Concrete

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

Published

4 years ago

January 15, 2022

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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

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Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

1 week ago

June 5, 2026

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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.

Concrete

Building a Greener Future Together

Published

1 week ago

June 4, 2026

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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.

Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

Published

2 weeks ago

June 1, 2026

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.