Technology
Cement companies are investing in technologies
Published
3 years agoon
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admin
Arvind Kakru, Director Sales, Rockwell Automation, talks about the difference digitisation can make in the cement manufacturing and distribution processes, its long term impact and its contribution to the sustainability efforts of the industry as a whole.
How important is digital transformation in cement plants? How can it impact the business positively?
The cement plant of the future will have to focus on lower operating costs and higher asset values, which would mean higher energy efficiency, yield and throughput. The big levers for the cement plants would be carbon emission, yield and throughput, process utilisations, automations, and more.
The objective or the ultimate gains that people are looking at are demand driven production, streamline quality and compliance, data and knowledge driven efficiency, risk management and secure operation of the plant. A lot of it has to go from the smart manufacturing point of view, that would not only result in increasing the safety and automating the decision making but also improve reliability, increased efficiencies, improved process controls, reducing power consumption of their energy efficiency which is a big thing for cement plants. Also, looking at real time monitoring, reducing the carbon footprint and improving the operational flexibility. And there are some things that we potentially opt for as solutions around the smart manufacturing space would be smart yield optimisation, asset life cycle management, creative quality, intelligent machine manufacturing, productive asset reliability and much more. Such things possibly give access to technology led innovations, also go on a little deeper in meeting the regulatory compliance, which could be statuary in nature, related to quality, compliance or even manufacturing standards of the cement industry in general. Since we all know that cement is a big contributor to the carbon dioxide emission, and these solutions are not the solutions just from the operations point of view but sustainability point of view which is impactful.
What is the expected monetary investment by cement organisations to make their plants adapt to new digitalisation?
This would vary from plant to plants or manufacturer to manufacturer. Also, depending upon what stage of digital journey they are on. Some people would be much more evolved and they already would have an investment, or seen business cases explained and executed. So, these are the people who possibly would spend much more.
People like us might be a little early in the cycle in that space. If I had to modify something, we would start from rupees forty to fifty lakhs, also which is around analytics and that could be used as a pilot case to be used to determine if there is a serious business case and that kind of investment would really pay off. Because the time for the execution would not be more than a few months and at the same point of time, the investment is not very much high. And they would possibly feel much more comfortable after evolving and evaluating that process and accordingly make the investments. This is very little investment and such investments are coherent which means that can be evolved and still be connected with other sections of the plant that could be integrated at the later stage, they are scalable, and ultimately going plant wide or the enterprise wide.
Other areas of benefit where small investments could result in big transformation could be processed digitalisation and process automation overall where 10 to 15 per cent is the estimated gain on the productivity. So, rupees forty to fifty lakh of investment could result in a much higher return of investment and possibly in less than a year. It could vary from a very small amount to ultimately a larger amount of capital expenditure which would be a few crore rupees but that could be distributed over a period of time. And if you go enterprise wise execution on the digital expansion or the digital roll outs for the programs looking at the multiple areas of the plant, process machinery, etc. it could go into a few years of capex and opex (recurring charges on the software that you possibly potentially upfront).
Multiple players in the industry are moving towards making cement production sustainable. How can your technology help in achieving those targets?
If you look at the labors for cement producers, they have increased in energy efficiency and use of alternate materials like fuel, raw materials, etc. The conventional measures to reduce carbon dioxide emission from cement manufacturing for further improvement in thermal energy efficiency and other innovative technologies that people keep on pursuing. This means all very significant in terms of transformation for the cement industry.
Talking about the commitment, by 2030 the cement industry contributes to possibly around 0.3 per cent annually, reducing the carbon emissions. So, process control becomes very critical to set your old machines to be very efficient, also making the plant connected which is a lot of technologies kept connected together because then you pull in individual resources and then get on to them at the corporate or an enterprise level which helps you look at everything like a dashboard or one consolidated level and that helps you to mind data through quality, production, process parameters and allowing operator to understand the energy consumption. Another big thing would be productive control, machine learning, etc. are some of the technologies that would be really helpful which possibly would help in productive maintenance forecasts. So when the failures occur, machine learning understands the forecasting orders and runs algorithms which predict failures, categorises them, observe the pattern and notify the people who need to know the insights. They also reduce the down time to reduce the maintenance cost related to that. AR, VR could be useful in space when you are looking at those downtimes, reducing them, and giving quality expert advice from remote rather than somebody physically traveling. This in turn results in quicker recovery or a turn-around time. Then there are things related to anomaly detection, which again comes from productive control or the machine learning part of cement operations such as grinding, blending, cooling, pre-heating. It detects failure or poor performance in the process and they also improve overtime making it easier for the cement plants to implement one or more solutions for persistent operative decision making. These are some of the areas which really help in energy performance, lowering the operating cost, improving the quality like reduction of raw materials, fuels, and also emission related to greenhouse gas and reduction contribution, because of all these process improvements in digital programs.
