Concrete

Reduce use of mineral-based lubricants

Published

5 years ago

March 1, 2022

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Gopalkrishna Murthy, Vice President, Zuari Cement, discusses the importance of lubricants in maintaining the heavy machinery at cement plants and ensuring its smooth operation and cost savings.

What is the role of lubricants in maintaining the machinery of cement plants?
The main role of lubricants used in the machinery of a cement plant rotating. A lubricant is bought to help in the cement manufacturing process. They lubricate the bearings, rollers, engines or whatever is used in operations is lubricated to ensure smooth functioning of the plant.

How often are quality checks and maintenance functions performed in a cement plant?
All manufacturers of the equipment of the cement plant give manuals along with it that have time intervals like 100 hours, 500 hours or 5000 hours depending on the equipment application for the replacement or for quality checking. There is a compliance guideline and a laboratory for checking, examination and replacement of lubricants. Viscosity, total base number, contamination and wear depreciation are all examined based on the compliance guidelines. Other frequently conducted tests like checking for water contamination, exhaustion of the life of the lubricant, requirement of filtering of the lubricant for reuse etc., are checked. Generally, the number of hours, be it 500 hours, 5000 hours or 10,000 hours, depends on the equipment.
The general maintenance of a cement plant is usually done once in six months when there is a shutdown for refractory maintenance, mill maintenance etc. It is then when the condition of the lubricants like oil for the kiln, grease for the bearings is also checked. In any cement plant they have open gear systems for the mills which are regularly checked for spray patterns and application of lubricants if it is going in as instructed or not.
In rare cases when there is excess stock or if the plant stops for any reason, even then the lubricants are checked.

What are the types of lubricants used in a cement plant? Tell us about their applications.
In a cement plant, right from the beginning at the mining site, where shovels, extractors etc. are used, we use engine oils for the engines, hydraulic oils for the hydraulic systems and transmission oils for the transmission process.
In the plant, where there are multiple gear boxes, oils are used as lubricants. In kilns and open gears or spur gears, grease is used with a grease spray. This grease is also used for bearings throughout the plant. There are multiple motors in the plant, even though they are lubricated across the plant. Some of the motors have lubrication oil circulating systems also depending on the size of the motors. Circulating oils, lubricating oil and greases are used in a cement plant.

Does the external environment impact the choice of lubricants made for the plant?
One of the major considerations while selecting lubricants for equipment is to look at its working conditions. We look at the temperature in the area of function, exposure to dust, if the lubricant will work with the seal etc. All these factors are monitored and then a lubricant is selected for the application. Hence, the external environment plays a major role in selecting the lubricant for the cement plant.

How do you select your provider for lubricants and plant maintenance?
Ready availability is one of the key parameters we consider while selecting the lubricant provider for the plants. Other parameters like cost and quality certifications are what we look into while selecting the provider.
If any lubricant by a provider is certified or showed confidence in by our machinery supplier or equipment supplier, we consider them. If other players in the industry are using the lubricant, it shows a trust in their quality, then we consider them. If a lubricant provider has special application and certifications from member companies, appreciation and experience of their product in the market is looked at while selecting them. Another consideration is their viscosity grade and national or international certification of quality by recognised bodies.
After sales service is also an important aspect we look into for this selection, such as collecting samples, taking materials for testing and feedback, maintaining a data bank of the organisation and then the lubricant providers update it and share it with the concerned department. These become important considerations while selecting our
lubricant provider.

What are the standards you look for in a product before shortlisting them for your brand?
Generally, all the lubricants used in the cement plants have an ISO certified viscosity grade. Greases used are certified by the National Lubricating Grease Institute (NLGI) grades; oils used are certified by American Petroleum grades and military oil grades. They also have quality certifications from the original manufacturers. Sometimes, when the manufacturer makes an oil especially for their equipment, we consider that quality as well.

Does using lubricants for the plant have an impact on the environment? Can it be made more eco-friendly?
We ensure that whichever lubricant we use does not contaminate the environment. The lubricants should be made in such a manner that they can be re-filtered, recycled and reused. The plants usually push for longer drain intervals so that it reduces the impact on the environment when discarded. The lubricants should also be made in such a manner that they can be used as a source of energy or can be burned in the kilns without causing pollution to the environment. We consider these factors when we choose them for our plant.
Bio lubricants are now coming up in a big way and the industry is slowly reducing the use of mineral-based lubricants. Now there are multiple synthetic lubricants being formulated that are environment friendly. Their drain intervals are longer and hence, they can be used for a longer time, which means they are discarded at much longer intervals than other oils reducing the contamination of the environment and stay longer in the plants.

