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Optimisation is about doing more with less

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Rizwan Sabjan, Head – Regional Sales Enablement, FLSmidth, sheds light on the use and implementation of connectivity-based technologies and AI for the smooth transitioning of the cement industry from manual to automated processes that make cement plants more sustainable and greener.

Tell us about the role of technology in increasing the productivity of cement. Which of your equipment can contribute to the same?

Recently, the cement industries have seen a change in what shapes growth. The spotlight has shifted from increasing capacity to enhancing productivity. Digitisation has considerable advantages to make this shift possible. To support our customers, we are building a growing portfolio of digital solutions that connect, monitor and optimise performance, in response to the demands of this changing business landscape. We call it FLSmidth ENABLR, because it enables customers to simplify their operations and improve productivity.

Which technology is underrated and less used by cement makers, but is likely to prove beneficial in the long run?

Advance Process Control systems are very often seen as one of the main drivers needed to reach the dream of autonomous operations. In this context, it’s commonly portrayed in the media that artificial intelligence (AI) is replacing APC systems. But this wrongly assumes that AI is already a synonym for fully autonomous operations. This kind of misrepresentation does not help, as such fully autonomous continuous-process plants are still not that close to reality. The ability of AI technologies to continuously adapt to changing conditions to find the optimal operating parameters and targets is one of the key areas in which AI can improve the ability of APC systems to optimise cement processes.

Cognitive augmentation: The ability to gather, analyse and combine various data streams in real time can bring relatively quick benefits from operational and safety perspectives. One example would be building new virtual sensors to replace unreliable or unavailable signals, particularly when the instrumentation is placed in risky areas or is often out of service.

Smart controllers: In certain contexts, controllers, such as linear and non-linear MPCs or fuzzy, can be enhanced and complemented by virtual models of machinery or processes, known as digital twins. If the digital twins are done well, they can be used to find the controller’s optimum parameters, which leads to more stable processes, achieves higher production and quality levels, or decreases the amount of energy or water used.

Dynamic adaptiveness: Many cement processes are by nature nonlinear and time-varying: this means that actions that were optimal to achieve specific goals yesterday (or even an hour ago) may be suboptimal or even inefficient now. A clear example of this is the cement kiln, where a strong push to substitute fossil fuels with alternative fuels, in as high a ratio as possible, makes stabilisation and optimisation a challenging task, both for human and expert systems.

Most equipment and machinery in plants are often regularly inspected visually. Can these inspections be made more precise and pre-empt damage to save downtime and costs?

With equipment in continuous use, damage can happen at any time. While visual inspections are important to provide broad, contextualised operational insights, relying only on intermittent site visits puts customers at the risk of missing the early warning signs that could enable them to drastically reduce both downtime and expenses. Online condition monitoring is a continuous service that enables customers to detect potential failures well in advance, giving them plenty of time to take preventative action and avoid actual failure.

All these symptoms warn the customers that damage is imminent. In many cases, when the visible symptoms appear, it is already much too late for an ‘easy’ fix. By contrast, sensors on customer equipment are able to capture data that may be otherwise ‘invisible. Our online condition monitoring services connect this data to the cloud where it is continuously monitored and trended. If something is wrong, an alarm notifies our team of experts who are able to analyse the data remotely and develop a recommended action plan to rectify the fault well ahead of it escalating. It’s a low-stress, low-cost, low-risk approach to maintenance that offers high returns.

Kanika Mathur

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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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