Tell us about the technology supporting the ‘Connected Cement Plant’.
You look at multiple levels in a particular program, one of the things is the devices operating on the shop floor or the manufacturing site. They have to be intelligent otherwise how will you get the data? So, we have to ensure that all of the data on the field level are intelligent devices, as in they have control over the process, they have sensors in place and have software connectivity which throws off the data on the larger enterprise level. Next is that when you connect these IoT gateways, you ensure that connectivity with process control with power equipment along the field which is actually controlling your machine and equipment in a particular manufacturing environment. And from there on you take it to the next level where you are controlling and after the monitoring, observing and taking a lot of data over there, which is helping in supply chain simulations, process optimisation, conditioning and monitoring the equipment and then throwing up to the next level, which is connecting all the third-party enterprises. And then look at process optimisation and then you connect them to a particular platform, which can be a scale up platform, control platform or an IoT platform related to visual analytics, remote monitoring, productive analytics and ultimately connecting to the enterprise and the business applications. You are connecting the suppliers of the market to the consumers. If you have that end-to-end visibility, it’s a great thing in terms of controlling the manufacturing operations, getting most out of your assets and design building, upgrading with confidence so as to take necessary decisions. We could see big things in the last two years during the Covid times and that is a helpful outcome of the digital process in a connected cement plant.
Cement plants often face challenges in understanding the fluctuating demand of the market. How can automation come to aid this challenge?
Cement countries are further exploring and investing in new age technologies which
includes artificial intelligence, machine learning, business analytics, and digital control towers to control and enhance supply chain and logistics visibility. Demand forecast helps in managing the demand and supply of the products, let’s say ready mix cement and complete supply and consolidated network of checkpoints, milestones, needs to be monitored for a very organised transaction. PwC (Pricewaterhouse Coopers) study says that digitised supply chains are the major revenue booster for cement manufacturing companies. An outgrown supply chain performs complex tasks from inventory, procurement to distribution of finished goods. Also, streamlines demand and inventory sourcing and distribution to the channel partners in the value chain overall. So, other than the inventory management, on the transportation side, how much fuel is consumed by the truckers is also monitored. We could optimise the transportation and make real time decisions on how demand is ramping up at some places or scaling down. If you also carry multiple operations, the states and geographies have varied rates of cement. So, one has to consider whether it is possible to transport from one manufacturing location to another region which is a more efficient manufacturing location and also profitable or not? It can even expand from the supply chain side of it all the fluctuating demand rate actually connecting with the operation and the top line and bottom line of the company.
How does The PlantPAx® distributed control system (DCS) help achieve efficiency in design and feature? How can the impact be quantified?
If you typically look at the DCS system of the cement plant, it has a behavioral pattern where the process automation includes instrumentation, power and control. So, there are electronics in the automation package which goes into the additional arenas as well also include control and instrumental package. We offer an open standard DCS distributed control system that has a flexible platform to address all ranges of plant sizes. It has a very high availability and redundancy to take care of running operation of the plant. There is no down time or failure. It has integrated diagnostics through which we are able to really look at what is happening right or wrong at your plant and accordingly take corrective actions. It has powerful and seamless connectivity with the field instrumentation and devices. The more connected you are the more ability you have in terms of looking at what is happening in a particular plant. And from there you can build up all the data which is at the heart of the system, then you have an embedded model equipped control with that you have premium integration with smart water control. So overall if you look at it there is simplified design, an improved operation, there is a safety and security part of it and its future ready enabled with the latest in the technology which can easily be connected with other intelligent devices across the manufacturing plant or any other place. It helps in manufacturing at the down time and is scalable. We have this feature in PlantPAx 5.0 onwards which reduces footprints and consistent delivery streamlining of workload, cyber security, and analytics enabled. It also results in empowering the operators and reducing the training cost for them. It also results in improved maintenance in all critical areas and helps in maintaining the availability. It enables decisions at a system level and also is very cyber secured and complied to ISA 99, ISA 62, which helps us to put in difference in depth solutions and help in making the process compliant, safe, secure and scalable.
