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Economy & Market

Market Watch (October-2013)

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Cement stocks underperform Cement stocks have corrected sharply over the past couple of months, due to growing macro concerns over weakening GDP growth, low infra and realty spends, and unbridled INR depreciation, further dimming the outlook for cement demand. INR depreciation is likely to increase costs (fuel and freight) for cement companies, though their limited US$ debt exposure insulates the balance sheet. While the rupee has corrected upwards against the USD, its sustainability is still in doubt.

Q1FY14 lower EBITDA/tonne
Cost remained flattish to moderately higher in Q1FY14 with marginal push in energy cost and raw material cost coupled with negative operating leverage. Due to the high base of last year, EBITDA for companies dipped in the 18% – 31% range. The current quarter too, is high base and with no improvement in demand and prices so far, earnings are expected to be disappointing in Q2FY14 as well.

Increased clinker consumption
Clinker consumption in the cement manufacturing process typically goes up during periods of high moisture content such as the monsoons. Early monsoons this year have driven clinker consumption higher YoY in Q1FY14, leading to an increase in power and fuel cost per tonne for manufacturers.

Coal India pricing
Effective June 2013, Coal India increased prices of C, D and E-grade coal by ~10%, while lowering prices for Grades A and B by a similar percentage (~12%). A major chunk of domestic coal purchased by the cement industry constitutes C, D and E-grade coal, which is used both for cement manufacture and for captive power generation. Further, higher petcoke prices would have also impacted fuel costs. However, the recent decline in e-auction prices could bring partial relief to major players.

Higher freight cost from rail surcharge
The Indian Railways increased rail freight by 5% effective 1 April, leading to higher landed cost of coal for manufacturers.

Pricing power holds key
Pricing power is essential for the companies to improve profitability. During the first quarter, while ACC saw flat volume growth, UltraTech and Ambuja saw their volumes decline by three per cent each, compared to the year ago quarter. The per- tonne realisations declined five-seven per cent for most companies, with the exception of UltraTech that saw flat realisations.

Diesel price hike
State-owned oil companies demanded a one-time steep increase in diesel prices to make for the widening losses, with the value of rupee dropping by 12 per cent against the US dollar making imports costlier. In the first week of September, diesel prices were increased by 50 paise a litre, excluding local taxes. The increase in diesel prices was the eighth since January. This recent diesel price hike will increase freight costs for ACC, Ambuja, India Cements, UltraTech and Grasim by Rs.70-100/tonne. Since, diesel is mainly used for transportation of cement and raw materials like coal and fly ash, industry experts say it will be adding up to the cost of sales and not the production cost. Taking into account the costs involved in transportation in terms of per- tonne- per- kilometre, on industry´s level it would result in a hike of Rs 1 on a 50 kg bag of cement. Transportation of cement through road accounts for 55 per cent while the rest is shipped largely by rail and to some extent, by sea. Companies will have to pass it on to consumers..

As and when the government bites the bullet and raises diesel prices at one shot, cement companies will have to take more of a burden. Limited visibility on recovery of the investment cycle could continue to dampen the prospects of demand revival. Cement is among the sectors that can see downgrades as the RBI is unlikely to reverse its tightening stance in a hurry and government spending cuts are likely. A good monsoon is expected to bring some respite as cement demand may start improving in October. Volumes are expected to rise in the second half, led by election-led government spending. Now with the INR free-fall resulting in a higher oil subsidy burden, government capital spending may not increase appreciably in H2FY14. Reduced odds of cheaper funding in the system also put in question any sizeable increase in private investments during H2FY14..

While there are no signs of a recovery in demand due to absence of corporate capex and low infra spend, companies will need to further improve efficiencies in order to minimise the impact of weak cement prices. Additionally, with cash flows being impacted in the near term due to challenging macro environment, there will be a slowdown in new project announcement, especially from regional players..

UltraTech Cement, a Birla group company, is our preferred exposure in the large-cap cement space. One, its all-India exposure helps negate fluctuations in offtake and prices in regional markets. Two, the company is growing sales by expanding its market reach. Three, the company controls its costs well, a key advantage in the current scenario of high input costs and drop in realisation for cement players..

ACC – highlights:
ACC is coming up with a Rs.600- crore cement plant in Kharagpur town of West Bengal. It has started the construction for the new unit. The new cement factory will start production after three years and it would produce 15 lakh tonnes of cement daily. It is also planning to invest Rs.3,000 crore to expand its capacity by nearly four million tonnes a year in three eastern region States in the next three years.

