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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

Cement Makers’ Margins To Fall Rs 50-75 Per Tonne Amid West Asia Conflict

Crisil Sees Margins Easing Despite Steady Demand

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Crisil said operating margins of Indian cement manufacturers are expected to decline by Rs 50-75 per tonne (t) this fiscal to Rs 925-950 per t due to higher input costs triggered by the West Asia conflict. The analysis covered 18 cement companies accounting for nearly 90 per cent of India’s domestic cement capacity and noted margins had improved sharply to around Rs 1,000 per t in fiscal 2026.

Crisil noted that the reduction would be driven mainly by higher power and fuel costs, which account for about 30 per cent of total costs, as petcoke and imported coal prices have surged amid geopolitical uncertainties. Freight costs, which account for about a quarter of total costs, are also expected to remain elevated because of higher diesel prices. The impact on profitability is likely to be more pronounced in the first half of the fiscal year before easing commodity prices moderate cost pressures later.

The rating agency said steady domestic demand and strong balance sheets should keep credit profiles stable despite the moderation in margins. Green energy currently accounts for 35-40 per cent of the sector’s total electricity consumption and is expected to partly cushion higher energy costs. Operating cash flows are likely to remain resilient, supported by projected 6-7 per cent growth in cement demand this fiscal.

Crisil highlighted that demand growth will be driven primarily by infrastructure spending, which meets about one-third of sector consumption, and by a nearly 18 per cent higher budgetary allocation for core ministries that should support project execution. Weaker rural housing demand amid pressure on agricultural incomes from a possible below-average monsoon may be offset by improved urban housing demand supported by favourable home-loan rates and a strong pipeline of Pradhan Mantri Awas Yojana-Urban projects. Ongoing capacity additions will keep capital expenditure elevated and may lift net debt to EBITDA to between 1.2 and 1.4 times from around 1.0 time last fiscal, though ratios are expected to remain healthy.

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Concrete

UltraTech Board Approves Rs 50 bn Fundraise Via NCDs

Company to issue half a million debentures for expansion plan

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UltraTech Cement’s board of directors has approved raising Rs 5,000 crore (Rs 50 bn) through non?convertible debentures issued in rupees.

The finance committee cleared a proposal to issue up to 500,000 fully paid, unsecured, listed, rated, redeemable, rupee?denominated, non?convertible, non?cumulative debentures of Rs 1 lakh each (Rs 0.1 mn each), aggregating to the Rs 5,000 crore programme.

As of June 2026 the firm reported net debt of Rs 15,875 crore (Rs 158.75 bn) and said its capacity expansion projects under execution are backed by capital expenditure of about Rs 17,000 crore (Rs 170 bn) over the next two to two?and?a?half years.

UltraTech spent Rs 9,500 crore (Rs 95 bn) on capital expenditure in financial year 2026 and in April the group crossed 200.1 mn tonnes per annum of domestic grey cement capacity and 205.5 mn tonnes per annum of global capacity.

The chief financial officer indicated the company would take consolidated capacity beyond 242 mn tonnes per annum, with grey cement capacity reaching 212.7 mn tonnes per annum by the end of financial year 2027. He noted the net debt?to?earnings before interest, taxes, depreciation and amortisation ratio stood at 0.87 times as of June 2026 and the company was confident of ending financial year 2027 with the ratio below one time.

In the first quarter of financial year 2026?27 UltraTech’s net profit attributable to owners rose 16.8 per cent year?on?year to Rs 2,599.3 crore (Rs 25.993 bn) and revenue from operations increased 15.9 per cent to Rs 24,648.20 crore (Rs 246.482 bn). The board approval is expected to complement internal cash flows as the company advances its expansion programme.

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Concrete

Lokesh Lays Stone For Rs 31 Billion Cement Unit In Kadapa

Line-2 expansion to make Kadapa a major cement hub

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Andhra Pradesh Education and IT Minister Nara Lokesh on Wednesday laid the foundation stone for the Line-2 expansion of Dalmia Bharat Cement at Chinnakomerla village in Mylavaram Mandal in Kadapa district. The project carries an investment of Rs 31 billion (bn) and is slated for completion by the third quarter of the financial year 2028. The expansion is intended to boost industrial growth and employment generation across the Rayalaseema region.

Once commissioned, the Kadapa facility will become Dalmia Bharat’s largest integrated cement manufacturing ecosystem in southern India, creating over 1,000 direct and indirect jobs and opening new business avenues for regional micro, small and medium enterprises and transport operators. Lokesh said the expansion signalled growing corporate confidence in the state and reflected the practical ease of doing business that secured repeat investment.

He placed the project within the government’s wider economic targets and recalled the Yuvagalam padayatra commitment to generate two million (mn) jobs within five years, noting that the state would cultivate talent while industry created opportunities. Lokesh highlighted Andhra Pradesh’s competitive pursuit of major manufacturing accounts, mentioning past successes and a personal initiative to engage global investors when persuading them to anchor expansion in the state.

The plant will leverage Kadapa’s abundant limestone reserves to scale production and sustainability. Clinker capacity is planned to rise from two point five million tonnes per annum (mn tpa) to six point one mn tpa, while overall cement output will increase from three point six mn tpa to nine point six mn tpa. The unit is designed to operate on over eighty per cent renewable energy and deploy waste heat recovery, zero liquid discharge, water recycling and advanced AI systems to optimise efficiency. Industries Minister TG Bharat, BC Welfare Minister S. Savitha and Jammalamadugu MLA C. Adinarayana Reddy attended the ceremony.

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