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CSR is an enabler of aspirations and achievements

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Dalmia Bharat Foundation has an internal monitoring and evaluation wing that provides actionable insights to better execute CSR projects, shares Vishal Bhardwaj, Group Head- CSR, Dalmia Bharat Group and CEO of Dalmia Bharat Foundation.

Please tell us about CSR activities done in Dalmia? Do you believe that it helps in building a strong brand name and good customer base?

It is broadly divided into three buckets. So the first bucket is the livelihoods bucket wherein we work both on the farm and the non-farm sector. The second bucket under climate action is about our work on water and access to clean energy while the third is social development where the focus is largely on infrastructure building. The needs and requirements vary from geography to geography. We try to fill existing gaps in villages around us, be it in the schools, Anganwadis or health facilities. So, these are the three major buckets where we keep our CSR focus.

We sincerely believe that there cannot be a complete disassociation between CSR and business. Water is very important to us. Wherever we have our cement plants, we share the aquifers with the local communities that need water for agriculture and domestic consumption. We do not want to put any pressure on the available water resources. Even though cement is not a very water-intensive manufacturing process, still, even if we draw 1 per cent of water from the aquifers, we want to give back many times of that to the communities. It gives us immense pride to share that Dalmia Cement is almost 10 times water positive. So for every litre of freshwater that we take from the shared resources, we make sure that we create a harvesting and conservation capacity of 10 litres. It ensures the long-term sustainability of the business and acts as a risk management tool to avert any conflicts between us and the communities related to resource sharing.

Further, the cement business is a pretty energy-intensive business. Dalmia is one of the most sustainable and least carbon footprint cement manufacturers. despite that, we do not lose out on any opportunity to offset our footprints. Taking a step further, we also assist communities around us to offset some of their footprints by adopting clean energy solutions. At least 10-15 Kgs of wood is burnt in each household around us in kitchens and one can only imagine the level of carbon emissions and the impact of fumes on the health of women and children. So, we provided them access to fuel-efficient cook-stoves and alternative fuels like biogas and LPGs. Then we saw people burning kerosene for lighting purposes, which is the biggest cause of burn injuries in rural areas. We encouraged such households to switch to solar lighting solutions. Our intent is to make the environment around us as clean as possible. We cannot ignore the issue of livelihood of our stakeholders. Our work on water gives us a good opportunity to work with the farmers on improving their productivity, yield, and therefore income. Besides, in sync with the Skill India initiative, we started to skill individuals who didn?? work on farms with the aim of creating alternative employment opportunities for them.

What were your CSR spending for the year 2020 and 2021? What is the strategy for planning CSR spending?

CSR in Dalmia is more than 80 years old. We started CSR ever since our genesis, even though it was not called CSR back then. But the trusteeship approach was similar to CSR. A decade before the CSR laws were promulgated, we had already established our Dalmia Bharat Foundation and were proactively engaging with our stakeholder communities. Our CSR budgets are driven by program needs. The 2 per cent limit doesn?? restrict us from investing in CSR when it is required. It is a beginning point to ensure that we spend what is mandated. But more often than not, we have actually gone beyond the mandate.

How do you evaluate and monitor CSR activities?

We proactively seek to measure the change brought out by our initiatives. In the last five years, we have carried out some independent assessments. One of the most important of them was the social returns on investment (SROI). We have used it to measure the impact of our work and have seen encouraging results. For every rupee that we invest in the livelihoods and water space, we get a return of about Rs 7 and Rs 3 respectively. We have also undertaken participatory appraisals through independent partners. Recently E&Y conducted an impact assessment of our work on livelihood, skilling and water. This is integrated into our strategy also. We have a theory of change that encompasses what we aspire to do and how do we achieve it. We also have an internal monitoring and evaluation wing that provides us with actionable insights to better execute our projects.

What has been the impact of the pandemic on CSR activities in cement and other industries?

It is noteworthy that we didn?? lose the momentum of what we were doing with respect to the three buckets even during the pandemic. Covid 19 brought in a different kind of challenge and we thought that it was our responsibility to work for all the stakeholders and not just the villages around us. During the first phase of Covid with the national lockdown imposed, we offered shelter, ration and medical assistance to the needy. We contributed financially to the PM Care Funds and various Chief Minister Relief funds. We extended a mix of financial and material support to our stakeholders.

The challenge of the second wave was principally around oxygen supply. We actively set up isolation facilities, Covid treatment centres, supplied oxygen and other medical equipment to hospitals. We believe that vaccination is now key to control the third wave. Due to the digital divide, we helped the villagers in getting registered on the vaccination portal. Eventually, we organised vaccination camps and arranged for their to-and-fro transportation. In the last month (June 2021), we assisted about 17,000 people to get vaccinated and I am sure that we will surpass that number this month.

