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Roller press is well-accepted technology in India

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With the focus of industry towards WHR systems, roller press grinding has further got acceptance as it uses no water for bed stabilisation and uses minimum hot gases as compared to other contemporary technologies, explains A K Dembla, President & Managing Director, Humboldt Wedag India.

With the focus of industry towards WHR systems, roller press grinding has further got acceptance as it uses no water for bed stabilisation and uses minimum hot gases as compared to other contemporary technologies, explains A K Dembla, President & Managing Director, Humboldt Wedag India.

Today, the requirement for the cement industry is to reduce the use of energy in the grinding process and make it more efficient. Please share your views on how this can be achieved.

 Grinding constitutes about 65-70 percent of the electrical energy consumption of cement manufacturing, any saving in grinding energy can be good for operating cost reduction. The energy cost is also increasing with time; therefore, cement manufacturing companies are looking for new technologies for low electrical energy consumption. Machinery manufacturers are putting a lot of R & D efforts in the grinding process to reduce electrical energy consumption in the cement industry which also helps in reduction in carbon footprints.

What is the latest energy-efficient grinding technologies/solution? What benefits cement companies can achieve in terms of energy consumption, quality, cost, etc?

The latest development related to raw materials grinding in finish grinding in Roller Press has paid dividends even for soft and medium to hard material. Hard raw materials are giving a higher bonus factor in finish grinding roller press systems and cement manufactures are getting 2-4 Kwh/t saving in electrical energy in raw material grinding itself by using this technology as compared to Vertical Mill technology. KHD has supplied 33 raw material grinding circuits in the last 10 years up to 10,000 tpd capacity plants. Typical circuit offered by KHD for raw materials grinding in ComFlex Grinding circuit has advantages to process raw materials with high moistures with the incorporation of V-Separator below the roller press and use of hot gases to dry the raw materials. With the focus of industry towards WHR systems, roller press grinding has further got acceptance as it uses no water for bed stabilisation and uses minimum hot gases as compared to other contemporary technologies.

In the case of cement grinding, again two technologies are being accepted –Vertical Roller Mill or Roller Press in semi-finish or finish grinding. Roller Press in finish grinding has the advantage of further saving of 3-4 Kwh/t as compared to Semi-finish grinding and Vertical Mill technology. With more acceptance of blended cement like PPC, PSC, and composite cement, roller press in finish grinding is accepted as advanced technology in cement grinding. KHD has sold 75 Cement Grinding Circuits in the last 10 years because of the need to save electrical energy. Typical Finish & Semi-finish Grinding circuits offered by KHD are very popular in the cement industry that includes the use of Roller Press alone or in a combination of Roller Press & Ball Mill respectively.

In the case of Slag grinding, the acceptance of roller press in finish grinding is well recognised. It offers the distinct advantage of saving of about 6-7 Kwh/t as compared to Vertical Roller Mill at 4200 Blaine. KHD has sold 27 Sag Grinding Circuits and maintains about 70 % market share in slag grinding in India. The advantage comes due to the hardness of Slag and pressure grinding in roller press instead of attrition and low pressure in Vertical Roller Press. Moisture issue is also tackled with the problem of coating by incorporating V-separator below roller press.

The most important properties of cement are strength and workability. This could be achieved by modifying the grinding equipment. Please share your views. What grinding technique/equipment can be used to ensure strength and workability?

 Strength and workability are two important parameters for cement when it is used as binding material in the form of concrete. Workability is one of the physical parameters of concrete which affects the strength and durability and can be defined as the ease with which the concrete can be mixed, placed, compacted, and finished. Concrete is said to be workable when it is easily placed and compacted homogenously i.e without bleeding or segregation. Technically speaking, workable concrete is the amount of useful internal work necessary to produce 100 percent compaction. Wet concrete is more workable than dry concrete and is a function of particle size distribution and water demand during the application of concrete in construction work. In this context 1 day, 3 days, and 7 days strength is important.

Similarly, the strength of cement depends upon the particle size distribution in cement which is achieved through a suitable grinding process and separator. Normally 3-32 micron size offers maximum strength and it should be in the range of 70-80 percent in cement. This range was established by conventional grinding in 2 chambers ball mill before acceptance of newer technology like Vertical Mill Roller Press technology. Semi-finish grinding in roller press has ball Mill along with roller press and therefore offers best particle size distribution (comparable to ball mill product). However, in the case of roller press in finish grinding and Vertical Mill, particle size distribution is steeper which is corrected through a high-efficiency separator. Also, with the advent of blended cement, the concept of particles in the range of 3-32 microns has also got diluted. 

