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Adoption of IT in cement industry

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The cement industry in India is more than a century old and is now second largest globally behind China in terms of installed capacity, production and consumption which is playing an important role in development of infrastructure in the country. Also, Government propels overall development in India and initiating policies like housing for all, road projects and Smart Cities Mission that ensures time-bound creation of world class infrastructure which will boost cement demand in the country.

Owing to its commodity nature, cement being a low cost and high-volume commodity comprising high transportation cost as almost 30 per cent of the cost of cement is involved in logistics. Deprived of automation and thriving on rather uneconomical modes of logistics, the Indian cement sector has for long been burdened with high logistics cost. Considering these facts, logistics has immense potential to deliver cost savings with customer expectations through improvement in service levels. Thus, Logistics in cement industry plays an indispensable role to decide the competitive advantage or disadvantage for a company.

However, cement industry has often been categorised as laggards when it comes to the adoption of digital technologies. But the benefits of digital technology, including revenue and other margin-impacting factors, are compelling the cement industry to consider harnessing the power of digital technology, more seriously. The digital space has witnessed major transformation in the last couple of years and the latest entrant to the digital space are the Internet of Things (IOT??), Artificial Intelligence (AI) and Live Dashboards for eliminating manual intervention and real time monitoring to upsurge operational efficiency. These technologies have enabled the supply chain management to innovate, drive cost reductions, improves service level and customer experiences.

Technology??ot a cost, but a revenue driver

Mehta believes that nowadays technology is no longer seen as a cost, but an opportunity and a revenue driver. He states that Shree Cement?? performance has been amongst the best in the industry because of its focused approach on constant improvement, challenging the status quo and finding innovative solutions. Shree Cement being one of the largest cement manufacturers in India with capacity of 43.40 MT and having 14 Plants across PAN India has the lowest logistics and distribution cost among the entire major cement players of India. We understand that ??oing more with less in lesser time is the key to stay competitive??

On the road to Digitalisation

Digitalisation is a very broad concept and its applications in the cement industry are countless. Over the past few years, with the help of data analytics, process reengineering and with the advent use of IOT?? and robotics, we have been led by example for other cement Industries. Our operational efficiency have been upsurged with continuously exploring innovating ways and technology through automations in the processes, seamless movement of vehicles inside the plant, understanding driver?? plight and improving facilities to decrease their discomforts. This transformation has already begun; it will only continue to accelerate. ??t all started with just a seed.??/p>

Here are few ways that are playing a major role in SCL journey to optimize logistics cost by working on time:

Automated bidding system: Road transportation is considered as a booming market in India but it is highly unorganised and volatile at the same time. Transportation of goods from one place to another has become a real pain point for the industries due to unavailability of vehicles at the right time and at right price. Over the years, cement industries has been burdened with high logistics cost due to traditional way of working. Earlier, we at Shree Cement were engaging transporters to operate fleets for particular routes/areas and for that, fixed basic freight were paid to them. Moreover, transporters with ideal fleets could not deploy their vehicles due to unavailability of real-time information of pending sales orders. As, real-time information access system was not available, order execution time was high and optimal freights could not be ascertained.

Thus, to create healthy competition among transporters, we introduced automated bidding system wherein transporters are taken to a single online window and all order details are visible to transporters. Ceiling freight has been fixed for each destination and at a pre-designated time, transporters can submit bids as desired within the time frame of the bidding and based on lowest freight bidded, orders are allocated to transporters for delivery. This bidding process runs at regular intervals in whole day.

In the initial phase, transporters were rigid looking to open access of orders to all at single window instead of direct allotment of orders for fixed routes. Over the period, system turns out to be flexible and transparent which creates an opportunity for transporters to engage fleets on more viable routes. Through this, we not only reduce the order execution time but also achieve reduction in freight cost by identifying gap between demand and supply of trucks and based on this information, able to maintain lowest current competitive freight rates expected by truckers.

Automated plant truck movement: Cement manufacturers usually face challenges while dispatching material as desired. Even though, they have the capability of dispatching over thousands of trucks every day, but doing it efficiently is a challenge. We at Shree Cement, have been handling 5,000 trucks on daily basis across all units. This massive volume was leading to Truck Turnaround Time (TAT) of 12-13 hours and sometimes even upto 15-18 Hrs due to lack of visibility and ultimately adding to our freight cost significantly.

Since, real-time truck position inside plant was not available leading to improper traffic management and Jams in plant premises, thus increase in TAT. All material is measured through weighbridges at multi-point and were operated manually by one personnel per shift. Security had to check the physical papers of trucks in absence of automations. This led to the vehicles being stranded within the plants at various stages as long as for 3-4 hours severely impacting the dispatch capacity. Even the historical data of vehicles couldn?? be checked leading to repetition, and the long waiting hours inside the plants with the engines running wasted lot of fuel as well traffic jams and safety issues.

To address these challenges, we have installed RFID based integrated logistics management system (ILMS), boom barriers at security check points, manless weighbridges, Auto Invoice Generation through robotics process automations (RPA) and Auto E-way bill through third party applications. This included IOT-based RFID tags and sensors, positioning sensors, cameras, LED displays, Voice command and software (integrated with ERP). Now, truck movement inside the plant premises is completely automatised with error free movement and commercial papers are generated automatically. In addition, real-time tracking of vehicles is being done leading to reduction in turnaround time to 4-5 hours. The 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 into more output and less new hiring.

