Connect with us

Concrete

A leap towards a technology horizon

Published

on

Shares

Indian cement plants are gearing up for the future by embracing digitisation to earn a competitive advantage in the market. The plant is just one component of the cement value chain, but it remains one of the most important components in achieving operational efficiencies, higher energy efficiency, reduced carbon footprint, and overall business goals.

Over the last few years, cement companies are increasingly focusing on transforming the way they do business, through implementing the right technologies. They are investing heavily in digital assets to automate their operations. Artificial Intelligence, big data, cloud, IoT, and systems integration technologies are some of the new technology horizons that Indian cement companies are adopting to offer a competitive advantage and create sustainable growth in the near future.

The ongoing pandemic has made cement companies realise the importance of technology in cement plants. Cement companies today have started embracing various technologies to achieve considerable productivity gains and to recover from the impact of Covid-19. We spoke to companies like ACC, Shree Cement, JK Lakshmi, and KnowledgeLens, to understand various trends and technologies in the cement industry. Our takeaway is that Indian cement companies are on a journey to achieve resilient, agile, green, and efficient cement plants.

According to new market research by Global Market Estimates, the Global Artificial Intelligence in Cement Production Market is projected to grow at a CAGR value of 28.5% during the forecast period of 2021 to 2026. Predictive analysis and AI help to identify the inefficiencies in the process and hence a lot of cement companies are looking for deploying such solutions. Solution providers such as ABB, Siemens, ES Processing, Petuum, Halliburton, and thyssenkrupp among others are the players in the artificial intelligence in the cement production market.

Technology advancements

A strong IT infrastructure enables a fully integrated cement value chain. Right from algorithms, cement quality, energy efficiency, and cement-to-clinker ratios, technology can automatically track and improve the efficiency level of each piece of equipment and procedure.

ACC and Ambuja Cement have technologies such as Tool Location System (TLS) and Supervisory Control and Data Acquisition (SCADA) to increase plant efficiency and uptime. Neeraj Akhoury, CEO India LafargeHolcim, MD & CEO of Ambuja Cements, explains, ??aunched almost a year ago, another innovation – the Remote Troubleshooting Tool using Smart Glass Technology has proven to be a delight for site engineers. This two-way tool ensures timely and expert support to plants, especially during this pandemic where this tool has been considered a boon. Digital Eye is another technology utilised by both companies to digitally monitor factory and plant operations using drones and video analytics to operate effectively and increase safety.??/p>

Similarly, Orient Cement has taken IT initiatives to accelerate the digitisation journey by leveraging Industry 4.0 technologies to improve their plant?? Operational Visibility and bring in Predictive Analytics for better operational efficiency.

Predictive analysis is the buzzword today. In cement plants, it can be used for Equipment Monitoring and Predictive Maintenance by installing factory-fitted sensors. These sensors are intelligent enough to detect the source of the problem. Having such tools reduces inspection time and ordering time, which leads to a reduction in overall cost to the company.

Technologies around predictive quality and process control are also been deployed at cement plants for major processes such as raw material crushing and grinding, baking raw material, and clinkerisation. In a typical traditional method, this process depends on a lot of parameters like the speed of the mill, mill temperature, clinker feed temperature, grinding duration, etc, which makes it time-consuming and complicated. Having an advanced predictive system can detect variability across these parameters.

Cement companies have realised the need of improving their processes. Such is the case of Orient Cement, the company needed a robust technology that could facilitate a manufacturing data lake to facilitate historical analytics of the plant data for operational insights, anomalies detection, and areas of process improvement. The cement company implemented iLens ??Industrial IoT Solution at their Plant at Devapur.

Sudheesh Narayanan, Founder & CEO of Knowledge Lens, explains, ??e interfaced the Plant?? PLCs (Programmable Logic Controller) with in-built protocol support to perform real-time data acquisition of around 4000 parameters across multiple PLC Machines in 3 Units to monitor the assets, storage of historian data and a mechanism to backup, synchronise the data from plant network to the corporate network in a secure manner. The data was stored in a highly scalable big data platform which served as a unified storage repository to perform monitoring and analytics.??/p>

Therefore, Data analysis is the key. It is another important area where cement companies are looking at automation. A few cement companies use data obtained from their systems and processes to determine and assess cement quality and energy consumption.