Two-compartment ball mills and air separators used to be the main process equipment in clinker grinding circuits. How has been the evolution in terms of technical innovations in this area?

 Two compartments ball mill with separator has been conventional cement grinding technology which is still existing in many countries where electrical energy costs are low. Subsequent developments like the use of Roller Press and Vertical Mill offers saving of 5-10 Kwh/t electrical energy consumption for a typical 3200 Blaine cement as compared to a ball mill.

Ball mill technology has also gone through innovations in terms of various modified impact liners, classifying liners, and flow control diaphragms. But these modifications have the potential of limited savings in the range of 1-2 Kwh/t as compared to conventional liners and diaphragms.

Separators have also gone through various technological developments, and we are offering 4th generation high-efficiency separators nowadays. These separators offer a sharp cut point and minimum bypass (particle below 3 microns).

The usage of cement additive materials is on a rise. Please share your views on the same. What kind of grinding aids are in demand and what are the advantages?

 Grinding aid or grinding additives are materials, which are added with raw mix while grinding the cement in either a ball mill or vertical roller mill to reduce the agglomeration of cement particles by neutralising the static charges and increasing the rate of size reduction to improve the throughput and performance of the cement. Grinding aids are mainly of two types-

a) Strength Enhancer which is used to increase the mechanical strength by chemical activation, without changing the cement surface and particle size distribution. Alkanolamines are frequently used and can increase the compressive strength (at different or all ages) by max. five MPa. These admixtures increase the productivity of the grinding aid at the same time.

b) Performance Enhancers which are supplementary cementitious materials such as granulated blast furnace slag, natural Pozzolanic, and fly ash to reduce CO2 emissions and material cost. However, supplementary cementitious materials may counteract strength development, powder flowability, mortar workability, and durability, which are critical for cement quality. Generally, the grinding aids can be Amine-based or Alcohol Based, or Ethyl Based Grinding Aids. Overall benefits include enhanced production process and the quality of cement, improved powder followability, strength development, mortar workability, and durability, adjusting the cement quality to meet the demands set by relevant standards and cement customers. Above all, it ensures less environmental impact by reducing utilisation of energy and resources combined with minimised carbon footprint.

Please share your roadmap in the grinding technology area.

At present focus is to use Roller Press in finish grinding to get maximum energy advantage as compared to Ball Mill Grinding especially for blended cement. Apart from electrical energy focus is also on the Roller Press surface which has minimum wear and offers trouble and maintenance-free operation. Stud technology has proven a boon for the industry in this area, Tungsten Carbide Studs are fixed on the roller surface by pressing in pre-drilled rollers which offer autogenous grinding and minimum wear. Life expected out of these roller surfaces varies from 25000-40000 hours of operations without any surface maintenance. Fig 2 gives a picture of the stud surface roller. Apart from this, developments are on optimising the process circuit for energy efficiency & pollution-free operation. Developments in actuated dosing gate for feeding material to Roller press and online monitoring of roller press surface are also worth noticing.

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Economy & Market

From Vision to Action: Fornnax Global Growth Strategy for 2026

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Jignesh Kundaria, Director & CEO, Fornnax Recycling Technology

As 2026 begins, Fornnax is accelerating its global growth through strategic expansion, large-scale export-led installations, and technology-driven innovation across multiple recycling streams. Backed by manufacturing scale-up and a strong people-first culture, the company aims to lead sustainable, high-capacity recycling solutions worldwide.

As 2026 begins, Fornnax stands at a pivotal stage in its growth journey. Over the past few years, the company has built a strong foundation rooted in engineering excellence, innovation, and a firm commitment to sustainable recycling. The focus ahead is clear: to grow faster, stronger, and on a truly global scale.

“Our 2026 strategy is driven by four key priorities,” explains Mr. Jignesh Kundaria, Director & CEO of Fornnax.

First, Global Expansion

We will strengthen our presence in major markets such as Europe, Australia, and the GCC, while continuing to grow across our existing regions. By aligning with local regulations and customer requirements, we aim to establish ourselves as a trusted global partner for advanced recycling solutions.

