Concrete

Keeping all gears in action

Published

3 years ago

March 7, 2022

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High performing lubricants, oils and greases are instrumental to the smooth working of a cement plant. Indian Cement Review takes a closer look at their contribution in enhancing productivity and helping companies achieve sustainability goals as well as the development of cost-effective bio-lubricants.

The cement manufacturing process is heavy duty. Activities such as carrying mined limestone on quarry belts to the pyroprocessor where clinker is produced at high heat levels cause immense load and severe operating conditions for equipment such as kilns, ball mills, conveyors and quarry-side mobile plants. The cement making machinery works around the clock, subjecting its components like gearboxes and bearings to overheating and premature wear and tear.

It is essential that care be taken and regular maintenance work be done for each of these equipment as the plant shall endure heavy financial and production losses if there is machinery failure, shutdown or loss of heat and energy in the mining area or manufacturing plants. To avoid such a situation and any unscheduled downtime, maintenance operators and managers invest in high performing lubricants, oils and greases that reduce the harm on machinery components.

Lubricants at work

Specially formulated lubricants are required at all stages of the cement making process, namely, extraction, crushing, conveying, grinding, clinker production, grinding and some general lubricants are needed for processes that happen in between.

Selecting the right lubricant for every machinery can be challenging. It isn’t about the equipment but the environment in which the machinery is operating that can vary from season to season depending on the plant’s location. This factor must be carefully considered while deciding which lubricants, oils or greases would work best for the machinery and the plant’s systems.

Productivity enhancement

Challenging operating conditions, continuous operations especially for the processing equipment such as the kilns, ball mills, conveyors and quarry-side mobile plants can lead to premature wear and tear or be subjected to overheating. Plant operators must maintain and choose the right lubricants to prevent any unscheduled downtime and costly additional maintenance, as well as safeguard their bottom line performance. Lubricants may cost upto 1 to 2 per cent of any cement company’s overall expense but play a key role in preventing major costs that may occur due to a faulty operation or shutdown.

Productivity of a cement plant is dependent on smooth operations, which in turn is dependent on the flawless functioning of plant machinery right from the point of extraction to packaging and exit of materials. Sustainability Goals
Specialty lubricants with innovative formulae have been created with research that help obtain operational excellence and support the balance of carbon emission in the industry. A systematic approach can lead the way of using these specialty lubricants in the cement plants if necessary to achieve the objectives.

Innovative lubricant manufacturers have developed cost-effective bio-lubricants. These eco-friendly lubricants can also be a great replacement for the lubricants that have graphite. It makes their handling and disposal safe for the work men and the environment.

Multiple organisations are putting in an effort to create lubricants with special formulations that support the intense conditions the machinery of a cement plant endures. From dust, water, pressure, vibrations or weight, the right lubricant applied in the correct manner can make productivity efficient, can avoid untimely shut downs and support the cement industry to make their processes run in a smooth and timely manner. It is essential that close attention is paid in selection of these lubricants as well as their maintenance, drainage and disposal.

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Concrete

Organisations valuing gender diversity achieve higher profitability

Aparna Reddy, Executive Director, Aparna Enterprises talks about company plans.

Published

1 day ago

February 22, 2025

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The building materials industry is projected to grow by 8-12 per cent over the next five years. How is Aparna Enterprises positioning itself to leverage this momentum and solidify its market presence?

The Indian construction and building materials industry is projected to witness significant expansion, with estimates suggesting an 8-12 per cent compound annual growth rate (CAGR) over the next five years. This growth is fuelled by rapid urbanisation, increased infrastructure investments and sustainability-focused policies. With India’s real-estate market expected to reach $ 1 trillion by 2030, the demand for high-quality building materials is at an all-time high.

The Government of India’s flagship programmes, such as PM Gati Shakti, the Smart Cities Mission and the Housing for All (PMAY-Urban) initiative, are key drivers of this surge. The infrastructure sector alone is expected to receive a budgetary push of over Rs 11 trillion in FY25, with enhanced capital expenditure allocation.

At Aparna Enterprises, we are proactively aligning with this momentum through capacity expansion, product diversification, and cutting-edge technological integration.

Our key strategic priorities include:

Expanding operations in high-growth regions across Tier-2 and Tier-3 cities, ensuring access to quality building materials nationwide
Investing in automation, AI-driven quality control systems and digital integration, enhancing efficiency and precision in manufacturing
Scaling up production capabilities in our RMC, tiles, uPVC and other divisions to meet the anticipated surge in demand.