Tell us more about the convergence of Information Technology (IT) and Operational Technology (OT) tools by Rockwell Automation. What is the return on investment a cement company expects on this technology investment?
Rockwell Automation is the company best known for its focus on Information Technology (IT) and Operational Technology (OT), we say we are the possibly the best company that has expertise in both areas. When we say convergence of IT and OT, the convergence of software and machinery in the production environment is assuring a new era of connected operations for a lot of industries and or cement also.
It offers enhanced levels of efficiency and opportunity for better decision making across all aspects of manufacturing and production. Connecting the process control measurement and safety system at a production site with IT infrastructure and application enables more connectivity for highly valuable time data and remote support. On the other hand, they want to minimise the risk of the outcome which can be managed in a very safe, secured and compliant way. There are multiple ways to integrate the process and ensure the information can flow freely across IT and OT systems, which would be to identify and align critical data facts to consider the entire supply value chain, fill in the security gap, set up for the third-party integration and enable capabilities.
If I look at securely converging IT and OT system which means potential, intentional network design and security at Rockwell Enterprises we address the cyber risk, connecting all asset converge plants via internet communications protocol, create an environment of real time resolution, and also look at the right execution standards and strategies, and maintain business continuity through implementation. It helps us to deliver the benefit to secure operation, reduce vulnerability and also achieve a lot of those benefits. In our own environment we tested in our factories, the annual production improvement included about 5 per cent apex, avoidance about 30 per cent inventory, in one particular case we reduced for 120-82 days and delivery went really good, also, the lead time was reduced by 50 per cent. It’s really important for people to make those decisions and gains are really big.
Data plays a huge role in bringing operational and productivity efficiency by connecting assets, people and information. How does your organisation make that happen through digital automation?
We start with smart devices, smart machines at some place which enables the data throw up at the enterprise level. Then the process automation and the package power overall which results in overall operation efficiency and modern technologies here improve the performance of process, equipment and people. A smart device we have a smart device and manufacturing overall connecting all the individual cells in a particular manufacturing environment and then taking it to larger manufacturing. Then looking at third party integration, market visibility which is from mining to market right where our consumers are and connected workforce. At the same point of time you throw up on the enterprise level a lot of data with the proper technologies you go into knowledge operation which means you offer solutions and enable better decision making. It’s like an end to end process from a basic manufacturing level to going right up to the enterprise level offering solutions that help you look at your past historical data, real time data (the current data). Also, in some cases you can have the data of the future which shows predictions.
What kind of innovative technological solutions for the cement plants can be expected in the future from your organisation?
We have been looking at some of the solutions already with some of the other industries where we have taken a lead. Cement did not used to be organised before and now that we see a lot of things coming in from the market point of view, regulatory point of view, sustainability point of view, helping people or cement manufacturers or the decision makers who focus aggressively on some of these things.
Talking about advanced process control which can be used to stabilise and optimise the key cement processes with the help of production increase in kilns and mills implications, controlling of energy usage which reduces in or helping in the reduction of process and quality variability. So, another thing was model productivity control which optimises material blending, optimises thermal and commercial control for kilns. We would offer data analytics and IoT environment, advanced algorithms that help in improving yield, through good quality, energy, efficiency, etc. which also helps in Automated tracking of Overall Equipment Effectiveness (AOEE). Typically, it’s in a machine or a discrete manufacturing environment that is very critical. And also, advanced analytic enabled software to make strategies to improve quality or equipment reliability. Looking at operations if they are running as per plans, natural disasters and planning which have been helpful in the past for certain manufacturers, they offer new opportunities for digital collaboration, assistance for trouble shooting in some cases over a video, etc. can improve training needs, enhancing the safety of the workers to a large extent. It’s very important to have a cyber security program in place which goes from identification to detection, to protection and finally helping in response and recovery quickly. Some of these strategies would help in ensuring that there is no cyber attack in the first place because your equipment, network is secured. Also model predictive control machine learning which really helps in utilising the mathematical models where MPCs used for responding changes to the process and variable. So, they help in reducing downtime and making the equipment much more efficient and making the process much more reliable.
–Kanika Mathur


As India’s cement industry heads for unprecedented growth, the importance of smart, sustainable and strategic lubrication is gaining ground. From reducing downtime and enhancing energy efficiency to enabling predictive maintenance, lubricants are transforming plant performance. ICR explores how advanced lubrication solutions are becoming critical enablers of reliability, resilience and environmental stewardship in the cement sector.