Technology for Seamless Supply chain

Seamless logistic operations are important in every cement plant because the raw material and the finished product are reactive to external conditions like moisture, heat, impurities, etc. The transport of materials mostly happens through heavy trucks. For a seamless operation, it is important to have control of your supply chain. Thus, cement companies are installing supply chain solutions to monitor the location of each vehicle in their fleet, and measure the payload carried by each vehicle. During Covid times, automation in this area has proved to be a boon to check the vitals of the crew members. IT solutions offer help in routing vehicles to their destinations without wasting time and cost.

Shree Cement is an excellent example who have gone from old methods to advanced Supply chain mechanism. Earlier, the company was handling 5000 trucks on daily basis across all units. This massive volume was leading to Truck Turnaround Time (TAT) of 12-13 Hrs and was resulting in a rise in freight cost significantly. Moreover, due to security checks, vehicles were being stranded within the plants at various for several hours, severely impacting the dispatch capacity.

To address these challenges, Shree Cement has installed RFID Based Integrated Logistics Management System (ILMS), Boom Barriers at security checkpoints, Manless weighbridges, Auto Invoice Generation through Robotics Process Automation (RPA), and Auto E-way bill through third-party applications.

Now, truck movement inside the plant premises is completely automated. Real-time tracking of vehicles is being done leading to a reduction in turnaround time to 4-5 Hrs. ??he visibility has increased dramatically leading to smooth and clutter-free movement. Not only this, all our 80 manless weighbridges and invoicing through RPA have saved 320 and 100 manpower respectively. This manpower was shifted to more productive operations resulted in more output and less new hiring,??says Yogesh Mehta, Vice President, Shree Cement.

Similarly, ACC and Ambuja Cement realised the need for digital implementation in Supply chain Management, and thus have implemented Blue Yonder Luminate Planning for supply chain transformation and digitalisation. They launched the Transport Analytics Center (TAC) in March 2020, which ensured allowing operational teams with real-time data on distribution safety, cost optimisation, and efficiency improvement.

Reaping the Benefits

Modernisation comes with loads of benefits to the cement industry, such as improved operations, better customer service, cost optimisation, and better collaboration.

Akhoury states that the company?? ??lants of Tomorrow??certified operation promises 15 to 20 per cent more operational efficiency compared to a conventional cement plant.

Interestingly, there are technologies been deployed by cement players to track real-time journeys. Some cement companies have installed integrated dashboards that offer key insights into their businesses. This integrated system aids decision-makers to identify the weakest links in the supply chain and take necessary steps to improve the process.

Cement plants are rethinking their products and taking energy-efficient measures to achieve carbon neutrality. According to few analysts, cement plants have the capacity to reduce CO2 emissions by up to 75 per cent by 2050. And this could be achieved by advanced measures like scaling of carbon capture, utilisation, and storage technologies.

Reducing CO2 emissions is on every cement company?? top agenda. By adopting the right technologies, the cement companies are aggressively looking forward to meeting their sustainability targets. Cement players are more conscious now of selecting and investing in technology to improve the energy efficiency of their production facilities. With help of technology, they are aiming at using alternative raw materials and fuels to replace CO2-intensive clinker.

Best practices

There cannot be a single approach for all cement plants. Each plant has its own objective and challenges and should choose its path depending on goals, desire for centralisation, existing in-house infrastructure, capacity, budget, and resources. One common objective could be around value generation. This is where technology comes into the picture. Companies need to introspect questions like–Can a fully integrated manufacturing unit generate higher margins?

Cost estimation and time estimation should be taken into account before choosing the right IT solution. Beyond that, some of these investments might be driven by compliance requirements.

CONCLUSION

Indeed, there has been an acceleration in the adoption level of IT at cement plants today and we feel that the Indian cement plants will operate in a drastically different way than it operates today.

Continue Reading
Click to comment

Leave a Reply

Your email address will not be published. Required fields are marked *

Concrete

India’s Steel Imports Drop 34 Per Cent, Exports Rise 25 Per Cent In April–October

Consumption grows despite weak prices and subdued demand

Published

on

By

Shares

India’s finished steel imports fell 34.1 per cent year-on-year to 2.5 million tonnes in the first seven months of the financial year, according to government data. Despite the decline, the world’s second-largest crude steel producer remained a net importer of finished steel during the April–October period. The fall in imports came alongside a 7.4 per cent rise in domestic consumption, which reached 92.2 million tonnes.

