Concrete

Till bagged cement is in use, innovation will continue to happen

Published

4 years ago

January 14, 2022

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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

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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.