Seamless clinker movement: Clinker movement from Integrated units to Grinding units with dedicated trucks on origin-destination pair. As dedicated trucks arrives in the plant, unique token number is generated through RFID and order is automatically allocated on FIFO basis. Once order is allocated, based on predictive analysis, trucks are auto called in for loading through SMS to the trucker based on truck position inside the plant. The trucker moves at manless weighbridge for both tare and gross weight and in between vehicle placed under the clinker loading hopper. Based on net weight, auto generation of commercial invoice and E-way bills handed over to driver at security gate, before leaving the plant premises. Same way, at unloading destinations, RFID based ILMS system and automated weighbridges have helped in seamless movement with minimal time. These automations have helped to reduce the clinker loading time from 8 Hrs to 2 Hrs and unloading time from 3 to 1.5 hours i.e. Net savings of 7.5 Hrs per trip. This translates into massive yearly savings of Rs 14-15 crore (Considering Rs 150 per hour cost of truck for 350 trucks daily) as a result of higher number of trips in a year. Reduced TAT as above, the transporters are reaping benefits through additional trips to earn freight and sharing benefits with us by way of reduction in freight cost.

Live dashboards: Real-time visibility is critical for efficient operation in any organization. Cement Industries operate in dynamic environment that are constantly changing, Bottlenecks in logistics, over-ordering of products, or long hold of orders at plant means losses in profits. For better decision making, various interactive real time Dashboards are prepared like dispatch, order pending, trucks waiting in plant beyond threshold limit, performance of transporter, e-way bill expiring, pending freight bills, etc. helps logistics team to see data upfront and make decisive decisions on real time basis. Based on algorithm and simulation, dashboards were designed in a way wherein trucks waiting in yard since long is being identified and paired with long pending orders based on their last trip history. Further, E-way bill expiring within the time frame are also identified and auto mail is being triggered to extend the validity of E-way bills which are likely to be expiring. Adding live dashboard make quicker decisions about prioritizing orders, review on time performance, and streamlining delivery process. This integrated system aids decision-makers to identify the weakest links in the supply chain and initiate cost saving actions.

From New Normal to New Future

There is a lot of fear and uncertainty in the world right now. At the same time, we??e also seen human ingenuity and compassion at work as people band together and leverage technology to fight Covid-19 as a global community. We are seeing first-hand how digital transformation can be used to not only improve business performance but to improve lives. Automation provides us with excellent tools both to fight the Covid-19 pandemic and to redefine the new normal in a post-Covid world. With the suspension of manufacturing and less support from logistics service providers, chains were seriously disrupted which in turn into high logistic cost. In this situation, IOTs, AI, and automations has proven that these are not only words but become inevitable for sustainable growth during pandemic.

Looking at the miserable condition of truck drivers in India, we at Shree cement took an initiative to improve driver?? conditions at our plant in view of pandemic. We make certain minimal interaction of driver with Plant staff and ensure that driver should remain inside his truck during the plant movement. Plant In to Plant Out movement are made automatic with the help of ERP-RFID based system and NPR (Number Plate recognition) integration. Also, Boom barrier were placed so as to allow entry to authorised vehicles only. This led to minimal interaction with driver and even after this, security features were enhanced. Moreover, rehabilitation facilities for drivers with social distancing maintained to avoid Covid-19 with proper masking was also enabled. With all these automations and facilities, SCL is becoming an attractive trucker destination.

The journey ahead

We have reached only halfway of journey. Way forward, we are working on GPS 24*7 real time data generated for improving efficiency and customer service levels. Further, Freight cost to be optimised with the help of machine learning and algorithm-based tools to take advantage of the demand-supply mismatch of orders & trucks by capitalising the benefit of spot gain in the freight bidding process. There is no doubt that digitalisation and automations is having an incredible impact on logistics across the globe and is here to stay.

Digital transformation of enterprises and automation of logistics are becoming the norm and necessity not solely for business development, but also for the long-term sustainability of company processes. For logistics, digitalisation is truly a pressing issue. To minimise operating costs, companies are being forced to re-evaluate their business models, to ensure smoothness and reliability of supply chain. The adoption of new technologies is driven by need to improve operational efficiency as well to increase utilisation of existing infrastructure. Thus, more and more industrial manufacturers are moving towards automated solutions to improve efficiency.

About the Author:

The article is authored by Yogesh Mehta (Vice President ??Shree Cement), who is a Chartered Accountant and has 30 years of experience in Cement Industry. He has proven to be a critical asset in driving Shree Cement?? Logistics function and winning CII-SCALE Award in cement industry since last five years. He has passion for performance, operational excellence and learning, which facilitates in steering company from 0.5 MT to 43.40 MT in 25 years.

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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

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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.

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JK Lakshmi Cement Plans Rs 18.16 Billion Expansion

Firm to boost clinker and grinding capacity in Chhattisgarh

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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.

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Balancing Rapid Economic Growth and Climate Action

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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.

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