What kind of feedback do you get from stakeholders in terms of meeting business objectives and how does CSR help in achieving the ultimate business goals of a company?

While the structures that we create for our projects like water harvesting are clearly visible, the need is to go much beyond that. That’s where studies and assessments step in. The E&Y study looked at various indicators to assess the quality of life in our communities. Through the study, we were able to understand whether the spending of the individuals went up, have they shifted from kacha house to pakka house, or has their mode of transportation changed. From a business point of view, many community members look at Dalmia as a potential employer. We absorb many of them into our workforce and provide upskilling opportunities for others to find an alternative source of livelihood. This creates harmony between us and the communities.

What are the key challenges while undertaking CSR activities? What best practices would you recommend overcoming those challenges?

During the initial days, we faced challenges in terms of deciding the organization?? priorities and strategies. We have come a long way from that. Until a decade back, we collaborated with NGO partners who delivered quality work but there was no direct link with the communities. That?? when we decided to capacitate our foundation to forge direct relationships with the people. Today, the Dalmia Bharat Foundation has been able to garner partnerships with communities, government and other corporates. This has enabled us to amplify our work and bring in more resources. We have institutionalised our CSR roadmap for 2030. In 2015, we aligned our CSR objectives with millennium development goals and later incorporated sustainable development goals to ensure that there is continuity throughout. So, there are more opportunities than challenges for us in CSR.

What is your CSR budget and roadmap for the next few years?

In terms of the roadmap, we propose to continue working largely on the issues of livelihood and climate action, with skilling and water being the major focus of these verticals. This is going to be our focus for the next 8 to 10 years, in line with our roadmap for 2030. In terms of the budget, this year our cement business is mandated to spend about Rs 13 crore. But with our ongoing projects, my hunch is that we would be exceeding the budget. Upon adding the contributions of other group companies and our partners, the entire resource pool would be in the range of Rs 40-45 crore.

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Concrete

JSW Cement Begins Production At Nagaur Rajasthan Plant

Greenfield integrated cement plant begins operations in Rajasthan

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JSW Cement has started production at a new greenfield integrated cement plant in Nagaur, Rajasthan, marking its first integrated facility in north India. The commissioning advances its national expansion and raises cement grinding capacity to 24.1 million tonnes per annum (MTPA) and clinker manufacturing capacity to nine point seven four MTPA including joint venture capacity. The plant is strategically located to serve high growth markets in Rajasthan, Haryana, Punjab and the National Capital Region.

The Nagaur plant comprises a three point three MTPA clinkerisation unit and a two point five MTPA cement grinding unit, with an additional one MTPA grinding unit under construction. The facility’s capacity additions enable it to meet regional demand and support infrastructure development. The project was funded by equity and long term debt and the company allocated Rs 8 bn from IPO proceeds to part finance the unit.

Company leadership said commissioning was completed within 21 months and that the expansion advances its aim to become a pan India player, with a mid term target of 41.85 MTPA and a long term vision of 60 MTPA. The plant includes sustainability features such as co processing of alternative fuels and a seven kilometre overland belt conveyor to transport limestone from the mines, reducing road transport impacts. The operation is expected to support economic growth and provide supplies for construction projects across the north.

The site will incorporate a 16 megawatt (MW) Waste Heat Recovery System to capture and reuse process heat, reducing the carbon footprint. JSW Cement’s operations include eight plants in India and a clinker unit in the UAE through a joint venture, providing a presence across the building materials value chain. The company emphasised use of industrial by products in manufacture and focus on producing eco friendly building materials.

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Concrete

MAPEI India Celebrates 15 Years of Building Excellence

MAPEI India celebrates 15 years with growth, expansion and CSR impact

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MAPEI India marks its 15th anniversary, celebrating a journey defined by innovation, trust, and continuous growth. Beginning in 2011 with just four employees and a single manufacturing facility in Bengaluru, the company has evolved into a key player in India’s construction chemicals industry, now employing over 380 professionals across the country. Over the past 15 years, MAPEI India has delivered strong performance with a sales CAGR of 31 per cent. From zero production in its early years, the company shipped 1,71,000 metric tonnes of materials in 2025, demonstrating robust operational capabilities and rising market acceptance.
To support expanding demand, MAPEI India has steadily scaled its manufacturing footprint. Following the Bengaluru plant in 2011, new facilities were launched in Vadodara in 2016 and Kosi (Mathura) in 2022. A fourth facility in Kharagpur is set to go live in 2026, strengthening the company’s nationwide supply network.
As part of its commitment to global standards, MAPEI India operates under an Integrated Management System (IMS) certified for ISO 9001 (Quality), ISO 14001 (Environment) and ISO 45001 (Health & Safety). These certifications reinforce its dedication to delivering safe, sustainable, and high quality solutions.
With a diverse portfolio of over 20 product lines, MAPEI India has supported iconic projects such as the Atal Tunnel, the Statue of Unity, and major airport and metro developments. The company has also invested Rs 3.2 crore in CSR initiatives focused on education, women’s empowerment, and rehabilitation. As it steps into the future, MAPEI India remains committed to excellence, sustainability, and customer trust.
Mapei hai to bharosa hai.

