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“Cement packaging can be made much better and safer for the environment.”

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Alpesh Patel is the founder and managing director of Knack Packaging Pvt. Ltd. He established the company in 1993 and since then has been supervising and controlling all processes at the organisation. He also holds prominent roles in the industry as the Chairman of Plastic Export Promotion Council – Gujarat, Chairman of Indian Institute of Packaging – Ahmedabad and President of Poly Woven Association – Gujarat. He has been recognised with the Rashtriya Udhyog Ratna Award in Council for Economic Growth and Research for “Excellence in their respective field” in 2011. His philosophy is to keep learning, improving and growing.

What are the various types of cement packaging bags made by your company? Tell us more about the composition of the most used packaging material for cement?
There are three types of bags and the fourth is the new renovation. The first type of bag is a PP unlaminated bag, the second type is PP laminated coated bag and third type is BOPP laminated bag with block bottom. The issue with the PP unlaminated bags is that cement comes out of it often since it has a wall and due to which it also creates dust. The fourth quality of cement bag is a new product, known as pinch bottom bag. These are one of the world’s finest quality bags. It looks like a brick but the system of packing it is the same as the wall bag packing system. It does not have any leakages and is considered to be the best. I personally think that the third quality bags, BOPP laminated bags with block bottom are also great. They serve 98 per cent of what the pinch bags can do. Since during their packaging their mouth is open, that leaves little chance of leakage and that’s why they are just close to perfect.

What is the volume of cement packaging manufactured and consumed by cement companies in India?
I’ll tell you three things. We are producing 700,000 bags per day of which 150,000 bags per day are supplied to the cement industry on an everyday basis. This is a big question to answer but according to me, yearly about 60 to 70 crore bags are consumed by the cement industry. From these crores of bags, Knack Packaging supplies about 3 to 4 crores of bags to the manufacturers of cement.

Tell us more about the technology of manufacturing the bags used for cement packaging?
We use polypropylene (PP) granules to make the fabric of the cement packaging bags. These granules are selected on the basis of the type of bags that are to be made. This also falls under the textile industry since the granules are converted to a fabric like material but made of PP. You can consider just how shirts are made from a fabric, similarly, cement packaging bags are made from granule fabric.
We have the infrastructure to create the every size and type of cement packaging bags required by our customers.

How well are these bags equipped to protect cement?
When cement is packed in unlaminated bags, it causes a lot of dust and wastage on the packaging floor, while loading it and wherever it is stored. Even when these bags are carried to the place of construction, there is a certain amount of leakage. This happens due to the pressure with which cement is packed in these bags. Because of the coating on coated bags, cement comes out or is wasted only from the top and bottom where the bag is sealed off. In the third type of bags, the BOPP laminated bags, the wastage is significantly reduced. The material for the bags used is the same so it isn’t harming the environment. Since these bags have three layers, it not only prevents wastage, it also allows major branding.

What alternative materials are used to make cement packaging more eco-friendly?
PP unlaminated bags are made from PP granules. Then the coating on these bags is done with a material in the same family as that of PP. The BOPP print, in the third layer of the bags is also done from a material in the same family as PP. Various quality bags are made with layering of these materials. These materials are very easily recyclable and cause almost no harm to the environment. The bags can be reused as well, thus, reducing the wastage that may occur due to discarding one time use bags. These combinations are used with colour combinations to distinguish between bags.

What is the wastage that occurs in cement packaging? What is its volume?
According to the industry standard, there is only 2 to 3 per cent wastage in the manufacturing of cement packaging bags. This can also be greatly reduced by increasing the production efficiency in making the bags. However, this is the minimum amount of wastage in the industry possible.

Tell us more about the efforts taken to reduce the wastage in cement packaging?
Our industry has taken the initiative of recycling the waste that occurs during the production of cement packaging. Those 2 or 3 per cent of waste material is turned into granules and used again to make cement packaging fabric. This makes our wastage zero.
This is an initiative taken only by us at the moment and as the chairman of the Indian Institute of Packaging, I request all packaging makers to make this effort to leave the world a better place for the next generation. As leaders in the industry, it becomes our responsibility to lead the way of making this small effort to reduce the wastage in a big volume. Reprocess and reuse for a better tomorrow.

How can cement packaging be made more eco-friendly and contribute towards the betterment of the environment?
Cement packaging can be made much better, safer for the environment and supportive of the circular economy by developing ‘Reprocessing Plants’.
I have taken the effort to install these plants in all my group companies and have helped my fellow entrepreneurs and friends set up the same in their plants to make a difference for the environment. There are many internal processes that have wastage, that itself can be reprocessed and granulated and can be used to make the fabric of the next batch of packaging material or can be sold out where it can be used.

What are the innovations expected in the future for cement packaging?
There are some changes that will be seen in the packaging in the near future.
One would be small packaging of cement, i.e., 10 kg and 25 kg against the 50 kilo bags that are largely available in the current times. Bulk packaging would be avoided in the near future. The other would-be green packaging. This would mean 100 per cent biodegradable bags. And as we have also begun manufacturing pinch bottom bags, they are going to be big in the coming years. What I would like to add with this interview is value to the cement industry and a message to everyone in the cement industry and the cement packaging industry is to collect the cement bags back instead of putting them in waste. These used bags can be used in the kilns as fuel to be burned and create heat. This can save natural resources and thus result in reduction of natural disasters. Cement industry can be a large contributor to the protection of the environment and small steps like these can make a big difference for the future.

Kanika Mathur

Concrete

Adani’s Strategic Emergence in India’s Cement Landscape

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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.

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Concrete

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

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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.

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Concrete

Driving Measurable Gains

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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.

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