Concrete
Till bagged cement is in use, innovation will continue to happen
Published
4 years agoon
By
admin
Molugu Purnachander, Director Procurement, Heidelberg Cement India heads multiple cement plans and grinding centers and a plant pan India. He has been awarded with the Global Purchasing Best Practice Award. In this interview, he shared his experiences and requirements for packaging in the cement industry.
How important is packaging in the cement manufacturing process?
It is said that “Do not judge the book by its cover”, however, when it comes to products, the cover i.e. packaging is the foremost thing that appeals the eye of the customer.
Similarly cement packaging also plays a very important and vital role in influencing the customer to choose your product from the shelf. Prima Facie, packaging is the face of the company and the product within. Apart from extrinsic value cement packaging also provides protection and helps in enhancing shelf life. It safeguards the cement from threats like moistures, chemical reaction, etc. It also makes the transportation as well as handling easy with less wastage. It is an environment friendly solution for printing necessary and important information / specifications about cement along with the manufacturer’s name and their registered trademark, ISI mark, cement grade, bag weight, price etc.
On which stages in the cement manufacturing process is packaging required?
Cement tends to harden when its exposed to moisture in any form, thus, making it is unfit for consumption. Hence the packaging is required after the last stage when the final process of cement manufacturing ie. grinding of clinker with other additives is completed and cement is stored in Silos ready for dispatch. Cement is dispatched either in 50 kgs / jumbo bags packaging or in bulk dispatched in bulkers for larger construction projects.
What technology is followed in the packaging and transportation of cement?
There are various technology which a cement manufacture can chose from for packing the cement. However, majority of packaging is based on Polypropylene (PP) Woven / Laminated bags manufactured from PP granules (a byproduct from petroleum refinery). The fabric is made by weaving the tape in the looms.
Since packaging is one of the foremost things which differentiates the product in the eye of the customer, hence recently the cement industry has started switching to latest technology as per new guidelines such as block bottom valve sacks made of plastic fabric i.e., laminated.
Another variety is BOPP i.e., Biaxially oriented polypropylene film that is applied as an additional layer to woven polypropylene bags. The film allows for custom, clear, and vivid printing to be applied to both sides of the bag, as well as the gussets. Also, cement is packed in paper bags too.
Tell us more about the packaging material that is currently used for packing cement.
The basic raw material for cement packing is Polypropylene (PP). Currently there are four types of bags used in the packaging of cement –
a) PP woven bags b) Laminated bags
c) BOPP bags d) Paper bags.
BOPP i.e. Biaxially Oriented Polypropylene is the most premium packaging with provides attractive printing on it. BOPP is the latest technology in cement packaging which is 100 per cent recyclable and provides strong resistance to moisture.
Laminated bags are block bottom sacks made without adhesives from coated polypropylene fabric. These bags help to reduce CO2 emissions during cement production.
Paper bags which were running the show have lost their luster and are being slowly replaced by BOPP bags as they have advantages of less wastage, easier to recycle, better printing and visibility and environmentally friendly.
What improvements can be made in the system and process of cement packaging?
Cement is the second most consumed product after water and packaging plays a vital role in insuring the shelf life of the cement. Although companies have been using packaging as an aesthetic tool to differentiate their products from competitors, however implementation of various standards like Six Sigma should be promoted for cement bag to ensure that they reach the end customer intact.
There have been various advancements in cement packaging like from Jute to PP and then from PP to Laminated and BOPP, hence adopting advanced technologies of packaging like BOPP should be promoted as it provides sturdiness to the cement bag.
Further, increased automation to reduce spillage of cement and palletised packaging are other areas which industry should work towards.
Tell us about the major challenges faced in packing cement and delivering it to the
end consumer?
Cement bags are transported either through rake or through trucks. There are various interchanging points which lead to burstage of a cement bag/ spillage of cement. Starting from loading of cement bags in trucks / rake followed by in-transit and then till the final offlaoding, major challenge in packaging is the spillage of cement during the handling of bags at the dealer point / end user. Despite various notifications on bags like Use No Hooks, bags are handled with hooks to pull / push them into the truck which leads to heavy spillage of cement from bags and in turn creating dust emissions along with wastage. Hence there is a necessity to train the workmen at dealer place for proper and professional handling of bags to avoid burstage /loss of cement. Although we as an organization have already done automation to reduce the spillage along with training of our channel partners on bag handling, yet it still remains a challenge which entire industry faces.
How does delivery of cement take place protecting and shielding it from moisture?
- Removing sharp objects from the cement transport vehicle / rack before loading cement bags so that the bags are not torn or damaged.