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Material Flow Efficiency

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We explore how material handling systems are becoming strategic assets in cement plants, enabling efficient movement of raw materials, clinker and finished cement. Advanced conveying, automation and digital technologies are improving plant productivity while supporting energy efficiency and sustainability goals.

Material handling systems form the operational backbone of cement plants, enabling the efficient movement of raw materials, clinker and finished cement across complex production networks. With India’s cement industry producing over 391 million tonnes of cement in FY2024 and possessing an installed capacity of around 668 mtpa, according to the CRISIL Research Industry Report, 2025, efficient material logistics have become critical to maintaining plant productivity and cost competitiveness. At the same time, cement production is highly energy intensive and contributes around 7 per cent to
8 per cent of global CO2 emissions, making efficient material flow and logistics optimisation essential for reducing operational inefficiencies and emissions states the International Energy Agency Cement Technology Roadmap, 2023. As plants scale capacity and integrate digital technologies, modern material handling systems, ranging from automated conveyors to intelligent stockyards, are increasingly recognised as strategic assets that influence plant stability, energy efficiency and environmental performance.

Strategic role of material handling
Material handling is no longer viewed as a secondary utility within cement plants; it is now recognised as a strategic system that directly influences production efficiency and process stability.
Cement manufacturing involves the continuous movement of large volumes of limestone, clay, additives, clinker and finished cement across multiple production stages. Even minor disruptions in conveying systems or storage infrastructure can lead to kiln feed fluctuations, production delays and significant financial losses. According to Indian Cement Industry Operational Benchmarking Study, 2024, unplanned downtime in large integrated cement plants can cost between Rs.15–20 lakh per hour, highlighting the economic importance of reliable material handling systems.
Modern cement plants are therefore investing in advanced mechanical handling systems designed for high throughput and operational reliability. Large integrated plants can process over 10,000 tonnes per day of clinker, requiring highly efficient conveying systems and automated stockyards to maintain continuous material flow, suggests the International Cement Review Industry Analysis, 2024. Efficient material handling also reduces spillage, minimises dust emissions and improves workplace safety. As cement plants become larger and more technologically advanced, the role of material handling is evolving from simple transport infrastructure to a critical operational system that supports both productivity and sustainability.

From quarry to plant
The transport of raw materials from quarry to processing plant represents one of the most energy-intensive stages of cement production. Traditionally, limestone and other raw materials were transported using diesel-powered trucks, which resulted in high fuel consumption, dust generation and increased operational costs. However, modern plants are increasingly adopting long-distance belt conveyors and pipe conveyors as a more efficient alternative. These systems allow continuous material transport over distances of 10–15 kilometres, significantly reducing fuel consumption and operating costs while improving environmental performance, states the FLSmidth Cement Industry Technology Report, 2024.
Milind Khangan, Marketing Manager, Vertex Market Research & Consulting, says, “Efficient and enclosed handling of fine materials such as cement, fly ash and slag requires modern pneumatic conveying systems. By optimising the air-to-material ratio, these systems can reduce energy consumption by 10 per cent to 15 per cent while ensuring smooth material flow. Closed-loop conveying further minimises dust loading and improves the performance of bag filters, supporting cleaner plant operations. In addition, flow-regulated conveying lines help prevent clogging and maintain reliable dispatch performance. Overall, automation in pneumatic conveying delivers immediate operational benefits, including improved equipment uptime, lower energy use, reduced material spillage and more stable kiln and mill performance.”
Pipe conveyor systems are particularly gaining traction because they provide a completely enclosed transport system that prevents material spillage and dust emissions. According to global cement engineering studies, conveyor-based transport can reduce energy consumption by up to 30 per cent compared to truck haulage, while also improving operational reliability. Several cement plants in India have already implemented such systems to stabilise quarry-to-plant logistics while reducing carbon emissions associated with diesel transport.

Stockyard management and homogenisation
Stockyards play a critical role in maintaining raw material consistency and stabilising kiln feed quality. Modern cement plants use advanced stacker and reclaimer systems to ensure efficient storage and blending of raw materials before they enter the grinding and pyroprocessing stages. Automated stacking methods such as chevron or windrow stacking enable uniform distribution of materials, while bridge-type or portal reclaimers ensure consistent extraction during kiln feed preparation. These systems are essential for maintaining stable chemical composition of raw meal, which directly influences kiln efficiency and clinker quality. The Cement Plant Operations Handbook, 2024 indicates that advanced homogenisation systems can reduce raw mix variability by up to 50 per cent, significantly improving kiln stability and energy efficiency. Integrated stockyard management systems also incorporate sensors for monitoring bulk density, moisture levels and stockpile volumes, enabling real-time control over material blending processes.