South Korea emerged as India’s largest source of finished steel imports, supplying 1.4 million tonnes. It was followed by China, Japan and Russia. Although total imports declined sharply, the figures show a continued inflow of foreign steel into the Indian market.

Domestic production remained strong. Finished steel output stood at 91.6 million tonnes for April–October, while crude steel production reached 95.7 million tonnes, underscoring the scale and resilience of India’s steel industry despite external competition.

In contrast to the fall in imports, India’s finished steel exports jumped 25.3 per cent year-on-year to 3.5 million tonnes. Europe was a major destination, with Italy and Belgium leading as top importers of Indian steel, followed by Spain. This highlights the growing global competitiveness of Indian steel in select markets.

The government noted that domestic steel prices have come under pressure due to weak demand and high supply. Trading activity also remained subdued during the festival season. This challenging environment has been particularly difficult for smaller steel producers, as previously reported.

Overall, the combination of declining imports, rising exports and increasing domestic consumption reflects the complex landscape of the Indian steel sector as it navigates muted internal demand and evolving international trade dynamics.

Continue Reading

Concrete

JK Lakshmi Cement Plans Rs 18.16 Billion Expansion

Firm to boost clinker and grinding capacity in Chhattisgarh

Published

on

By

Shares

JK Lakshmi Cement announced on Tuesday that it will invest Rs 18.16 billion to expand its manufacturing operations in Chhattisgarh. The company intends to raise its clinker production capacity by 2.31 million tonnes per annum (MTPA) and its cement grinding capacity by 1.2 MTPA, supported by this proposed investment.

The Memorandum of Understanding for the expansion was signed during the Chhattisgarh Investor Connect event in New Delhi, in the presence of Chief Minister Vishnu Deo Sai. The added capacity will enhance the company’s ability to serve the rapidly growing markets of Eastern and Central India, where demand for building materials remains robust.

The move supports JK Lakshmi Cement’s broader goal of increasing its total capacity to around 30 MTPA in the coming years. Deputy Managing Director Shrivats Singhania said the expansion marks a significant step in the company’s next phase of growth, adding that Chhattisgarh has long been central to its manufacturing strategy.

Over the past decade, JK Lakshmi Cement has contributed to strengthening Chhattisgarh’s industrial landscape since establishing its integrated plant in Durg in 2015. The company has implemented multiple initiatives, including a manufacturing facility with 1.8 MTPA of clinker capacity and 2.7 MTPA of cement capacity, operational upgrades with energy-efficient technology and automation, and logistics improvements through enhanced rail connectivity.

Chhattisgarh continues to show strong economic momentum, making it one of the most promising markets for cement demand, said Arun Shukla, President and Director at JK Lakshmi Cement. The company’s shares closed 0.28 per cent higher at Rs 782.10 on the BSE.

Continue Reading

Concrete

Balancing Rapid Economic Growth and Climate Action

Published

on

By

Shares

Dr Yogendra Kanitkar, VP R&D, and Dr Shirish Kumar Sharma, Assistant Manager R&D, Pi Green Innovations, look at India’s cement industry as it stands at the crossroads of infrastructure expansion and urgent decarbonisation.

