Economy & Market
Digitalisation drives productivity in cement production
Published
4 years agoon
By
admin
Cement producers are adopting Industry 4.0 across the flowsheet, taking advantage of digital solutions not only to support equipment availability, but also to reduce fuel consumption, increase production, improve product quality and save energy.
??igital technologies are having a major impact on cement production. Leading cement producers are embracing digitalisation as a critical enabler of productivity.??/strong>
Rather than slowing the pace of digital adoption, COVID-19 has shone a spotlight on just how important digital solutions are for the cement industry. When it becomes difficult or even impossible to be at site, the value of digitalisation becomes even more apparent.
For decades, we have worked on creating innovative solutions, enabling our customers to increase productivity and resolve challenges. Today we continue that journey into the area of digitalization and data-based optimisation.
A strong foundation for your digitalization journey: the process control platform
Do you worry about your plant reliability? Sustainability? Cybersecurity? Finding skilled operators? Our latest ECS/ControlCenter v8.4 Process Control Software Platform helps provide peace of mind on all these issues and more. With complete lifecycle support and third-party system integration, ECS/ControlCenter v8.4 provides a strong foundation for your digitalization journey.
With more than 1500 active process and product control
installations in the cement industry, the ECS/ControlCenter Platform is a trusted process control solution for cement businesses around the world. It is also a key component of our growing portfolio of digital solutions and services, which we call ENABLR.
In combination with our ECS/ACESYS??Control Library, the ECS/ControlCenter Software Platform is the digital heart of your operation: an advanced, reliable, adaptable and secure software platform that provides the foundation to control anything from machinery to full plants. It enables your business to get the most out of both your equipment and your operators, while simultaneously supporting greater sustainability and future productivity improvement.
Driving growth through productivity and reducing environmental footprint ??Artificial Intelligence
We have launched new cognitive technologies and functions in ECS/ProcessExpert v8.5 that contribute to greater sustainability. For the first time, we??e incorporated the capability to use non-symbolic artificial intelligence (AI) technologies based on machine learning and deep learning algorithms. These technologies create their own understanding of a process by finding patterns in the raw process data ??and then use that understanding to solve problems.
Meanwhile, the new PXP DataBooks module aims to bridge the gap between automation engineers and data scientists by enabling your data scientists to integrate their existing machine learning and deep learning algorithms into the PXP applications and control strategies.
We??e now also better able to demonstrate the sustainability advantage that intelligent process control technologies, such as PXP, bring to cement operations. The PXP Insights analytics module automatically converts operational benefits into meaningful environmental KPIs, for example, CO2 footprint benchmarks. These KPIs are then visualized using pre-defined dashboards that are delivered with the solution. The solution also calculates and compares the KPIs when the system was in operation and when it wasn’t. In doing so, we can clearly show how PXP enables more sustainable operations.
Driving sustainable productivity with ECS/ProcessExpert software and MissionZero:
Improving energy efficiency not only lowers operating costs. By reducing the amount of electricity and fuels used, it also helps to reduce the environmental impact of your operations.
Intelligent process control solutions, such as the ECS/ProcessExpert platform, stabilize and optimize your processes, enabling you to achieve up to 100% alternative fuels, reduce emissions by more than 5% and increase production up to 6% ??whilst maintaining product quality.
This directly aligns with and supports our MissionZero ambitions to operate zero-emissions cement plants and manage zero-emissions mining processes by 2030.
Realtime operations intelligence, data-driven decision making
Without accurate data and the digital systems needed to identify non-performing areas of your operations, productivity will suffer and personnel will lack the insights needed to make improvements. FLSmidth provides a suite of data management systems focused on transforming your process and quality data into actionable insights to increase throughput, reduce plant downtime, improve the quality of your decisions, foster collaboration and much more.
ECS/PlantDataManagement is an information system that transforms your process and quality data into real-time operations intelligence. Part of our ENABLR portfolio of digital solutions, ECS/PlantDataManagement automatically generates online Key Performance Indicators, supporting the decision-making process and promoting collaboration.
ECS/UptimeGo is a downtime analysis solution to help plant staff to identify the issues that interrupt operations and to prevent unwanted future downtime. Part of our ENABLR portfolio of digital solutions, ECS/UptimeGo calculates the economic value of downtime, allowing plant staff to focus on finding the root causes of the problems that impact plant productivity.
SiteConnect??Mobile Insights App connects you to critical asset performance and health data ??anywhere and at any time, in real-time. Part of our ENABLR portfolio of digital solutions, SiteConnect empowers asset management, shortening response time to unplanned events and enabling optimum productivity.
Turning Big Data into actionable insights ??predictive/preventive maintenance
Data alone can?? support process improvements ??but data combined with analytics can help you to spot trends and identify issues before they escalate: the foundation of a predictive maintenance strategy. Predictive maintenance aims to avoid unplanned downtime by taking timely action to address maintenance issues. This requires sensors attached to all critical machines to monitor conditions such as vibration, temperature and pressure ??also known as online condition monitoring. The data from these sensors is collected through Field Agent and can also be connected to FLSmidth?? 24/7 Global Remote Service Centre for expert analysis.
Analytics-driven predictive maintenance is a key driver of digital transformation within the cement industry ??and a sure-fire way to boost equipment availability and cut costs.
The cement industry is on the path to digital transformation ??are you keeping up?
Areas such as remote monitoring and diagnosis, predictive maintenance, and process optimisation are at the heart of the cement industry?? digital transformation journey, and the benefits ??ranging from increased uptime and improved throughput to safety, cost savings and environmental gains ??are evident. Looking ahead, we anticipate that those cement producers who are early adopters of digital technologies will be empowered, finding new ways to drive efficiency and deliver sustainable productivity, while those who lag behind may find it a struggle to compete on all fronts
About the Author: Rizwan Sabjan,Head of Regional Sales Enablement ??Digital Business, FLSmidth
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Concrete
Adani’s Strategic Emergence in India’s Cement Landscape
Published
4 days agoon
September 16, 2025By
admin
Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.
India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.
Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:
- September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
- December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
- August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
- April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
- Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
- Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
- Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
- Orient Cement: It would serve as a principal manufacturing facility following the merger.
Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:
- By FY 2026: Reach 118 MTPA
- By FY 2028: Target 140 MTPA
These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).
Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.
Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.
Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.
Challenges potentially include:
- Integration challenges across systems, corporate cultures, and plant operations
- Regulatory sanctions for pending mergers and new capacity additions
- Environmental clearances in environmentally sensitive areas and debt management with input price volatility
When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.
Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.
About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.
Concrete
Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series
Published
1 month agoon
August 16, 2025By
admin
PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.
Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.
Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.
Beyond energy efficiency, the retrofit significantly improved operational parameters:
- Lower thermal stress on equipment
- Extended lubricant drain intervals
- Reduction in CO2 emissions and operational costs
These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.
Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:
- Enhanced component protection
- Extended oil life under high loads
- Stable performance across fluctuating temperatures
By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.
Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.
A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

Adani’s Strategic Emergence in India’s Cement Landscape

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

Driving Measurable Gains

Reshaping the Competitive Landscape

CCU testbeds in Tamil Nadu

Adani’s Strategic Emergence in India’s Cement Landscape

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

Driving Measurable Gains

Reshaping the Competitive Landscape
