Economy & Market

Innovation, customer support and cost optimisation are the keys to success

Published

4 years ago

October 19, 2021

admin

Ashok Dembla President & Managing Director, KHD Humboldt Wedag India

With over 155 years of experience in the cement industry, KHD is a global leader in cement plant technology, equipment, and services. Ashok Dembla, President & Managing Director, KHD Humboldt Wedag India speaks on the spectrum of products and aftermarket services that the company offers for the cement industry.

Give us a brief on your organisation?s Indian and worldwide operations….
The year 2016 marks KHD?s 160th anniversary. With over 160 years of experience in the cement industry, KHD Humboldt Wedag is a global leader in cement plant technology and services. The holding company KHD Humboldt Wedag International AG is based in Cologne, Germany. The group has over 750 employees worldwide with customer service centres and sales offices in growing markets like India, China, Turkey and Russia as well as in Europe and USA. Humboldt Wedag India is an important Customer Service Center which serves all of India as well as the SAARC Countries. KHD?s Indian location also provides more and more global support to other Group CSCs.

What are the core competencies of KHD? How is the flow of technology from Germany to India?
KHD Humboldt Wedag offers a wide range of products and aftermarket services for the cement industry and is the leader in energy-efficient and environmentally friendly technology for the grinding and pyro-processing sections of cement plants. In addition to our high-quality product offerings, process engineering and project management are among our core competencies. Humboldt Wedag India was established way back in year 2000. Most of the experts at the time had experience in working with Cimmco Birla Limited, which had a technical collaboration with KHD Humboldt Wedag from 1983-2000. KHD Humboldt Wedag decided to start a wholly-owned Indian subsidiary, Humboldt Wedag Pvt Ltd, which focused especially on the cement plant and machinery area in order to seamlessly continue to serve its prestigious Indian clients (after the closure of Cimmco Birla). Humboldt Wedag India has so far supplied 39 operating pyro-processing plants, 21 raw material grinding systems, 70 cement grinding systems and 22 slag grinding systems to esteemed clients like UltraTech, Dalmia Cement, Shree Cement, JSW Cement, Holcim, KCP Cement, Birla Corp, Penna Cement, and NCL, etc. Humboldt Wedag India has also supplied customers outside of India in countries like Iran, Oman, Nigeria, Jordan and Yemen.

Today Humboldt Wedag India is 285 people strong, who are capable of providing almost all cement plant technology and services. As a competence centre, our German headquarters in Cologne, Germany, provides us with process engineering support and manages the design of the Group?s core products. Critical equipment like our market-leading Roller Press also comes from Germany.

Some of the important plants supplied by Humboldt Wedag India are;

Rajashree Cement (UTCL) – All four kiln lines, including raw material and cement grinding. The line No 4 is at present operating at 12,000 t/d;
UTCL Raipur – Kiln No II – presently operating at 12000 t/d;
UTCL Tadpatri, Kotputli and Aditya Cement (Line II) GCo identical kiln lines, each operating at an average output of 9,500-9,600 t/d;
Shree Cement – All kiln lines at Ras, Raipur and one kiln line at Beawar and cement grinding units at Beawar Ras, Khushkhera and Bihar;
JSW Cement – All cement and slag grinding units at Vijaynagar, Nandyal and kiln line at Nandyal.

Give us some idea on the technological innovations carried out by KHD-HW. KHD has been a pioneer in many technologies. To name a few:
I)First 4-stage Preheater Technology – The first plants with 300 t/d capacity and 600 t/d capacity, came in from Humboldt in Andhra Pradesh at the end of the 1960s. These plants have now been upgraded to 3-4 times of their original capacity.
II)Roller Press Technology – First plants again came from Humboldt in Diamond Cement, Rajashree Cement and Vikram Cement, in the year 1986-87, which have now been upgraded.
III)V Separator Technology – This technology came as a boon for energy savings and reliability for semi-finish grinding technology in the year 1995.
IV) Alternative Fuels – Extended PYROCLON? and KHD?s Combustion Chamber came as an excellent technology to use petcoke, city waste and other waste derived fuels.
V)5 & 6 Stage Preheater Technology – The first of these type of plants came on line in India, e.g., Diamond Cement, Vikram Cement and Rajashree Cement, in order to reduce thermal energy consumption.
VI)Latest Generation Grate Coolers – The KHD Grate Cooler got its start at Vikram Cement. Later came the PYROSTEP? Cooler and now PYROFLOOR? cooler.