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Concrete

Global Start-Up Challenge Launched to Drive Net Zero Concrete Solutions

Innovandi Open Challenge aims to connect start-ups with GCCA members to develop innovations

Published

3 days ago

February 21, 2025

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Start-ups worldwide are invited to contribute to the global cement and concrete industry’s efforts to reduce CO2 emissions and combat climate change. The Global Cement and Concrete Association (GCCA) and its members are calling for applicants for the Innovandi Open Challenge 2025.

Now in its fourth year, the Innovandi Open Challenge aims to connect start-ups with GCCA members to develop innovations that help decarbonise the cement and concrete industry.

The challenge is seeking start-ups working on next-generation materials for net-zero concrete, such as low-carbon admixtures, supplementary cementitious materials (SCMs), activators, or binders. Innovations in these areas could help reduce the carbon-intensive element of cement, clinker, and integrate cutting-edge materials to lower CO2 emissions.

Thomas Guillot, GCCA’s Chief Executive, stated, “Advanced production methods are already decarbonising cement and concrete worldwide. Through the Innovandi Open Challenge, we aim to accelerate our industry’s progress towards net-zero concrete.”

Concrete is the second most widely used material on Earth, and its decarbonisation is critical to achieving net-zero emissions across the global construction sector.

Concrete

StarBigBloc Acquires Land for AAC Blocks Greenfield Facility in Indore

The company introduced NXTGRIP Tile Adhesives alongside its trusted NXTFIX and NXTPLAST brands.

Published

4 days ago

February 19, 2025

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StarBigBloc Building Material, a wholly-owned subsidiary of BigBloc Construction, one of the largest manufacturers of Aerated Autoclaved Concrete (AAC) Blocks, Bricks and ALC Panels in India has acquired land for setting up a green field facility for AAC Blocks in Indore, Madhya Pradesh. Company has purchased approx. 57,500 sq. mts. land at Khasra No. 382, 387, 389/2, Gram Nimrani, Tehsil Kasrawad, District – Khargone, Madhya Pradesh for the purpose of AAC Blocks business expansion in central India. The total consideration for the land deal is Rs 60 million and Stamp duty.

StarBigBloc Building Material Ltd currently operates one plant at Kheda near Ahmedabad with an installed capacity of 250,000 cubic meters per annum, serving most part of Gujarat, upto Udaipur in Rajasthan, and till Indore in Madhya Pradesh. The capacity utilisation at Starbigbloc Building Material Ltd for the third quarter was 75 per cent. The planned expansion will enable the company to establish a stronger presence in Madhya Pradesh and surrounding regions. Reaffirming its commitment to the Green Initiative, it has also installed a 800 KW solar rooftop power project — a significant step toward sustainability and lowering its carbon footprint.

Narayan Saboo, Chairman, Bigbloc Construction said “The AAC block industry is set to play a pivotal role in India’s construction sector, and our company is ready for a significant leap forward. The proposed expansion in Indore, Madhya Pradesh aligns with our growth strategy, focusing on geographic expansion, R&D investments, product diversification, and strategic branding and marketing initiatives to enhance visibility, increase market share, and strengthen stakeholder trust.”

Bigbloc Construction has recently expanded into construction chemicals with Block Jointing Mortar, Ready Mix Plaster, and Tile Adhesives, tapping into high-demand segments. The company introduced NXTGRIP Tile Adhesives alongside its trusted NXTFIX and NXTPLAST brands, ensuring superior bonding, strength, and performance.

In May 2024, the board of directors approved fund-raising through SME IPO or Preferential issue to support expansion plans of Starbigboc Building Material subject to requisite approvals and market conditions, Starbigboc Building Material aims to expand its production capacity from current 250,000 cubic meters per annum to over 1.2 million cubic meters per annum in the next 4-5 years. Company is targeting revenues of Rs 4.28 billion by FY27-28, with an expected EBITDA of Rs 1.25 billion and net profit of Rs 800 million. In FY23-24, the company reported revenues of Rs 940.18 million, achieving a revenue CAGR of over 21 per cent in the last four years.

Incorporated in 2015, BigBloc Construction is one of the largest and only listed AAC block manufacturer in India, with a 1.3 million cbm annual capacity across plants in Gujarat (Kheda, Umargaon, Kapadvanj) and Maharashtra (Wada). The company, which markets its products under the ‘NXTBLOC’ brand, is one of the few in the AAC industry to generate carbon credits. With over 2,000 completed projects and 1,500+ in the pipeline, The company’s clients include Lodha, Adani Realty, IndiaBulls Real Estate, DB Realty, Prestige, Piramal, Oberoi Realty, Tata Projects, Shirke Group, Shapoorji Pallonji Group, Raheja, PSP Projects, L&T, Sunteck, Dosti Group, Purvankara Ltd, DY Patil, Taj Hotels, Godrej Properties, Torrent Pharma, GAIL among others.