ACC plans are afoot for expanding capacities at two existing plants Jamul in Chhattisgarh and Sindri in Jharkhand – the company expects to start construction of a 1.5 million tonne grinding unit at Kharagpur by next January next. The company plans to increase its capacity 10 mt a year from the existing 6 mt a year in three years in the east. This will entail an investment of about Rs.3,000 crore. The projects will be financed through internal accrual.

UltraTech Cement – highlights:
UltraTech Cement announced acquisition of Jaiprakash Associates´ cement assets in Gujarat (4.8 mTPA) for ~Rs 38billion (US$125/t). This is not a big climb-down from a year ago, when media reported likely valuation of Rs 42billion. However, there are definite positives:

1)Removal of a substantial volume-driven competitor,
2)Addition of 4.8 mTPA at ~Rs 8,000/t which can generate ~Rs 550/t of EBITDA straightaway in UTCEM´s hands,.
3)Limestone reserves worth 90 yrs at present capacity and option to scale up substantially in Kutch. Given its own substantial capex commitments (~Rs 78bn in FY14-15), the leverage (0.41x net D/E in FY14E) may border on uncomfortable.
Breakeven requires an EBITDA/t of ~Rs1,200, and the deal will result in EPS dilution for sure.

Concerns
Additional capacities coming on stream and/or fall in growth of demand could lead to decline in cement prices and in turn, lower realisations. There could also be a pressure on margins, which may have to be offset by control in costs. Rise in input costs like coal, slag, fly ash and gypsum could put pressure on margins as could increase in freight costs. Final resolution of the Competition Commission´s order if negative, could impact ACC´s and UTCL´s cash flows and profits. The latest restructuring proposal by Holcim could impact valuation of ACC in the interim.

Conclusions
CY13 could remain a challenging year due to a slowdown in demand, rise in cost pressure and inability to pass on the hike fully to consumers led by weak demand. Demand has continued to remain sluggish at the pan-India level during June-July. UTCL still has been the best performing large cap cement stock with outperformance of 16% in the last one year. As Ultratech is one of the most geographically diversified players in the Indian cement space, it could be the least impacted from ongoing slow-down seen across the industry.

Further, UTCL is valued the lowest in terms of EV/ton among its peers. On the back of weak topline growth trends, inability of the company to pass on any increase in operating expenses would lead to continued pressure on near-term EBITDA margins. The proposed deal of Holcim´s ownership in both ACC and Ambuja may result in UTCL enjoying premium valuations in the sector. However, a sharp revival in profitability is needed for UTCL stock price to perform.

Disclaimer: This document has been prepared by HDFC securities Limited. Publishers of ICR or HDFC securities Limited do not represent that it is accurate or complete and it should not be relied upon as such.

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Economy & Market

TSR Will Define Which Cement Companies Win India’s Net-Zero Race

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Jignesh Kundaria, Director and CEO, Fornnax Technology

India is simultaneously grappling with two crises: a mounting waste emergency and an urgent need to decarbonise its most carbon-intensive industries. The cement sector, the second-largest in the world and the backbone of the nation’s infrastructure ambitions, sits at the centre of both. It consumes enormous quantities of fossil fuel, and it has the technical capacity to consume something else entirely: the waste our cities cannot get rid of.

According to CPCB and NITI Aayog projections, India generates approximately 62.4 million tonnes of municipal solid waste annually, with that figure expected to reach 165 million tonnes by 2030. Much of this waste is energy-rich and non-recyclable. At the same time, cement kilns operate at material temperatures of approximately 1,450 degrees Celsius, with gas temperatures reaching 2,000 degrees. This high-temperature environment is ideal for co-processing, ensuring the complete thermal destruction of organic compounds without generating toxic residues. The physics are in our favour. The infrastructure is not.

Pre-processing is not the support act for co-processing. It is the main event. Get the particle size wrong, get the moisture wrong, get the calorific value wrong and your kiln thermal stability will suffer the consequences.

The Regulatory Push Is Real

The Solid Waste Management (SWM) Rules 2026 mandate that cement plants progressively replace solid fossil fuels with Refuse-Derived Fuel (RDF), starting at a 5 per cent baseline and scaling to 15 per cent within six years. NITI Aayog’s 2026 Roadmap for Cement Sector Decarbonisation targets 20 to 25 per cent Thermal Substitution Rate (TSR) by 2030. Beyond compliance, every tonne of coal replaced by RDF generates measurable carbon reductions which is monetisable under India’s emerging Carbon Credit Trading Scheme (CCTS). TSR is no longer a sustainability metric. It is a financial lever.

Yet our own field assessments across multiple Indian cement plants reveal a sobering reality: the primary barrier to scaling AFR adoption is not waste availability. It is the fragmented and under-engineered pre-processing ecosystem that sits between the waste and the kiln.