A major milestone in this journey will be export-led global installations. In 2026, we will commission Europe’s highest-capacity shredding line, reinforcing our leadership in high-capacity recycling solutions.

Second, Product Innovation and Technology Leadership

Innovation remains at the heart of our vision to become a global leader in recycling technology by 2030. Our focus is on developing solutions that are state-of-the-art, economical, efficient, reliable, and environmentally responsible.

Building on a decade-long legacy in tyre recycling, we have expanded our portfolio into new recycling applications, including municipal solid waste (MSW), e-waste, cable, and aluminium recycling. This diversification has already created strong momentum across the industry, marked by key milestones scheduled to become operational this year, such as:

  • Installation of India’s largest e-waste and cable recycling line.
  • Commissioning of a high-capacity MSW RDF recycling line.

“Sustainable growth must be scalable and profitable,” emphasizes Mr. Kundaria. In 2026, Fornnax will complete Phase One of our capacity expansion by establishing the world’s largest shredding equipment manufacturing facility. This 23-acre manufacturing unit, scheduled for completion in July 2026, will significantly enhance our production capability and global delivery capacity.

Alongside this, we will continue to improve efficiency across manufacturing, supply chain, and service operations, while strengthening our service network across India, Australia, and Europe to ensure faster and more reliable customer support.

Finally: People and Culture

“People remain the foundation of Fornnax’s success. We will continue to invest in talent, leadership development, and a culture built on ownership, collaboration, and continuous improvement,” states Mr. Kundaria.

With a strong commitment to sustainability in everything we do, our ambition is not only to grow our business, but also to actively support the circular economy and contribute to a cleaner, more sustainable future.

Guided by a shared vision and disciplined execution, 2026 is set to be a defining year for us, driven by innovation across diverse recycling applications, large-scale global installations, and manufacturing excellence.

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Concrete

Technology plays a critical role in achieving our goals

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Arasu Shanmugam, Director and CEO-India, IFGL, discusses the diversification of the refractory sector into the cement industry with sustainable and innovative solutions, including green refractories and advanced technologies like shotcrete.

Tell us about your company, it being India’s first refractory all Indian MNC.
IFGL Refractories has traditionally focused on the steel industry. However, as part of our diversification strategy, we decided to expand into the cement sector a year ago, offering a comprehensive range of solutions. These solutions cover the entire process, from the preheater stage to the cooler. On the product side, we provide a full range, including alumina bricks, monolithics, castables, and basic refractories.
In a remarkably short span of time, we have built the capability to offer complete solutions to the cement industry using our own products. Although the cement segment is new for IFGL, the team handling this business vertical has 30 years of experience in the cement industry. This expertise has been instrumental in establishing a brand-new greenfield project for alumina bricks, which is now operational. Since production began in May, we are fully booked for the next six months, with orders extending until May 2025. This demonstrates the credibility we have quickly established, driven by our team’s experience and the company’s agility, which has been a core strength for us in the steel industry and will now benefit our cement initiatives.
As a 100 per cent Indian-owned multinational company, IFGL stands out in the refractory sector, where most leading players providing cement solutions are foreign-owned. We are listed on the stock exchange and have a global footprint, including plants in the United Kingdom, where we are the largest refractory producer, thanks to our operations with Sheffield Refractories and Monocon. Additionally, we have a plant in the United States that produces state-of-the-art black refractories for critical steel applications, a plant in Germany providing filtering solutions for the foundry sector, and a base in China, ensuring secure access to high-quality raw materials.
China, as a major source of pure raw materials for refractories, is critical to the global supply chain. We have strategically developed our own base there, ensuring both raw material security and technological advancements. For instance, Sheffield Refractories is a leader in cutting-edge shotcreting technology, which is particularly relevant to the cement industry. Since downtime in cement plants incurs costs far greater than refractory expenses, this technology, which enables rapid repairs and quicker return to production, is a game-changer. Leading cement manufacturers in the country have already expressed significant interest in this service, which we plan to launch in March 2025.
With this strong foundation, we are entering the cement industry with confidence and a commitment to delivering innovative and efficient solutions.
Could you share any differences you’ve observed in business operations between regions like Europe, India, and China? How do their functionalities and approaches vary?
When it comes to business functionality, Europe is unfortunately a shrinking market. There is a noticeable lack of enthusiasm, and companies there often face challenges in forming partnerships with vendors. In contrast, India presents an evolving scenario where close partnerships with vendors have become a key trend. About 15 years ago, refractory suppliers were viewed merely as vendors supplying commodities. Today, however, they are integral to the customer’s value creation chain.
We now have a deep understanding of our customers’ process variations and advancements. This integration allows us to align our refractory solutions with their evolving processes, strengthening our role as a value chain partner. This collaborative approach is a major differentiator, and I don’t see it happening anywhere else on the same scale. Additionally, India is the only region globally experiencing significant growth. As a result, international players are increasingly looking at India as a potential market for expansion. Given this, we take pride in being an Indian company for over four decades and aim to contribute to making Aatma Nirbhar Bharat (self-reliant India) a reality.
Moving on to the net-zero mission, it’s crucial to discuss our contributions to sustainability in the cement industry. Traditionally, we focused on providing burnt bricks, which require significant fuel consumption during firing and result in higher greenhouse gas emissions, particularly CO2. With the introduction of Sheffield Refractories’ green technology, we are now promoting the use of green refractories in cement production. Increasing the share of green refractories naturally reduces CO2 emissions per ton of clinker produced.
Our honourable Prime Minister has set the goal of achieving net-zero emissions by 2070. We are committed to being key enablers of this vision by expanding the use of green refractories and providing sustainable solutions to the cement industry, reducing reliance on burnt refractories.