The Indian cement industry, a cornerstone of the nation’s infrastructure development, is experiencing significant growth. In 2023, India’s cement production reached 374.55 million tonnes, marking a 6.83 per cent year-on-year growth. Projections indicate that the market size will expand from 3.96 billion tonnes in 2023 to 5.99 billion tonnes by 2032, reflecting a compound annual growth rate (CAGR) of 4.7 per cent during 2024-32. This expansion underscores the increasing demand for efficient and sustainable operations within the sector.
In cement manufacturing, equipment such as kilns, crushers, vertical mills, ball mills, conveyors and fans operate under extreme temperatures, heavy loads and high dust exposure. These demanding conditions make proper lubrication not just essential, but mission-critical. Selecting the right type of lubricant and maintaining an effective lubrication regime can drastically improve machine uptime, reduce maintenance costs, and enhance plant safety. In many cases, lubricant-related failures account for a significant proportion of unplanned downtime, underscoring the value of a well-structured lubrication strategy.
The Indian cement sector is also undergoing a technological transformation, with increasing emphasis on automation, predictive maintenance and energy efficiency. In this evolving landscape, lubricants are no longer just consumables—they are enablers of performance, longevity and sustainability. With the growing availability of advanced lubricants and condition-monitoring technologies, Indian cement plants have the opportunity to optimise their lubrication practices in line with global standards. Additionally, tightening environmental regulations and sustainability goals are driving the shift toward eco-friendly lubricants and responsible usage practices, making lubrication management a key factor in both operational and environmental performance.
As the industry moves forward, there is a growing realisation that lubrication excellence can be a competitive differentiator. This article explores the critical role of lubricants in cement manufacturing, the latest technological advancements, the environmental considerations shaping lubricant use, and the challenges and opportunities for cement producers in India aiming to maximise equipment reliability and operational efficiency.
The role of lubricants in cement manufacturing
Cement manufacturing involves heavy-duty machinery operating under extreme conditions—high temperatures, heavy loads and continuous operations. Lubricants are essential in minimising friction, reducing wear and tear, and preventing equipment failures. Proper lubrication ensures that components such as kilns, crushers and grinding mills function optimally, thereby reducing downtime and maintenance costs.
Moreover, the integration of advanced lubrication technologies has enabled predictive maintenance strategies. By monitoring lubricant conditions, operators can anticipate equipment issues before they escalate, allowing for timely interventions and uninterrupted production cycles.
“Lubricants play a crucial role in enhancing the efficiency and reliability of cement plant operations. High-performance lubricants reduce friction and wear in critical machinery such as crushers, kilns, mills, and conveyors, ensuring smoother operation and extending equipment life. By minimising mechanical breakdowns and unplanned downtime, they contribute to consistent production and lower maintenance costs. Additionally, specialised lubricants designed to withstand high temperatures, heavy loads, and dusty environments help maintain optimal performance under demanding conditions. Proper lubrication also improves energy efficiency by reducing power loss due to friction. In essence, the right lubrication strategy not only enhances equipment reliability and operational uptime but also supports overall cost-effectiveness and productivity in cement manufacturing,” says Hiten Ved, Sales Head, Royal Petro Specialities.
In addition to enhancing equipment longevity, lubricants are pivotal in ensuring uninterrupted production cycles. Cement manufacturing is a 24/7 operation, and any unexpected downtime due to mechanical failure can lead to significant financial losses. Lubricants with high thermal stability and oxidation resistance prevent the breakdown of oil films under intense heat, especially in applications like rotary kilns, vertical roller mills and clinker coolers. By reducing the likelihood of equipment seizures or breakdowns, these lubricants act as silent enablers of plant reliability and uptime.
Gaurav Mathur, Director and Chief Executive Officer, Global Technical Services, says, “Wall paintings in tombs show workers using water to move statues, indicating early recognition of lubrication. By 1400 BC, animal fat was used to lubricate chariot axles, ever since then mankind has been relentlessly working to improvise the efficiency of lubricants. Tribological advancements have propelled industrialisation in the world. Machines working in demanding environment need better performance, however merely just better lubricant that is made from highly refined base oils is not good enough. Mineral and synthetic base oils and advanced additives chemistry have given birth to advanced lubricants. These lubricants have better performance characteristics and longer service life.”