Why Indian Waste Is a Different Engineering Problem

Indian municipal solid waste is not the material that imported shredding equipment was designed for. Our waste streams frequently exceed 40 per cent to 50 per cent moisture content, particularly during monsoon cycles, saturated with abrasive inerts including sand, glass, and stone. Plants relying on imported OEM equipment face months of downtime awaiting proprietary spare parts. Machines built for segregated, low-moisture waste fail quickly and disrupt the entire pre-processing operation in Indian conditions.

The two most common failures we observe are what I call the biting teeth problem and the chewing teeth problem. Plants relying solely on a primary shredder reduce bulk waste to large fractions, but the output remains too coarse for stable kiln combustion. Others attempt to use a secondary shredder as a standalone unit without a primary stage to pre-size the feed, leading to catastrophic mechanical failure. When both stages are present but mismatched in throughput capacity, the system becomes a bottleneck. Achieving the 40 to 70 tonnes per hour required for meaningful coal displacement demands a precisely coordinated two-stage process.

Engineering a Made-in-India Answer

At Fornnax, our response to these challenges is grounded in one principle: Indian waste demands Indian engineering. Our systems are built around feedstock homogeneity, the holy grail of kiln stability. Consistent particle size and predictable calorific value are the foundation of stable kiln combustion. Without them, no TSR target is achievable at scale.

Our SR-MAX2500 Dual Shaft Primary Shredder (Hydraulic Drive) processes raw, baled, or loosely mixed MSW, C&I waste, bulky waste, and plastics, reducing them to approximately 150 mm fractions at throughputs of up to 40 tonnes per hour. The R-MAX 3300 Single Shaft Secondary Shredder (Hydraulic Drive), introduced in 2025, takes that primary output and produces RDF fractions in the 30 to 80 mm range at up to 30 tonnes per hour, specifically optimised for consistent kiln feeding. We have also introduced electric drive configurations under the SR-100 HD series, with capacities between 5 and 40 tonnes per hour, already operational at a leading Indian waste-processing facility.

Looking ahead, Fornnax is expanding its portfolio with the upcoming SR-MAX3600 Hydraulic Drive primary shredder at up to 70 tonnes per hour and the R-MAX2100 Hydraulic drive secondary shredder at up to 20 tonnes per hour, designed specifically for the large-scale throughput that higher TSR ambitions require.

The Investment Case Is Now

The 2070 Net-Zero target is not a distant goal for India’s cement sector. It starts today, with decisions being made on the plant floor.

The SWM Rules 2026 are already in effect, requiring cement plants to replace coal with RDF. Carbon credit markets are opening up, and coal prices are not going to get cheaper. Every tonne of coal a cement plant replaces with waste-derived fuel saves money on one side and generates carbon credit revenue on the other. Pre-processing infrastructure is no longer just a compliance requirement. It is a business investment with a measurable return.

The good news is that nothing is missing. The technology works. The waste is available in every Indian city. The government has provided the policy direction. The only thing standing between where the industry is today and where it needs to be is the commitment to build the right infrastructure.

The cement companies that move now will not just meet the regulations. They will be ahead of every competitor that waits.

About The Author

Jignesh Kundaria is the Director and CEO of Fornnax Technology. Over an experience spanning more than two decades in the recycling industry, he has established himself as one of India’s foremost voices on waste-to-fuel technology and alternative fuel infrastructure.

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Concrete

WCA Welcomes SiloConnect as associate corporate member

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The World Cement Association (WCA) has announced SiloConnect as its newest associate corporate member, expanding its network of technology providers supporting digitalisation in the cement industry. SiloConnect offers smart sensor technology that provides real-time visibility of cement inventory levels at customer silos, enabling producers to monitor stock remotely and plan deliveries more efficiently. The solution helps companies move from reactive to proactive logistics, improving delivery planning, operational efficiency and safety by reducing manual inspections. The technology is already used by major cement producers such as Holcim, Cemex and Heidelberg Materials and is deployed across more than 30 countries worldwide.

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Concrete

TotalEnergies and Holcim Launch Floating Solar Plant in Belgium

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TotalEnergies and Holcim have commissioned a floating solar power plant in Obourg, Belgium, built on a rehabilitated former chalk quarry that has been converted into a lake. The project has a generation capacity of 31 MW and produces around 30 GWh of renewable electricity annually, which will be used to power Holcim’s nearby industrial operations. The project is currently the largest floating solar installation in Europe dedicated entirely to industrial self-consumption. To ensure minimal impact on the surrounding landscape, more than 700 metres of horizontal directional drilling were used to connect the solar installation to the electrical substation. The project reflects ongoing collaboration between the two companies to support industrial decarbonisation through renewable energy solutions and innovative infrastructure development.

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