In addition, there have been many innovations in burner technology, where the original KHD design has become the world standard. We also have a lot of proprietary knowledge in the area of environmentally-friendly technology. We have earned an excellent reputation in the areas of energy efficiency and reliability. In fact our buzzword for technology is Energy, Efficiency and Environment, or the 3Es.

What is your USP?
Humboldt Wedag India plants operate at thermal and electrical energy levels comparable to best in the Indian cement industry. For example, KCP Cement is operating at 45 kWh/tonne (until clinkerisation), UTCL Dharni is operating at 21 kWh/tonne in PPC grinding and JSW Cement is operating at 34 kWh/tonne for slag grinding at Blaine value of 4500. Also Dalmia Belgaum is operating at less than 10 kWh/tonne in raw material grinding. Kiln lines at Rajashree Cement and KCP Cement are operating at thermal energy consumption of 685 Kcal /kg clinker. These energy figures have set the norms in our industry.

You have been appreciated for energy efficient grinding systems coupled with roller presses. Give us some insight….
As already mentioned, our buzzword for technology is Energy, Efficiency and Environment. All KHD grinding circuits follow the 3E concept, for example: With our proven COMFLEX? grinding system, we can use the same energy-efficient configuration for raw material, cement and slag grinding. This process circuit can handle materials with high moisture content, especially in case of slag and raw materials, without the problem of clogging of vent ducts and bucket elevators. Due to its flexibility, customers can also determine exactly the type of cement they want to grind, even in the area of high-blaine cements. In terms of the 3E concept, the advantages are; Energy: The COMFLEX? grinding system consumes less energy compared to other process circuits. The same system works for raw material, clinker and slag grinding. More and more customers are also beginning to use this roller press-based system in the finish-grinding mode and are achieving excellent results with the same quality of cement. However, they consume far less specific power compared to other technologies available at present.

Efficiency: It is proven that our roller press gives more efficiency than other grinding systems. Under normal operation conditions, our studded roller surfaces are maintenance free for a number of years. This gives customers increased reliability and availability in comparison with other grinding systems.

Environment: COMFLEX? grinding plants offer a dust-free circuit with no belt conveyers and a very effective de-dusting concept.

With the cement industry not doing so well right now, many jobs are in cold storage; when do you think the situation will improve?
With an installed capacity of around 400 million tonnes and annual production of 270 million tonnes in 2015-2016, the industry is running at less than 70 per cent utilisation. Future investment plans and policies of the Indian government indicate a continued increase in Indian cement demand. The cement industry is expected to grow at 6-7 per cent in 2016-2017 compared to 1.5-2 per cent last year. To meet government plans on the development of new highways, Smart Cities, affordable housing and other infrastructure, the projected demand for cement in 2019-2020 will exceed 400 million tonnes.

The Indian demand for cement is expected to continue its fast-paced growth and attain an installed capacity of 850 million tonnes per annum by 2030 and 1350 million tonnes by 2050. The industry has made tremendous strides in technology in recent years.

A vast number of jobs being generated today are for incremental improvements in the existing system or retrofitting. What are the limitations of such jobs?
To increase existing production capacity and improve operational efficiency in terms of energy conservation, Humboldt Wedag India offers many solutions like;

Modification/upgradation of preheater cyclones to improve dust collection efficiency and to reduce pressure steps.
PYROBOX? for solid fuel (coal/petcoke) firing in calciner.
Static inlet for clinker cooler and grate plate replacements.
High-efficiency dynamic classifier for raw meal, cement and slag.
PYROJET? burner installation for low primary air and low NOx.
Kiln services, like kiln ovality monitoring and correction, bending stress analysis etc.
Installation of high-efficiency separators.
Installation of market-leading roller press technology to increase grinding capacity and reduced power consumption.