Technology is advancing rapidly. What role does it play in helping you achieve your targets and support the cement industry?
Technology plays a critical role in achieving our goals and supporting the cement industry. As I mentioned earlier, the reduction in specific refractory consumption is driven by two key factors: refining customer processes and enhancing refractory quality. By working closely as partners with our customers, we gain a deeper understanding of their evolving needs, enabling us to continuously innovate. For example, in November 2022, we established a state-of-the-art research centre in India for IFGL, something we didn’t have before.
The primary objective of this centre is to leverage in-house technology to enhance the utilisation of recycled materials in manufacturing our products. By increasing the proportion of recycled materials, we reduce the depletion of natural resources and greenhouse gas emissions. In essence, our focus is on developing sustainable, green refractories while promoting circularity in our business processes. This multi-faceted approach ensures we contribute to environmental sustainability while meeting the industry’s demands.

Of course, this all sounds promising, but there must be challenges you’re facing along the way. Could you elaborate on those?
One challenge we face is related to India’s mineral resources. For instance, there are oxide deposits in the Saurashtra region of Gujarat, but unfortunately, they contain a higher percentage of impurities. On the magnesite side, India has deposits in three regions: Salem in Tamil Nadu, Almora in Uttarakhand, and Jammu. However, these magnesite deposits also have impurities. We believe the government should take up research and development initiatives to beneficiate these minerals, which are abundantly available in India, and make them suitable for producing high-end refractories. This task is beyond the capacity of an individual refractories company and requires focused policy intervention. While the government is undertaking several initiatives, beneficiation of minerals like Indian magnesite and Indian oxide needs to become a key area of focus.
Another crucial policy support we require is recognising the importance of refractories in industrial production. The reality is that without refractories, not even a single kilogram of steel or cement can be produced. Despite this, refractories are not included in the list of core industries. We urge the government to designate refractories as a core industry, which would ensure dedicated focus, including R&D allocations for initiatives like raw material beneficiation. At IFGL, we are taking proactive steps to address some of these challenges. For instance, we own Sheffield Refractories, a global leader in shotcrete technology. We are bringing this technology to India, with implementation planned from March onwards. Additionally, our partnership with Marvel Refractories in China enables us to leverage their expertise in providing high-quality refractories for steel and cement industries worldwide.
While we are making significant efforts at our level, policy support from the government—such as recognising refractories as a core industry and fostering research for local raw material beneficiation—would accelerate progress. This combined effort would greatly enhance India’s capability to produce high-end refractories and meet the growing demands of critical industries.

