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We have increased digital initiatives many folds during Covid time

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Rajesh Kumar Singh,Vice President ??IT, JK Lakshmi Cement

Kindly share your views on role of technology in cement industry today.

Cement being a high-density and mass consumption item, requires a prompt supply chain to serve its consumers. The scale of production of cement is another important aspect that is helping consumers in getting the product at a reasonable price. Characteristics like high density, Mass consumption, prompt supply chain, and scale of production are facets where the industry can innovate immensely with use of technology. Care of the environment is another area where this industry can use technology to reduce its carbon footprints and to consume industrial and domestic waste for a cleaner environment.

What are the various digital / IT technologies deployed in your company and what was the objective behind the implementation?

In JK Lakshmi Cement, IoT and AI enablement have been deployed at Crushers, Clins, and Cement Mills to improve productivity through consuming lesser raw materials, fuels, etc, and to control wastes in the form of heat and any other by-product. The supply chain cockpit has been set up for the planning and execution of logistics. This digital investment has facilitated optimising the supply chain and has enabled a swifter fulfilment model and better service to our customers. AI-ML and Auto-ML solutions have been deployed for Predictive Maintenance and automation of Packing Sections. A digital platform has been created to digitise our customers and channel partners. IoTs have been deployed in the health monitoring of hydrant systems, borewells, and water flow systems to conserve water to the maximum level.

Please elaborate on the stages of implementation. Was it done in a phased manner? How much time did it take? Did you find any hurdles?

These digital initiatives have been deployed in a phased manner. Criteria for phased deployment was primarily based on the readiness of the context where these solutions have been deployed. In cases, maturity of core technologies or availability of complementary technologies or its pricing has pushed us to go for a phased approach.

A transformation whether it is related to production processes or predictive maintenance or setting up a supply chain cockpit is generally spanned over 16 to 18 months and phased in two sprints. Through one sprint it can be complete in 9 to 12 months, but it is getting too risky to go ahead with one sprint as the degree of success will be known only after the sprint is over, thus limiting opportunities to refine the strategy in case something is not going as intended.

Managing change is a hurdle that needs to be planned judiciously to overcome. Any shortcoming on this will impact the timelines of deployment. In some cases, we faced challenges wherever planning on change management was not perfect but luckily it has impacted only on timelines of the project and not on success and its deliverables.

Kindly provide project cost/allocation of budget for technologies deployed, if possible.

We were very aggressive on investment in digital. We are ensuring that yearly returns from the initiatives are in multiples and not in percentages.

What benefits have you derived after IT implementation? How are new processes better than old methods?

With these initiatives, we are having better control over the cost of production. We have reduced the unplanned shutdown of machines and have improved services to our customers. With the new digital platform, now our customers feel that we are closer to them for every interaction they are doing with us.

In the new setup, we are sensing the situation early enough to respond in a timely manner and appropriately. In some cases, the ease and efficiency of processes have increased because new processes have got simpler and automated.

How was the upskilling done for training the staff with new technologies and processes? Were there any challenges?

Barring AI-ML, upskilling was not a challenge at all because the deployment of technologies has simplified the processes so it can be performed with lesser skillset and with higher efficiency and accuracy.

Even in the case of AI-ML, deployment of data science platform has de-skilled analytics tasks, which were otherwise possible by only skilled programmers and persons having high proficiency in data science.

Having said that, training would require for the teams who are transforming the processes through the deployment of technologies. But this training was lesser on technologies and more on how to manage change which will be inevitable because of transformation.

Training to the teams who were engaged in the transformation was a mesmerising experience and not a challenge.

How has IT played an important role in expanding your footprints in India/abroad? Do you think it helped you to compete with others in the market?

IT or digital platform which we have created for our customers has helped immensely by taking us closer to them. It has also enabled us to increase our reach and penetration in the markets we were operating or in the market where we were not present. More important is that it has helped us in identifying the market where we can operate more profitably.

Certainly, these IT deployments are helping us to do much better than what we were doing earlier. It might be resulting in increasing our competitiveness, but our focus is still to do better than what we have done the day had bygone.

How has COVID-19 emerged as a need for IT implementation in the cement industry? What initiatives did your company take during Covid times to achieve better efficiency even during lack of resources?

The need was always there for the implementation of IT solutions in cement or any other industry in India. As it happened for other industries, Covid-19 has amplified the requirement for digitisation and has also triggered the intent.

Our resources were very much there with us during Covid-19 breakdown, but they were not moving freely. In the beginning, they would not be connected adequately. So, we rushed to connect them securely, and then things started to fall in place in no time. Seeing the new normal, a lot of mindset and cultural issues have transformed instantaneously.

One big positive change worth mentioning during Covid-19 times was that acceptance for the change came with zero cost. We leveraged this opportunity and have multiplied digital initiatives to give a boost to our digital initiatives and succeeded. to a great extent. Increasing interaction between internal teams and business partners by use of digital technologies was the key to our success during the Covid time.

What are your future plans in terms of IT implementation and overall company goals?

As said earlier, we have increased digital initiatives many folds during Covid time. So, in immediate future, we would like to tap the benefits of newly deployed solutions.

Embedding AI-ML to every function and every process is the next goal we are aspiring for.

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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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Concrete

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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Concrete

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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