The cement industry plays an indispensable role in India’s infrastructure development and economic growth. As the world’s second-largest cement producer after China, India accounts for more than 8 per cent of global cement production, with an output of around 418 million tonnes in 2023–24. It contributes roughly 11 per cent to the input costs of the construction sector, sustains over one million direct jobs, and generates an estimated 20,000 additional downstream jobs for every million tonnes produced. This scale makes cement a critical backbone of the nation’s development. Yet, this vitality comes with a steep environmental price, as cement production contributes nearly 7 per cent of India’s total carbon dioxide (CO2) emissions.
On a global scale, the sector accounts for 8 per cent of anthropogenic CO2 emissions, a figure that underscores the urgency of balancing rapid growth with climate responsibility. A unique challenge lies in the dual nature of cement-related emissions: about 60 per cent stem from calcination of limestone in kilns, while the remaining 40 per cent arise from the combustion of fossil fuels to generate the extreme heat of 1,450°C required for clinker production (TERI 2023; GCCA).
This dilemma is compounded by India’s relatively low per capita consumption of cement at about 300kg per year, compared to the global average of 540kg. The data reveals substantial growth potential as India continues to urbanise and industrialise, yet this projected rise in consumption will inevitably add to greenhouse gas emissions unless urgent measures are taken. The sector is also uniquely constrained by being a high-volume, low-margin business with high capital intensity, leaving limited room to absorb additional costs for decarbonisation technologies.
India has nonetheless made notable progress in improving the carbon efficiency of its cement industry. Between 1996 and 2010, the sector reduced its emissions intensity from 1.12 tonnes of CO2 per ton of cement to 0.719 tonnes—making it one of the most energy-efficient globally. Today, Indian cement plants reach thermal efficiency levels of around 725 kcal/kg of clinker and electrical consumption near 75 kWh per tonne of cement, broadly in line with best global practice (World Cement 2025). However, absolute emissions continue to rise with increasing demand, with the sector emitting around 177 MtCO2 in 2023, about 6 per cent of India’s total fossil fuel and industrial emissions. Without decisive interventions, projections suggest that cement manufacturing emissions in India could rise by 250–500 per cent by mid-century, depending on demand growth (Statista; CEEW).
Recognising this threat, the Government of India has brought the sector under compliance obligations of the Carbon Credit Trading Scheme (CCTS). Cement is one of the designated obligated entities, tasked with meeting aggressive reduction targets over the next two financial years, effectively binding companies to measurable progress toward decarbonisation and creating compliance-driven demand for carbon reduction and trading credits (NITI 2025).
The industry has responded by deploying incremental decarbonisation measures focused on energy efficiency, alternative fuels, and material substitutions. Process optimisation using AI-driven controls and waste heat recovery systems has made many plants among the most efficient worldwide, typically reducing fuel use by 3–8 per cent and cutting emissions by up to 9 per cent. Trials are exploring kiln firing with greener fuels such as hydrogen and natural gas. Limited blends of hydrogen up to 20 per cent are technically feasible, though economics remain unfavourable at present.
Efforts to electrify kilns are gaining international attention. For instance, proprietary technologies have demonstrated the potential of electrified kilns that can reach 1,700°C using renewable electricity, a transformative technology still at the pilot stage. Meanwhile, given that cement manufacturing is also a highly power-intensive industry, several firms are shifting electric grinding operations to renewable energy.
Material substitution represents another key decarbonisation pathway. Blended cements using industrial by-products like fly ash and ground granulated blast furnace slag (GGBS) can significantly reduce the clinker factor, which currently constitutes about 65 per cent in India. GGBS can replace up to 85 per cent of clinker in specific cement grades, though its future availability may fall as steel plants decarbonise and reduce slag generation. Fly ash from coal-fired power stations remains widely used as a low-carbon substitute, but its supply too will shrink as India expands renewable power. Alternative fuels—ranging from biomass to solid waste—further allow reductions in fossil energy dependency, abating up to 24 per cent of emissions according to pilot projects (TERI; CEEW).
Beyond these, Carbon Capture, Utilisation, and Storage (CCUS) technologies are emerging as a critical lever for achieving deep emission cuts, particularly since process emissions are chemically unavoidable. Post-combustion amine scrubbing using solvents like monoethanolamine (MEA) remains the most mature option, with capture efficiencies between 90–99 per cent demonstrated at pilot scale. However, drawbacks include energy penalties that require 15–30 per cent of plant output for solvent regeneration, as well as costs for retrofitting and long-term corrosion management (Heidelberg Materials 2025). Oxyfuel combustion has been tested internationally, producing concentrated CO2-laden flue gas, though the high cost of pure oxygen production impedes deployment in India.
Calcium looping offers another promising pathway, where calcium oxide sorbents absorb CO2 and can be regenerated, but challenges of sorbent degradation and high calcination energy requirements remain barriers (DNV 2024). Experimental approaches like membrane separation and mineral carbonation are advancing in India, with startups piloting systems to mineralise flue gas streams at captive power plants. Besides point-source capture, innovations such as CO2 curing of concrete blocks already show promise, enhancing strength and reducing lifecycle emissions.
Despite progress, several systemic obstacles hinder the mass deployment of CCUS in India’s cement industry. Technology readiness remains a fundamental issue: apart from MEA-based capture, most technologies are not commercially mature in high-volume cement plants. Furthermore, CCUS is costly. Studies by CEEW estimate that achieving net-zero cement in India would require around US$ 334 billion in capital investments and US$ 3 billion annually in operating costs by 2050, potentially raising cement prices between 19–107 per cent. This is particularly problematic for an industry where companies frequently operate at capacity utilisations of only 65–70 per cent and remain locked in fierce price competition (SOIC; CEEW).
Building out transport and storage infrastructure compounds the difficulty, since many cement plants lie far from suitable geological CO2 storage sites. Moreover, retrofitting capture plants onto operational cement production lines adds technical integration struggles, as capture systems must function reliably under the high-particulate and high-temperature environment of cement kilns.
Overcoming these hurdles requires a multi-pronged approach rooted in policy, finance, and global cooperation. Policy support is vital to bridge the cost gap through instruments like production-linked incentives, preferential green cement procurement, tax credits, and carbon pricing mechanisms. Strategic planning to develop shared CO2 transport and storage infrastructure, ideally in industrial clusters, would significantly lower costs and risks. International coordination can also accelerate adoption.
The Global Cement and Concrete Association’s net-zero roadmap provides a collaborative template, while North–South technology transfer offers developing countries access to proven technologies. Financing mechanisms such as blended finance, green bonds tailored for cement decarbonisation and multilateral risk guarantees will reduce capital barriers.
An integrated value-chain approach will be critical. Coordinated development of industrial clusters allows multiple emitters—cement, steel, and chemicals—to share common CO2 infrastructure, enabling economies of scale and lowering unit capture costs. Public–private partnerships can further pool resources to build this ecosystem. Ultimately, decarbonisation is neither optional nor niche for Indian cement. It is an imperative driven by India’s growth trajectory, environmental sustainability commitments, and changing global markets where carbon intensity will define trade competitiveness.
With compliance obligations already mandated under CCTS, the cement industry must accelerate decarbonisation rapidly over the next two years to meet binding reduction targets. The challenge is to balance industrial development with ambitious climate goals, securing both economic resilience and ecological sustainability. The pathway forward depends on decisive governmental support, cross-sectoral innovation, global solidarity, and forward-looking corporate action. The industry’s future lies in reframing decarbonisation not as a burden but as an investment in competitiveness, climate alignment and social responsibility.