“However, the way lubrication is done is more critical and if lubrication is not performed in a proper way, highest performing lubricants would also under perform compared to the lowest specification product. Total Lubrication Management has to be implemented for better machine reliability, equipment availability and lower down time. Implementation of TLM has paid rich dividends in the industry. Pillars of TLM being, contamination free lubrication, regular testing of lubricants to access the lubricant and machine condition and regeneration of lubricants,” he adds.
Lubricants contribute directly to energy efficiency. Friction losses within rotating equipment can account for up to 30 per cent of the total energy consumption in certain plant areas. Advanced synthetic lubricants, with low traction coefficients and superior film strength, reduce this internal resistance, thus improving mechanical efficiency and lowering the plant’s overall energy footprint. As Indian cement plants pursue energy benchmarking and ISO 50001 certifications, the use of high-performance lubricants becomes an integral strategy in achieving energy conservation goals.
“The cement industry has many lubrication points that require NLGI Grade 2 grease that can be used in high temperature applications. These may include bearings on vibrating screens and roller mills; rotating joints on grinding units; and various shafts, pivots, and metal to metal contact points found throughout the plant. CorrLube™ VpCI® Lithium EP Grease has a dropping point of 360 °F (182 °C), allowing it to be used in a broad range of temperatures. For areas that need a slightly harder grease of NLGI Grade 3, EcoLine® Biobased Grease offers a
similar dropping point of 365 °F (185 °C), explain Julie Holmquist, Marketing Content Writer,
Cortec Corporation.
Market dynamics: growth and trends
The Indian industrial lubricants market was valued at $13.05 billion in 2024 and is projected to reach $ 20.72 billion by 2033, growing at a CAGR of 4.12 per cent. This growth is driven by the expanding industrial sector, increased mechanisation, and the adoption of advanced machinery requiring specialised lubricants.
In the cement sector specifically, the demand for high-performance lubricants is rising. The lubricants for cement market are estimated to be $ 2.5 billion in 2024 and is expected to reach $ 3.9 billion by 2033, at a CAGR of 5.3 per cent from 2026 to 2033. This surge is attributed to the need for lubricants that can withstand harsh operating conditions and enhance equipment reliability.
Advancements in lubrication technology
Recent years have witnessed significant advancements in lubrication technology tailored for the cement industry. Synthetic lubricants, known for their superior thermal stability and longer service life, are increasingly being adopted. These lubricants perform effectively under extreme temperatures and heavy loads, common in cement manufacturing processes.
Additionally, the development of bio-based lubricants offers environmentally friendly alternatives without compromising performance. These lubricants, derived from renewable sources, reduce the environmental footprint and align with global sustainability goals. Their biodegradability and low toxicity make them suitable for applications where environmental considerations are paramount.
Smart lubrication systems are another breakthrough in the cement industry. These systems use IoT-enabled sensors and controllers to monitor lubricant condition in real time—tracking parameters such as viscosity, temperature, contamination levels and usage. This data is integrated into plant maintenance software to automate lubricant replenishment and alert operators to potential failures. Predictive lubrication ensures that each component receives the right amount of lubricant at the right time, minimising waste, reducing manual intervention, and extending machinery life.
“Many VpCI® products can be applied to surfaces with minimal pre-cleaning, and the protective VpCI® layer typically does not need to be removed before equipment is put back into service. VpCI® ‘s save significant labor, time, and associated costs compared to methods that require extensive surface preparation (e.g., sandblasting) and post-application cleaning or degreasing. This allows for faster startup after maintenance,” elaborates Ana Juraga, Content Writer, Cortec Corporation.
Furthermore, Original Equipment Manufacturers (OEMs) and lubricant suppliers are collaborating to develop application-specific lubricants tailored to the unique operating conditions of cement manufacturing units. For example, gear oils designed for high-load kilns or open gear systems now come with superior Extreme Pressure (EP) additives and anti-wear properties to cope with shock loading and variable speed operations. These co-developed solutions not only enhance mechanical reliability but also ensure compatibility with diverse materials used in modern cement equipment, ensuring peak performance in both greenfield and brownfield plants.
Sustainability and environmental considerations
The cement industry is under increasing pressure to reduce its environmental impact. Lubricants contribute to this goal by enhancing energy efficiency and reducing emissions. High-quality lubricants decrease friction, leading to lower energy consumption and, consequently, reduced greenhouse gas emissions.