Give us some information on Continuous Emission Monitoring System (CEMS) for the cement industry. Where is the Indian cement industry on this subject, compared to other countries in the South-East Asia region and China?
The exit gases from cement kilns are de-dusted in filters or electrostatic precipitators and the dust is normally returned to the process. At present norms exist for dust, TOC, HCl, HF, SOx, NOx Hg, heavy metals and dioxin in India, which are comparable or better as compared to China, Indonesia and the Philippines. The table below shows the comparison; In India, the CEMS system started approximately five-seven years ago for monitoring particulate emissions and subsequently NOx. Policy guidelines were also formulated and released on 10th May 2016 for emission control by the Ministry of Environment. A brief status as compared to China, Indonesia and the Philippines is as follows;

Do you think that the Indian cement industry is ready for continuous monitoring of emissions? What about the old plants?
As mentioned, the Indian government (Ministry of Environment, Forests and Climate Change) released a new notification on 10th May 2016 for control of emissions released from the cement industry. The Indian government is constantly working on policy development and sharing its updates on various platforms during international seminars like the NCB and CII. The momentum indicates that India is ready for continuous monitoring of emissions.

To protect the environment, the emission norms are to be followed for all cement plants in India and continuous emission monitoring systems (CEMS) are to be installed. However, some cement manufactures in India have not yet installed CEMS systems in their cement plants. Cement manufactures, suppliers, consultants and the government need to work together to achieve this objective, i.e., emission control. From the above, it is evident that India has a long way to go in the implementation of CEMS for the cement industry.

What have been your offerings for increasing TSR in the use of alternate fuels?
KHD Humboldt Wedag has expertise in using alternative fuels either in the calciner or in the kiln. We also supply our award-winning combustion chamber for dry municipal waste and other difficult fuels that can be used in our pyro-processing system. In fact, Humboldt Wedag India supplied Vikram Cement a handling and firing system in order to use Jaipur?s city waste. We also delivered a similar system to Jaypee Cement to use Chandigarh?s waste. Among others, UTCL is using a KHD-supplied conveying and firing system for rice husk, shredded tyres, coconut waste and other agricultural wastes.

The Indian cement industry has a huge potential to use alternative fuels in the manufacture of cement and Humboldt Wedag India has the know-how and expertise to help customers with their very individual needs and requirements.

Give us more details about your other businesses….
KHD Humboldt Wedag focuses on cement plants and the related equipment. However, our roller press offers a number of advantages in mineral processing. The KHD Group has provided WEIR Minerals with an exclusive license to sell and manufacture KHD Roller Press Technology. We also cooperate with WEIR on a number of interesting projects, where KHD separator technology is required. With over 10,000 employees, WEIR Minerals has a strong footprint in the global mining industry.

Customer centricity is becoming a focal point for the capital equipment Industry. What is your take on this with specific reference to your India operations?
At KHD Humboldt Wedag, customers always come first. We have Customer Service Centers (CSCs) in India, China, USA and Russia. Our head office in Cologne serves cement operators in Europe, Middle East and Africa. The entire group places an enormous value on customer relationships. We see our customers as partners. They are the ones who give us the first feedback regarding improvements required in our technology and also provide us a platform for testing our innovations. KHD Humboldt Wedag has also implemented the account management concept in various CSCs with the objective of bringing our customers close to various stakeholders in the company. This helps in understanding customer requirements and we align our activities accordingly. Recently we held a customer meet in Goa, where we met and interacted with 88 customers from all over India for two days. The teamwork and feedback that we experienced was nothing short of excellent.