References

  • Infomerics, “Indian Cement Industry Outlook 2024,” Nov 2024.
  • TERI & GCCA India, “Decarbonisation Roadmap for the Indian Cement Industry,” 2023.
  • UN Press Release, GA/EF/3516, “Global Resource Efficiency and Cement.”
  • World Cement, “India in Focus: Energy Efficiency Gains,” 2025.
  • Statista, “CO2 Emissions from Cement Manufacturing 2023.”
  • Heidelberg Materials, Press Release, June 18, 2025.
  • CaptureMap, “Cement Carbon Capture Technologies,” 2024.
  • DNV, “Emerging Carbon Capture Techniques in Cement Plants,” 2024.
  • LEILAC Project, News Releases, 2024–25.
  • PMC (NCBI), “Membrane-Based CO2 Capture in Cement Plants,” 2024.
  • Nature, “Carbon Capture Utilization in Cement and Concrete,” 2024.
  • ACS Industrial Engineering & Chemistry Research, “CCUS Integration in Cement Plants,” 2024.
  • CEEW, “How Can India Decarbonise for a Net-Zero Cement Industry?” (2025).
  • SOIC, “India’s Cement Industry Growth Story,” 2025.
  • MDPI, “Processes: Challenges for CCUS Deployment in Cement,” 2024.
  • NITI Aayog, “CCUS in Indian Cement Sector: Policy Gaps & Way Forward,” 2025.

ABOUT THE AUTHOR:
Dr Yogendra Kanitkar, Vice President R&D, Pi Green Innovations, drives sustainable change through advanced CCUS technologies and its pioneering NetZero Machine, delivering real decarbonisation solutions for hard-to-abate sectors.

Dr Shirish Kumar Sharma, Assitant Manager R&D, Pi Green Innovations, specialises in carbon capture, clean energy, and sustainable technologies to advance impactful CO2 reduction solutions.

Continue Reading

Trending News

SUBSCRIBE TO THE NEWSLETTER

 

Don't miss out on valuable insights and opportunities to connect with like minded professionals.

 


    This will close in 0 seconds