Could you share your opinion on the journey toward achieving net-zero emissions? How do you envision this journey unfolding?
The journey toward net zero is progressing steadily. For instance, even at this conference, we can observe the commitment as a country toward this goal. Achieving net zero involves having a clear starting point, a defined objective, and a pace to progress. I believe we are already moving at an impressive speed toward realising this goal. One example is the significant reduction in energy consumption per ton of clinker, which has halved over the past 7–8 years—a remarkable achievement.
Another critical aspect is the emphasis on circularity in the cement industry. The use of gypsum, which is a byproduct of the fertiliser and chemical industries, as well as fly ash generated by the power industry, has been effectively incorporated into cement production. Additionally, a recent advancement involves the use of calcined clay as an active component in cement. I am particularly encouraged by discussions around incorporating 12 per cent to 15 per cent limestone into the mix without the need for burning, which does not compromise the quality of the final product. These strategies demonstrate the cement industry’s constructive and innovative approach toward achieving net-zero emissions. The pace at which these advancements are being adopted is highly encouraging, and I believe we are on a fast track to reaching this critical milestone.

– Kanika Mathur

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Technology

ARAPL Reports 175% EBITDA Growth, Expands Global Robotics Footprint

Affordable Robotic & Automation posts strong Q2 and H1 FY26 results driven by innovation and overseas orders

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Affordable Robotic & Automation Limited (ARAPL), India’s first listed robotics firm and a pioneer in industrial automation and smart robotic solutions, has reported robust financial results for the second quarter and half year ended September 30, 2025.
The company achieved a 175 per cent year-on-year rise in standalone EBITDA and strong revenue growth across its automation and robotics segments. The Board of Directors approved the unaudited financial results on October 10, 2025.

Key Highlights – Q2 FY2026
• Strong momentum across core automation and robotics divisions
• Secured the first order for the Atlas AC2000, an autonomous truck loading and unloading forklift, from a leading US logistics player
• Rebranded its RaaS product line as Humro (Human + Robot), symbolising collaborative automation between people and machines
• Expanded its Humro range in global warehouse automation markets
• Continued investment in deep-tech innovations, including AI-based route optimisation, autonomy kits, vehicle controllers, and digital twins
Global Milestone: First Atlas AC2000 Order in the US

ARAPL’s US-based subsidiary, ARAPL RaaS (Humro), received its first order for the next-generation Atlas AC2000 autonomous forklift from a leading logistics company. Following successful prototype trials, the client placed an order for two robots valued at Rs 36 million under a three-year lease. The project opens opportunities for scaling up to 15–16 robots per site across 15 US warehouses within two years.
The product addresses an untapped market of 10 million loading docks across 21,000 warehouses in the US, positioning ARAPL for exponential growth.

Financial Performance – Q2 FY2026 (Standalone)
Net Revenue: Rs 25.7587 million, up 37 per cent quarter-on-quarter
EBITDA: Rs 5.9632 million, up 396 per cent QoQ
Profit Before Tax: Rs 4.3808 million, compared to a Rs 360.46 lakh loss in Q1
Profit After Tax: Rs 4.1854 lakh, representing 216 per cent QoQ growth
On a half-year basis, ARAPL reported a 175 per cent rise in EBITDA and returned to profitability with Rs 58.08 lakh PAT, highlighting strong operational efficiency and improved contribution from core businesses.
Consolidated Performance – Q2 FY2026
Net Revenue: Rs 29.566 million, up 57% QoQ
EBITDA: Rs 6.2608 million, up 418 per cent QoQ
Profit After Tax: Rs 4.5672 million, marking a 224 per cent QoQ improvement

Milind Padole, Managing Director, ARAPL said, “Our Q2 results reflect the success of our innovation-led growth strategy and the growing global confidence in ARAPL’s technology. The Atlas AC2000 order marks a defining milestone that validates our engineering strength and accelerates our global expansion. With a healthy order book and continued investment in AI and autonomous systems, ARAPL is positioned to lead the next phase of intelligent industrial transformation.”
Founded in 2005 and headquartered in Pune, Affordable Robotic & Automation Ltd (ARAPL) delivers turnkey robotic and automation solutions across automotive, general manufacturing, and government sectors. Its offerings include robotic welding, automated inspection, assembly automation, automated parking systems, and autonomous driverless forklifts.
ARAPL operates five advanced plants in Pune spanning 350,000 sq ft, supported by over 400 engineers in India and seven team members in the US. The company also maintains facilities in North Carolina and California, and service centres in Faridabad, Mumbai, and San Francisco.

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