- Ensuring the vehicle/rake is clean and dry before loading the cement bags.
- The plastic sheet must be spread on the vehicle/rake floor.
- Cement bags should be properly covered with plastic sheets with second layer of tarpaulin.
- Load cement bags carefully into the cement transport vehicle, making sure that they are covered and tied down securely.
Always stack the cement bags in the same way even if the bags are not palletised. Otherwise, if any pothole comes up, then cement bags may get toppled down.
How should dealers or end consumers of cement store packaged cement to prevent it from coming in contact with moisture?
- Cement should be stored in window-less room and rest it on a wooden platform, cement bags should not put directly on floor.
- Keep the cement bags 2 feet away from the nearest wall and ceiling.
- Don’t keep more than 15 bags on top of each other, if it’s more than 15 bags then there are chances of cement turning into lumps.
- During rains the cement bags should cover by tarpaulin.
- FIFO (First IN First OUT) should follow
- In warehouses, adequate ventilation is to be provided, Install exhaust fans on blank walls
Can cement packaging be made more eco-friendly and sustainable? Tell us more about the changes your organization is making.
Yes, many researches are going on to make the cement packing eco-friendly and sustainable. We as an organization are constantly taking efforts to make this green change and as a first step, we are shifting from normal PP woven bag to BOPP bag in a phase manner, as BOPP bags are 100 per cent recyclable.
- Ongoing RandD to make the bags now biodegradable.
- Adoption of Green cement.
- We are switching over to usage of laminated bags replacing PP bags and completely replacing paper bags by BOPP bags. Laminated/BOPP bags are extremely durable, break-resistant and protects the content from moisture which reduces loss of cement and avoids hardening of cement while multiple handlings. Less cement loss means less cement to be produced and consequently less CO2 emissions.
- BOPP bags are easily recyclable, the empty bags have to be collected by dealers from end users for some attractive value or offer attractive promotions to ensure collection of these used bags and recycling towards sustainability.
What innovation in cement packaging can be seen in the near future?
Globally cement is considered an industrial product, hence there is an inclination towards bulk over bagged cement. However, until bagged cement is in use innovation on the same will continue to happen. It is said that However you do, someone else will come and re-do it in a different way. Hence innovation in cement packaging will continue as it is major differentiator from competition. At present we can see that slowly and steadily the market is inclining towards the Block Bottom Bags and in next 5 years we can expect the current market share of 25 per cent block bottom could hit up to 80 per cent.
Kanika Mathur
Concrete
Adani’s Strategic Emergence in India’s Cement Landscape
Published
2 weeks agoon
September 16, 2025By
admin
Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.
India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.
Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:
- September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
- December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
- August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
- April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
- Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
- Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
- Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
- Orient Cement: It would serve as a principal manufacturing facility following the merger.
Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:
- By FY 2026: Reach 118 MTPA
- By FY 2028: Target 140 MTPA
These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).
Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.
Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.
Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.
Challenges potentially include:
- Integration challenges across systems, corporate cultures, and plant operations
- Regulatory sanctions for pending mergers and new capacity additions
- Environmental clearances in environmentally sensitive areas and debt management with input price volatility
When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.
Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.
About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.
Concrete
Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series
Published
1 month agoon
August 16, 2025By
admin
PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.
Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.
Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.
Beyond energy efficiency, the retrofit significantly improved operational parameters:
- Lower thermal stress on equipment
- Extended lubricant drain intervals
- Reduction in CO2 emissions and operational costs
These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.
Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:
- Enhanced component protection
- Extended oil life under high loads
- Stable performance across fluctuating temperatures
By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.
Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.
A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

Adani’s Strategic Emergence in India’s Cement Landscape

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

Driving Measurable Gains

Reshaping the Competitive Landscape

CCU testbeds in Tamil Nadu

Adani’s Strategic Emergence in India’s Cement Landscape

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

Driving Measurable Gains

Reshaping the Competitive Landscape