Furthermore, the use of long-life lubricants minimises the frequency of oil changes, thereby reducing waste generation and disposal issues. The shift towards bio-based and recyclable lubricants also supports circular economy principles, promoting resource efficiency and environmental stewardship.
A report by Klüber Lubrication India suggests that sustainability continues to be a key focus for industries, the Securities and Exchange Board of India (SEBI) has mandated Business Responsibility and Sustainability Reporting (BRSR) for the top 1,000 listed companies. This framework requires organisations to disclose their environmental, social and governance (ESG) initiatives, including energy conservation, emission reductions and resource optimisation. Beyond compliance, BRSR reporting allows companies to showcase their sustainability leadership and build investor confidence. Organisations that proactively address sustainability challenges are better positioned to attract long-term investors, secure financing, and maintain a competitive advantage in an evolving regulatory landscape.
The report also states that their high-performance synthetic lubricants play a crucial role in helping cement manufacturers meet these regulatory requirements by enhancing energy efficiency and reducing CO2 emissions in critical machinery such as vertical roller mills (VRMs) and main gearboxes. By adopting our energy-efficient solutions, companies can strengthen their BRSR compliance while achieving tangible operational benefits.
An emerging trend in the lubricant industry is the formulation of biodegradable lubricants specifically tailored for heavy industries like cement manufacturing. These eco-friendly alternatives are made from renewable base stocks and are designed to degrade naturally without leaving behind harmful residues. In environmentally sensitive zones or operations with high spill risk, such as open gear applications or hydraulic systems exposed to the elements, biodegradable lubricants offer a sustainable solution that aligns with stricter environmental regulations and the growing emphasis on corporate social responsibility (CSR) in India’s industrial sector.
KB Mathur, Founder and Director, Global Technical Services, says, “In the world of industrial machinery, lubricating oils while essential; are often misunderstood in terms of their life cycle. When oils are used in machinery, they don’t simply ‘DIE’. Instead, they become contaminated with moisture (water) and solid contaminants like dust, dirt and wear debris. These contaminants degrade the oil’s effectiveness but do not render it completely unusable. Used lubricants can be regenerated via advanced filtration processes/systems and recharged with the use of performance enhancing additives hence restoring them. These oils are brought back to ‘As-New’ levels. This new fresher lubricating oil is formulated to carry out its specific job providing heightened lubrication and reliable performance of the assets with a view of improved machine condition. Hence, contributing to not just cost savings but leading to magnified productivity, and diminished environmental stress.”
Lubricant manufacturers are increasingly focusing on circular economy principles, offering oil analysis, filtration and recycling services that extend lubricant life and minimise waste. Used oil regeneration programs not only reduce disposal costs but also help cement plants meet regulatory norms under the Hazardous Waste Management Rules of India. This closed-loop approach not only lowers the environmental burden but also enhances economic efficiency—making sustainability a dual benefit for operational and ecological performance. As cement companies work towards science-based targets and carbon neutrality, lubricant selection and management play a more strategic role in meeting these broader sustainability commitments.
Challenges and opportunities
Despite the benefits, the adoption of advanced lubricants in the Indian cement industry faces challenges. These include the higher initial costs of synthetic and bio-based lubricants and a lack of awareness about their long-term benefits. Additionally, the integration of lubrication management systems requires investment in training and infrastructure.
However, these challenges present opportunities for innovation and collaboration. Manufacturers
can work closely with lubricant suppliers to develop customised solutions that meet specific operational needs. Moreover, government incentives and regulatory frameworks promoting sustainable practices can accelerate the adoption of advanced lubrication technologies.
Another key challenge is the limited awareness and technical training available at the plant level regarding proper lubrication practices. Many maintenance teams still rely on outdated methods such as manual greasing or fixed-interval lubrication schedules, which often lead to over-lubrication, under-lubrication or lubricant contamination. This results in premature equipment wear and higher operating costs. There is a growing need for skill development programmes and collaboration with lubricant suppliers to train technicians on best practices, condition-based monitoring, and the use of smart lubrication systems.
“Oil in the machine is like blood in the human body. There is no rotating machine that works without lubricants (liquid, semi liquid or solid). Based on the machine component, type of lubricant is used to minimise the mechanical changes in the machine. Lubricant being the product that separates two or more materials under movement. With modern machines being more and more sophisticated and tolerances being finer than before, cleanliness of Lubricants is critical, would the source of contamination be internal wear or external contamination. These contaminations rupture and compromises lubricant film, contamination particles when come in-between the fine tolerances, become cause of catastrophic failure,” expounds Gaurav Mathur.