As a key stakeholder, what is your message to the industry?
With the unlimited growth potential in India, it becomes vital that we keep in mind that the natural resources we are using are depleting and to some extent they are nonrenewable too. Effective utilisation of these resources is the key to our sustainability. So it becomes important to look out for the other alternatives to be used as raw material and additives. In parallel, increased use of blended cement also leads to the concepts of co-utilisation. Of course, everything comes with a price, but advancement and success lie in the technological innovations which are effective and cost competitive also. Continual development based on the need from the industry is the direction in which we as cement technology suppliers have to think ahead.

Ashok Dembla is the President & Managing Director of Humboldt Wedag India. He has 35 years of experience in the cement industry and has held senior management positions at Cimmco Birla Limited, Gebr Pfeiffer India, Jaypee Cement and the Beumer Group in India. As Head of Projects at Jaypee Cement, he was responsible for growing capacity from 7 million tonnes to 32 million tonnes. As the Founding-President of KHD?s Indian operations, Dembla was also instrumental in bringing Humboldt Wedag India from five employees in 2001 to its current size of over 280 employees and a market-leading position. With a Bachelor?s Degree in Chemical Engineering from Punjab University, Chandigarh, as well as a Diploma in Management from the All India Management Association, Ashok Dembla has also published more than 40 technical papers in cement magazines on various aspects of cement technology, operating norms, developmental areas, including papers on grinding and pyro-technology.

Concrete

Fuller Institute and Adani Cement Join Forces to Train 450 Engineers in Plant Excellence

Published

24 minutes ago

November 4, 2025

admin

Fuller Institute, the training arm of Fuller Technologies, has partnered with Adani Cement to train 450 engineers in plant operations, maintenance, and quality control. The collaboration aims to bridge the industry’s skills gap, enhance efficiency, and support a more sustainable future for cement manufacturing.

The Fuller Institute – the training and knowledge arm of Fuller Technologies (formerly FLSmidth Cement) – has launched a comprehensive technical training programme in partnership with Adani Cement, India’s second-largest cement manufacturer. Initiated in July 2025, the collaboration will train 450 graduate and diploma engineers across nine Adani Cement groups in cement plant operations, maintenance, and quality control.

Bridging the Skills Gap for a Sustainable Future
As the cement industry navigates automation, decarbonisation, and an evolving talent landscape, upskilling has become vital for operational excellence and sustainability. With a global shortage of skilled professionals and the retirement of experienced workers, structured training ensures that new engineers are ready to manage complex plant systems with reliability and efficiency.
“Even with greater automation, human expertise remains at the heart of operational performance,” said a Fuller Institute spokesperson. “Hands-on learning helps engineers connect theory with practice, boosting both confidence and long-term engagement in the cement sector.”

Blended Learning for Global Standards
The Fuller Institute delivers both in-person and online training programmes for cement producers worldwide. While several are conducted in collaboration with major players such as Adani Cement individual plants can also access these services to enhance employee skills and plant performance.

Its online certification programme, CementPro, offers modular courses in process engineering, mechanical systems, and automation, designed to elevate productivity, efficiency, and quality standards across cement operations.

First Session Sets the Tone

The partnership began with a six-day mechanical maintenance training at ACC Wadi, where 96 Adani Cement engineers received hands-on instruction from Fuller’s most experienced field engineers, each bringing decades of expertise in plant operation and maintenance.

Feedback from participants and Adani Cement’s leadership has been overwhelmingly positive, citing the “depth of knowledge shared” and “engaging, insightful sessions.”

With additional sessions planned for Q4 2025 and beyond, the programme is expected to make a measurable impact on Adani Cement’s key performance indicators (KPIs).

“This long-term partnership demonstrates Adani Cement’s strong commitment to building technical excellence and nurturing the next generation of cement professionals,” the spokesperson added.

Concrete

The primary high-power applications are fans and mills

Published

4 weeks ago

October 10, 2025

admin

Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.

As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.

How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.

What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.

Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.

Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.

How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.

What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.

Concrete

We conduct regular internal energy audits

Published

4 weeks ago

October 10, 2025

admin

Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.

In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.

How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.

What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.

How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.