • Customers prefer higher uptimes and longer service intervals to ensure lower maintenance and operating costs.

We, at Fleetguard, strive continuously to ensure that all the pains experienced by our customers are addressed with the fit to market solutions. Balancing the cost of filtration solutions with their performance and durability can be challenging, especially where the requirements of high filtration standards are required. Also, wrong disposal methods for used filters can have environmental impact.

  • Kanika Mathur

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