What innovative products do you suggest should be in the market for efficient cement plant lubrication?
There are two major requirements of the cement industry at this given time. Synthetic lubricants should be made for all kinds of applications and the cost should be in moderation that will allow more manufacturers to make the switch.
The cement industry consumes multiple lubricants and in large quantities. A scientific innovation should be made in the formulation to allow longer drainage intervals. Today the available synthetic lubricants are much costlier as compared to other type of lubricants and their drain intervals are also shorter.
The lubricants should also be energy efficient. If an organisation decides to invest in a higher costing lubricant, it should provide energy efficiency that will help them reduce their costs in other arenas. This would in turn make these lubricants environment friendly.

How do you foresee the collaboration of the lubricant industry and cement industry in the future?
Lubricant banks are developed by multiple oil industries, which they place in cement industries. This facility is not for all but cement plants do buy lubrication from the oil industry. However, this causes lack of availability. If all the lubricant manufacturers develop a banking type of structure in the plant campus itself, that will help in better interaction between the plant personnel and the lubricant makers and easy availability of the lubricants.
It will also help us recognise the many varieties of lubricants available in any category of lubricants which will help us make better informed choices and thus, improve the plant efficiency. The lubricant manufacturers will also have the opportunity to sell their best products and having these lubricants readily available on the plant campus will reduce lead time as well.
This development will make a better collaboration and interaction between the lubricant industry and cement industry.

-Kanika Mathur

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JK Lakshmi Cement to Expand EV Fleet to 120 Vehicles by March 2027

JK Lakshmi Cement has deployed more than 70 EVs across its logistics network.

Published

13 hours ago

October 30, 2026

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JK Lakshmi Cement has deployed more than 70 electric vehicles (EVs) across its logistics network and plans to increase the fleet to 120 vehicles by March 2027. The expansion is part of its decarbonisation strategy, which aims to reduce transport-related emissions and improve operational efficiency.

The company has achieved nearly 100 per cent EV-based clinker dispatches from its Sirohi plant in Rajasthan to the Kalol Grinding Unit in Gujarat. The transition marks an increased use of electric mobility for long-haul cement transportation and is intended to lower the environmental impact of logistics operations.

The existing fleet operates on routes connecting the Sirohi plant with the Kalol Grinding Unit, Palanpur Unit and Surat Grinding Unit. JK Lakshmi Cement is working with electric vehicle logistics providers SwitchLabs and Billion E to support fleet deployment and manage transportation requirements across these routes.

The company expects the planned expansion to increase the use of electric mobility throughout its logistics network for moving cement and clinker. Chairperson and Managing Director Vinita Singhania said the programme reflected the integration of sustainable practices with the company’s focus on long-term business efficiency, while describing the Sirohi–Kalol transition as an important step in its wider decarbonisation strategy.

The EV programme forms part of JK Lakshmi Cement’s green logistics and sustainability roadmap, alongside initiatives to improve efficiency and reduce emissions across its value chain. The company has set a long-term target of achieving net-zero emissions by 2047. It is part of the JK Organisation and operates integrated cement plants in Rajasthan and Chhattisgarh, along with grinding units in Gujarat, Haryana and Odisha. The company has an annual turnover of more than Rs. 60 bn, combined cement capacity of approximately 18 mn t per annum and a target to raise capacity to 30 mn t by 2030. Its portfolio includes ready-mix concrete, gypsum plaster, wall putty, primer, adhesives and fly ash blocks.

Concrete

Martin Engineering Appoints Ashwini Khunte as India General Manager

Published

19 hours ago

October 30, 2026

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Martin Engineering names Ashwini Khunte India General Manager to strengthen operations and drive growth across key bulk material handling sectors.

Pune

Martin Engineering, a global provider of bulk material handling solutions, has appointed Ashwini Khunte as General Manager of its India business, strengthening its leadership as the company expands its presence across the country’s cement, mining, steel, power and infrastructure sectors.

Khunte brings more than a decade of experience with Martin Engineering, having joined its Indian operations in 2013 as a Design Engineer, shortly after the company established its presence in the country in 2012.

A mechanical engineer by qualification, she spent her initial five years developing bulk material handling solutions in collaboration with the company’s operations team. During this period, she gained extensive experience addressing operational challenges in the steel, cement and coal industries. She subsequently moved into project engineering, managing major engineering, procurement and construction (EPC) and original equipment manufacturer (OEM) projects from initial enquiry to commissioning. Her responsibilities later expanded to overseeing Martin Engineering’s conveyor product portfolio in India, involving customer engagement, technical presentations and site visits across heavy industries.

In 2024, Khunte was promoted to Head of Sales & Marketing for the company’s Europe, Middle East, Africa and India (EMEAI) region. The position broadened her international market exposure and strengthened her strategic and commercial leadership capabilities.