At the same time, the industry is witnessing an opportunity to leverage digitalisation in lubrication management. Advanced lubrication tracking tools, coupled with ERP and maintenance software, can now offer real-time visibility into lubricant consumption, scheduling and health diagnostics. Integration of AI-powered analytics helps predict equipment failure based on lubricant data, enabling a shift from reactive to predictive maintenance. For Indian cement manufacturers aiming to digitise plant operations as part of Industry 4.0, lubrication is an ideal entry point that delivers immediate ROI and long-term gains in efficiency, asset life and sustainability.
Conclusion
As the Indian cement industry continues its trajectory of growth, the role of high-performance lubricants in ensuring operational reliability, energy efficiency and cost savings cannot be overstated. From kilns and crushers to ball mills and gearboxes, modern lubrication solutions are critical in
reducing downtime and maximising equipment lifespan. With rising demand and increased production pressures, cement plants must adopt a proactive approach to lubrication management—viewing it not as a routine maintenance task, but as a strategic pillar of plant performance.
Recent advancements in lubricant technology, such as synthetic formulations, nano-additives, and smart dispensers, have opened new avenues for boosting equipment efficiency and longevity. Digital tools and IoT-based systems now allow plant operators to monitor lubricant condition in real time, enabling predictive maintenance and minimising the risk of failure. As cement manufacturers increasingly pursue digital transformation and automation under Industry 4.0 frameworks, lubrication systems must be seamlessly integrated into broader asset management strategies.
At the same time, sustainability imperatives are reshaping lubrication choices. There is growing emphasis on biodegradable lubricants, optimised lubricant consumption, and environmentally responsible disposal practices. Overcoming challenges such as limited awareness, inconsistent maintenance practices, and cost sensitivity will require collaboration between lubricant manufacturers, OEMs and cement producers. The opportunities, however, are substantial—by aligning lubrication strategies with efficiency, digitalisation and sustainability goals, the Indian cement industry can significantly enhance its competitiveness and resilience in the years ahead.
– Kanika Mathur
Concrete
We consistently push the boundaries of technology
Published
2 months agoon
April 18, 2025By
admin
Swapnil Jadhav, Director, SIDSA Environmental, discusses transforming waste into valuable resources through cutting-edge technology and innovative process solutions.
SIDSA Environmental brings decades of experience and expertise to the important niche of waste treatment and process technologies. As a global leader that is at the forefront of sustainable waste management, the company excels in recycling, waste-to-energy solutions and alternative fuel production. In this conversation, Swapnil Jadhav, Director, SIDSA Environmental, shares insights into their advanced shredding technology, its role in RDF production for the cement industry and emerging trends in waste-to-energy solutions.
Can you give us an overview of SIDSA Environmental’s role in waste treatment and process technologies?
SIDSA is a leading innovator in the field of waste treatment and process technologies, dedicated to delivering sustainable solutions that address the growing challenges of waste management.
SIDSA is a more than 52-year-old organisation with worldwide presence and has successfully realised over 1100 projects.
Our expertise is in the engineering and development of cutting-edge systems that enable the conversion of waste materials into valuable resources. This includes recycling technologies, waste-to-energy (W2E) systems, and advanced methods for producing alternative fuels such as refuse derived fuel (RDF). The organisation prioritises environmental stewardship by integrating energy-efficient processes and technologies, supporting industrial sectors—including the cement industry—in reducing their carbon footprint. Through our comprehensive approach, we aim to promote a circular economy where waste is no longer a burden but a resource to be harnessed.
How does SIDSA Environmental’s shredding technology contribute to the cement industry, especially in the production of RDF?
SIDSA’s shredding technology is pivotal in transforming diverse waste streams into high-quality RDF. Cement kilns require fuel with specific calorific values and uniform composition to ensure efficient combustion and operational stability, and this is where our shredding systems excel. In India, we are segment leaders with more than 30 projects including over 50 equipment of varied capacity successfully realised. Some of the solutions were supplied as complete turnkey plants for high capacity AFR processing. Our esteemed client list comprises reputed cement manufacturers and chemical industries. Our technology processes various types of waste—such as plastics, textiles and industrial residues—breaking them down into consistent particles suitable for energy recovery.
Key features include:
- High efficiency: Ensures optimal throughput for large volumes of waste.
- Adaptability: Handles mixed and heterogeneous waste streams, including contaminated or complex materials.