Clinker and cement conveying technologies
Once clinker is produced in the kiln, it must be efficiently transported to storage silos and subsequently to grinding and packing units. Modern cement plants rely on high-capacity belt conveyors, bucket elevators and pneumatic conveying systems to manage this stage of material flow. Steel-cord belt bucket elevators are now capable of lifting materials to heights exceeding 120 metres with capacities reaching 1,500 tonnes per hour, making them suitable for large-scale clinker production lines, states the European Cement Engineering Association Technical Paper, 2023.
For fine materials such as cement, fly ash and slag, pneumatic conveying systems provide a reliable and dust-free solution. These systems transport powdered materials using controlled airflow, ensuring enclosed and contamination-free movement between grinding units, silos and packing stations. Optimised pneumatic systems can reduce energy consumption by 10 per cent to 15 per cent compared to older conveying technologies, while also improving plant cleanliness and environmental compliance, according to the Global Cement Technology Review, 2024.

Automation and digitalisation
Digitalisation is transforming material handling systems by introducing real-time monitoring, predictive maintenance and automated control. Advanced sensors and Industrial Internet of Things (IIoT) platforms enable plant operators to track conveyor health, stockpile levels and equipment performance in real time. Predictive maintenance systems analyse vibration patterns, temperature fluctuations and equipment load data to detect potential failures before they occur. According to McKinsey’s Industry 4.0 Manufacturing Report, 2023, for heavy industries, digital monitoring and predictive maintenance technologies can reduce equipment downtime by up to 30 per cent and increase productivity by 10 per cent to 15 per cent. Digital control centres also integrate data from conveyors, stacker reclaimers and dispatch systems, enabling centralised management of material flows from quarry to dispatch.

Handling of AFR
The growing adoption of Alternative Fuels and Raw Materials (AFR) has introduced new challenges and opportunities for material handling systems in cement plants. AFR materials such as refuse-derived fuel (RDF), biomass and industrial waste often have irregular particle sizes, variable moisture content and lower bulk density compared to conventional fuels. As a result, specialised storage, dosing and feeding systems are required to ensure consistent kiln combustion. According to the Cement Sector Decarbonisation Roadmap published by NITI Aayog in 2026, increasing the use of AFR could enable India’s cement sector to achieve thermal substitution rates of around 20 per cent in the coming decades. To support this transition, plants are investing in automated receiving stations, shredding units, drying systems and precision dosing equipment to stabilise AFR supply and combustion performance.

Energy efficiency and dust control
Material handling systems also play a crucial role in improving plant energy efficiency and environmental performance. Modern conveyor systems equipped with variable speed drives and energy-efficient motors can significantly reduce electricity consumption. Permanent magnet motors used in conveyor drives can deliver 8 per cent to 12 per cent energy savings compared to conventional induction motors, improving overall plant energy efficiency according to the IEA Industrial Energy Efficiency Study, 2023. Dust control is another major concern in cement plants, particularly during material transfer and storage operations. Enclosed conveyors, dust extraction systems and advanced bag filters are widely used to minimise particulate emissions and improve workplace safety.

Future trends in material handling
The future of material handling in cement plants will be shaped by automation, digitalisation and sustainability considerations. Emerging technologies such as AI-driven logistics optimisation, autonomous mobile equipment and digital twins are expected to further improve plant efficiency and operational visibility. Digital twin models allow engineers to simulate material flow patterns, optimise stockyard operations and predict equipment performance under different operating conditions. According to the International Energy Agency Digitalisation and Energy Report, 2024, the adoption of advanced digital technologies could improve industrial energy efficiency by up to 20 per cent in heavy industries such as cement manufacturing. As cement plants expand capacity and adopt low-carbon technologies, intelligent material handling systems will play a critical role in maintaining productivity and reducing environmental impact.

Conclusion
Material handling systems have evolved from basic transport infrastructure into strategic operational systems that directly influence plant efficiency, reliability and sustainability. From quarry transport and automated stockyards to digital dispatch platforms and advanced conveying technologies, modern material handling solutions enable cement plants to manage large production volumes while maintaining process stability.
As India’s cement industry continues to expand to meet infrastructure and urban development demands, investments in advanced material handling technologies will become increasingly important. By integrating automation, digital monitoring and energy-efficient systems, cement manufacturers can improve operational performance while supporting the industry’s long-term sustainability and decarbonisation goals.

  • Kanika Mathur

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