Connect with us

Economy & Market

Digitalisation drives productivity in cement production

Published

on

Shares

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

Continue Reading
Click to comment

Leave a Reply

Your email address will not be published. Required fields are marked *

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

on

By

Shares

World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

Continue Reading

Concrete

Building a Greener Future Together

Published

on

By

Shares

Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

Continue Reading

Concrete

Dalmia Bharat Acquires Jaiprakash Associates Cement Assets for ₹2,850 Crore

Published

on

By

Shares

Dalmia Cement executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra, to acquire 5.2 MnTPA of cement capacity across Madhya Pradesh and Uttar Pradesh.

Dalmia Cement (Bharat) announced on May 22, 2026 that it had signed a Business Transfer Agreement with Jaiprakash Associates Limited and Adani Infra (India) Limited for the acquisition of cement plants located at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh. The deal was struck at an enterprise value of ₹2,850 crore and is expected to close within two weeks of execution.

The acquired assets from Jaiprakash Associates include 5.2 MnTPA of cement capacity and 3.3 MnTPA of clinker capacity. The package also covers 99 MW of thermal power capacity and railway sidings at Rewa, Chunar, and a common siding at Churk. This infrastructure gives the acquisition immediate operational utility beyond just production tonnage.

The transaction has a long backstory. Dalmia Cement had originally entered into a framework agreement with Jaiprakash Associates in December 2022, covering the sale of these business assets along with a long-term clinker supply arrangement. However, before the deal could be completed, Jaiprakash Associates was admitted to insolvency proceedings under the Insolvency and Bankruptcy Code. The earlier agreements could not be consummated as a result.

In an official statement, Puneet Dalmia, Managing Director & CEO, Dalmia Bharat, said, “I am very excited about addition of these assets in our portfolio. This serves as a great strategic fit for Dalmia. It helps us move forward in our journey to be a pan India player and provide a strong head start to serve the high potential markets in Central region. I am optimistic that the expansion potential of these assets along with close proximity with Dalmia’s captive mines will help us create a capacity hub for the future”.

Following the approval of Adani Group’s resolution plan for Jaiprakash Associates under the IBC framework, Dalmia approached the new management to revive discussions. The fresh Business Transfer Agreement was executed to settle all pending disputes, legal proceedings, and arbitration matters arising from the original framework agreement with Jaiprakash Associates.

Expanding market reach

Dalmia added, “Our familiarity with these assets under the earlier tolling arrangement gives us a deep understanding of the facilities and helps us establish strong connect with channel partners and vendors. We believe that this will help us in faster ramp up of capacities and quicker inroads into the market. As we look forward, I am very confident that we will be able to leverage the strengths of Dalmia to operate these assets in a manner where we can maximise value creation for all our stakeholders.”

With the addition of these plants, Dalmia Bharat’s total installed cement capacity will rise to 54.7 MnTPA upon consummation. The company has further expansion projects underway at Belgaum, Pune, and Kadapa, which are expected to take overall capacity to 66.7 MnTPA by Q2 to Q3 FY28.

The Central India location of the Jaiprakash Associates plants gives Dalmia Bharat faster access to markets in Madhya Pradesh and Uttar Pradesh than a greenfield build would have allowed. The company also cited debottlenecking and brownfield expansion as near-term opportunities at the acquired sites. Dalmia Bharat said the assets were expected to contribute positively to EBITDA and overall returns, given the pricing environment in the region and the company’s cost structure.

Continue Reading

Video Thumbnail

    SIGN-UP FOR OUR GENERAL NEWSLETTER


    Trending News

    SUBSCRIBE TO THE NEWSLETTER

     

    Don't miss out on valuable insights and opportunities to connect with like minded professionals.

     


      This will close in 0 seconds