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Keeping all gears in action

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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

Indian Railways Plans Green Fly Ash Transport Network

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Specialised rail logistics will move fly ash from power plants to infrastructure industries.

New Delhi

Indian Railways is planning a large-scale green logistics initiative to transport fly ash from thermal power plants to industries where it can be reused in infrastructure and construction activities.

The initiative was discussed during a review meeting chaired by Union Minister for Railways Ashwini Vaishnaw. Union Ministers of State for Railways V Somanna and Ravneet Singh Bittu were also present.

India generates nearly 340 million tonnes of fly ash every year from thermal power plants. The proposed initiative aims to create an efficient rail-based transport system using specialised containers and dedicated logistics arrangements to move fly ash safely from power plants to end-use industries.

Fly ash is widely used in road construction, cement manufacturing, brick production, concrete, blocks and boards. By improving its movement through the railway network, the initiative is expected to support better utilisation of this industrial by-product while reducing environmental concerns linked to storage and disposal.

The move also aligns with India’s circular economy goals by converting waste from thermal power generation into a useful raw material for the construction and infrastructure sectors. Wider availability of fly ash can help reduce material costs in areas such as bricks and cement, supporting more affordable infrastructure and housing development.

Through this initiative, Indian Railways aims to provide a cleaner, safer and more organised transport solution for fly ash, turning an environmental challenge into an infrastructure resource.

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Concrete

ACC To Expand Cement Capacity Amid Strong Infrastructure Demand

Chairman signals calibrated growth and sustainability focus

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ACC will continue to expand its cement capacity in a calibrated manner, deepen its ready-mix concrete (RMC) footprint and accelerate the adoption of low-carbon technologies, the company chairman conveyed in the latest annual report. The note emphasised a balanced and disciplined approach as the business pursues growth while maintaining environmental safeguards.

He argued that the long-term growth outlook for the Indian economy remains strong but that demand conditions in the near term were likely to stay moderate, necessitating cautious expansion. He pointed to India’s relatively low per capita cement consumption compared with global averages as an indicator of significant long-term potential and highlighted the rise in public capital expenditure to Rs 12 trillion (Rs 12 tn), which he said accounted for about four point four per cent of the GDP.

Against this backdrop, ACC and the wider Adani Cement business are positioning themselves as integrated building materials solution providers rather than traditional commodity suppliers, prioritising capability creation over consolidation. The chairman framed cement as the ingredient and concrete as the performance and said that infrastructure and real estate development increasingly demand engineered solutions delivered at site.

He described how deeper integration across energy, logistics and digital systems is intended to improve responsiveness and efficiency across manufacturing, transport and market operations. The company intends to strengthen technical engagement, mix optimisation and application support to improve project timelines, reduce wastage and enhance structural durability while embedding data analytics and predictive systems.

On sustainability, ACC affirmed its commitment to reducing its environmental footprint through greater use of blended cement, renewable energy, alternative fuels and improved thermal efficiency, presenting industrial growth and environmental responsibility as parallel objectives. The message positioned the group to supply engineered concrete solutions at the point of application as it scales capacity and service offerings.

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Ambuja Sees Cement Demand Easing To Around Five Per Cent In FY27

Company Cites Housing, Infrastructure And Government Capex

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Ambuja Cements has said in its latest annual report that cement demand in India is likely to moderate to around five per cent in fiscal year twenty seven, marking a slowdown from the estimated six point five to seven point five per cent growth anticipated for fiscal year twenty six. The company described this as a transition to a more measured pace of expansion after several years of strong momentum in the sector.

It said that underlying demand drivers such as housing, infrastructure development, urbanisation and government capital expenditure remain intact and are expected to sustain cement consumption across regions. The report noted that global geopolitical uncertainties and weather risks, including forecasts of a below normal monsoon, could influence near term demand, while emphasising that the longer term infrastructure story for India continues to provide a solid foundation for the sector.

Industry observers have said that the sector may move towards mid single digit growth rates in fiscal year twenty seven after stronger performances in recent years. The company outlined a calibrated expansion strategy with capacity additions phased to match project pipelines, regional demand patterns and market absorption, seeking to avoid oversupply and pressure on pricing.

Ambuja has crossed the 100 million tonnes per annum capacity milestone (100 mn t per annum) following acquisitions and organic expansion, strengthening its position in the competitive market. The outlook in the report broadly aligns with other market assessments that placed demand at around five per cent in fiscal year twenty five, a recovery to six point five to seven point five per cent in fiscal year twenty six and an easing in fiscal year twenty seven as capacity increases. Executives remain focused on long term demand fundamentals driven by infrastructure and housing.

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