- Reliability: Reduces the likelihood of operational disruptions in RDF production. By standardising RDF properties, our shredding technology enables cement plants to achieve greater energy efficiency while adhering to environmental regulations.
What are the key benefits of using alternative fuels like RDF in cement kilns?
The adoption of RDF and other alternative fuels offers significant advantages across environmental, economic and social dimensions:
- Environmental benefits: Cement kilns using RDF emit fewer greenhouse gases compared to those reliant on fossil fuels like coal or petroleum coke. RDF also helps mitigate the issue of overflowing landfills by diverting waste toward energy recovery.
- Economic savings: Alternative fuels are often more cost-effective than traditional energy sources, allowing cement plants to reduce operational expenses.
- Sustainability and resource efficiency: RDF facilitates the circular economy by repurposing waste materials into energy, conserving finite natural resources.
- Operational flexibility: Cement kilns designed to use RDF can seamlessly switch between different fuel types, enhancing adaptability to market conditions.
What innovations have been introduced in waste-to-energy (W2E) and recycling solutions?
SIDSA’s machinery is meticulously engineered to handle the complex requirements of processing hazardous and bulky waste.
This includes:
- Robust construction: Our equipment is designed to manage heavy loads and challenging waste streams, such as industrial debris, tires and large furniture.
- Advanced safety features: Intelligent sensors and automated controls ensure safe operation when dealing with potentially harmful materials, such as chemical waste.
- Compliance with standards: Machinery is built to adhere to international environmental and safety regulations, guaranteeing reliability under stringent conditions.
- Modular design: Allows for customisation and scalability to meet the unique needs of various waste management facilities.
How does your organisation customised solutions help cement plants improve sustainability and efficiency?
We consistently push the boundaries of technology to enhance waste management outcomes.
General innovations and new product development focus on:
- Energy-efficient shredders: These machines consume less power while maintaining high throughput, contributing to lower operational costs.
- AI-powered sorting systems: Utilise advanced algorithms to automate waste classification, increasing material recovery rates and minimising errors.
- Advanced gasification technologies: Convert waste into syngas (a clean energy source) while minimising emissions and residue.
- Closed-loop recycling solutions: Enable the extraction and repurposing of materials from waste streams, maximising resource use while reducing environmental impact.
What future trends do you foresee in waste management and alternative fuel usage in the cement sector?
Looking ahead, several trends are likely to shape the future of waste management and alternative fuels in the cement industry:
- AI integration: AI-driven technologies will enhance waste sorting and optimise RDF production, enabling greater efficiency.
- Bio-based fuels: Increased use of biofuels derived from organic waste as a renewable and low-carbon energy source.
- Collaborative approaches: Strengthened partnerships between governments, private industries and technology providers will facilitate large-scale implementation of sustainable practices.
- Circular economy expansion: The cement sector will increasingly adopt closed-loop systems, reducing waste and maximising resource reuse.
- Regulatory evolution: More stringent environmental laws and incentives for using alternative fuels will accelerate the transition toward sustainable energy solutions.
(Communication by the management of the company)
Concrete
FORNNAX Technology lays foundation for a 23-acre facility in Gujarat
Published
3 months agoon
March 17, 2025By
admin
FORNNAX Technology, a leading manufacturer of recycling equipment in India, has marked a major milestone with the Groundbreaking (Bhoomi Pujan) ceremony for its expansive 23-acre manufacturing facility in Gujarat. Specialising in high-capacity shredders and granulators, FORNNAX is strategically positioning itself as a global leader in the recycling industry. The new plant aims to produce 250 machinery units annually by 2030, making it one of the largest manufacturing facilities in the world.
The foundation stone for this ambitious project was laid by Jignesh Kundaria, CEO and Director, alongside Kaushik Kundaria, Director. The ceremony was attended by key leadership members and company staff, signifying a new chapter for FORNNAX as it meets the growing demand for reliable recycling solutions. Speaking on the occasion, Jignesh Kundaria stated, “This marks a historic moment for the recycling sector. Our high-quality equipment will address various waste categories, including tyre, municipal solid waste (msw), cables, e-waste, aluminium, and ferrous metals. this facility will strengthen our global presence while contributing to India’s Net Zero emissions goal by 2070.”
FORNNAX is actively expanding its footprint in critical markets such as Australia, Europe and the GCC, forging stronger sales and service partnerships. The facility will house an advanced Production Department to ensure seamless manufacturing.

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