Commenting on her appointment, Ashwini Khunte, General Manager, Martin Engineering India, said: “India represents a tremendous opportunity for Martin Engineering. The country’s continued investment in cement, mining, steel, power and infrastructure is creating increasing demand for safer, cleaner and more productive bulk material handling, and that’s exactly what we do. My priority will be to build on the strong foundations already established in India, while continuing to develop our people, strengthen customer relationships and bring practical solutions to the challenges faced by our industry.”

Robert Whetstone, Area Vice President – EMEAI, Martin Engineering, highlighted Khunte’s technical expertise, market understanding and leadership experience.

“Ashwini brings an exceptional combination of technical understanding, customer knowledge and commercial leadership. She has grown as Martin Engineering has grown, and has consistently demonstrated outstanding capability to transform her expertise into practical solutions. Her knowledge of the Indian market, together with her international experience, makes her ideally suited to lead our India business through its next stage of growth for years to come.”

Since establishing its Indian business in 2012, Martin Engineering has expanded its local workforce, manufacturing capabilities and dealership network. The company supplies conveyor products, transfer point solutions, material flow aids, training and technical support to bulk material handling industries. Khunte’s appointment positions the company to further strengthen customer relationships and expand its solutions portfolio in India’s growing industrial and infrastructure markets.

Concrete

CII Calls for Greater Alternative Fuel Use in Cement Industry

Published

2 days ago

October 29, 2026

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The Confederation of Indian Industry (CII), through its Green Business Centre and Energy Efficiency Council, inaugurated the 16th Conference on Alternative Fuel and Raw Material Usage (AFR) in Goa on 27 October 2026. The two-day conference brought together more than 350 industry leaders, policymakers, waste management experts and technology providers to explore strategies for accelerating alternative fuel adoption in India’s cement industry.

Held under the theme ‘Preparation for Net-Zero: Alternative Fuels & Raw Material in Cement Manufacturing’, the conference focused on reducing dependence on conventional fuels, improving waste utilisation and strengthening circular economy practices across cement manufacturing operations.

E R Raj Narayanan, Chairman, AFR Conference 2026, and Business Head and Chief Manufacturing Officer, UltraTech Cement, highlighted the industry’s progress in alternative fuel adoption. He emphasised the need to scale implementation, strengthen supply chains and extend circularity beyond fuel substitution to alternative raw materials through technological innovation and industry collaboration.

Harish Adconkar, Managing Director, Goa Waste Management Corporation, highlighted Goa’s progress in scientific waste management and refuse-derived fuel (RDF) production. He stated that approximately 765,000 tonnes of RDF had been supplied to cement plants, contributing to an estimated displacement of 320,000–560,000 tonnes of coal. He emphasised the importance of consistent RDF offtake and stronger coordination between urban local bodies, waste management agencies and cement manufacturers.

Dr L P Singh, Director General, National Council for Cement and Building Materials, identified AFR as an important opportunity for decarbonisation and resource efficiency. Drawing parallels with the industry’s successful utilisation of fly ash, he stressed the need to address quality, technological and economic challenges to expand alternative fuel adoption.

Dr Sharad P Kale, Special Advisor to the Chief Minister of Goa and former Head of Technology Transfer and Collaboration at BARC, emphasised treating waste as a resource. He highlighted decentralised biodegradable waste processing, reduced food waste and improved resource recovery as essential measures for minimising landfill dependence.

Kiran Ananth, Executive Director, Energy Efficiency, Renewable Energy and Green Entrepreneurship, CII-Green Business Centre, noted that India’s cement production reached approximately 491 million tonnes in FY2025-26, while the industry’s thermal substitution rate (TSR) stood at 7.5 per cent, with around 7 million tonnes of alternative fuels utilised annually.

He added that the industry had invested over Rs 12 billion in co-processing infrastructure during the past six years. Improving RDF supply reliability and quality assurance would be crucial to maximising the utilisation of existing infrastructure and accelerating industrial decarbonisation.

The conference also featured discussions on advanced AFR co-processing technologies, waste pre-processing solutions and industrial best practices for improving fuel substitution and resource recovery.

A publication titled ‘From Waste to Kiln: Scaling the Use of MSW-Derived RDF in Indian Cement Plants’ was launched during the inaugural session. The report identified inconsistent RDF supply and quality as major barriers to achieving higher thermal substitution rates.

According to the publication, many cement kilns already possess the technical capability to achieve higher alternative fuel substitution. However, variations in RDF availability, moisture content, particle size and calorific value continue to limit utilisation. The report emphasised the need to strengthen waste segregation, pre-processing and aggregation systems to establish reliable RDF supply chains.

The conference’s second-day agenda includes discussions on innovative domestic and industrial waste management solutions, alternative raw materials for low-carbon cement and strategies to increase alternative fuel utilisation across India’s cement manufacturing sector.