Concrete
Mukutban plant is among the most advanced cement plants: Birla Corp
Published
3 years agoon
By
admin
Arvind Pathak, MD & CEO, on why the plant was planned in Maharashtra
Birla Corporation had signed a deal with Reliance Infrastructure whereby it took over its cement production unit (RCCPL) for Rs 4,800 crore at a valuation of $140 a tonne* in 2016. RCCPL had three cement units — an integrated cement plant at Maihar (Madhya Pradesh) and grinding units at Kundanganj (Uttar Pradesh) and Butibori (Maharashtra) — with an aggregated capacity of 5.58 mtpa (million tonne per annum) of cement and 3.30 mtpa of clinker. With the Mukutban plant and debottlenecking, the total capacity under the RCCPL units comes to 9.81 mt against its operational capacity of 10.19 mt in its holding company, which includes plants in Satna, Chanderia, Durgapur and Raebareli.
Arvind Pathak, Managing Director & CEO, Birla Corp, shares more on the Mukutban plant, its technological advancements and why the plant was planned in Maharashtra in conversation with Shriyal Sethumadhavan.
At Rs 2,744 crore, the Mukutban plant is the Company’s largest greenfield investment in its history. In terms of operational capacity of 3.9 mt, it is second to your Chanderia plant in Rajasthan, which has 4 mt. How would you distinguish its technical prowess?
I would compare the Mukutban plant to the Maihar plant in Madhya Pradesh. Maybe, the cement grinding capacity in Chanderia could be higher because it does not have any attached grinding unit. Whereas in Maihar, if you look at it clinker-wise, it is a 10,000-ton per day unit. Also, Maihar so far has the distinction of being our most efficient plant. But the Mukutban plant would be a step ahead as it is supported by all the latest technological changes.
In terms of parameters of technology and efficiency, what makes this plant one of the most advanced cement factories in the country?
The plant incorporates state-of-the-art technology. It is 100 per cent operated on captive power, which will give us a cost advantage over time. We have also opted for an air-cooled condenser wherein we are trying to conserve the water required for cooling fuel gases within the plant. The entire conveying system is done through belts. We do not have any mobile equipment in place and the gamma metrics control helps us make the stockpile. We have opted for a roller press, which is the most efficient mode for this type of raw material. Every equipment we have used is the most efficient in the country or maybe in the industry across the world.
Also, tell us about the plant’s efforts towards minimising water consumption and the technology used to achieve the same.
The highest water consumption takes place in a power plant. The hot flue gases need to be condensed and the water recirculated. Instead of water cooled, we have gone in for an air cool condenser. Although it is slightly more power consuming, it saves a lot of water. Also, normally in cement plants, they use vertical mills, which also do not require much water. For the cooler for the clinker, after it comes out, companies generally economise on the length, saving on the capex, and only to control the exit temperature of the clinker, water is sprayed on it. However, we have opted for the full length of the cooler and are trying to cool it with the air from cooler fans. We have the permission to utilise ground water but we do not intend to use it. When it comes to full capacity, this plant will be water-positive.
Further, you have used fly ash – a waste product of thermal power plants – to build the plant….
Most infrastructure companies and companies developing multi-storied sites would prefer OPC cement. This is not because of any difference in quality, performance or durability but for speed of construction. The industry is aware of the positive attributes of blended cement. With inhouse R&D, we tried to see if the setting time required with the fly-ash-based cement could more of less match that of OPC. Once we cracked this, we wanted to use it as a demonstration both for the construction industry as well as from the point of view of sustainability. We wanted to walk the talk and show the world that a big plant of this nature could also be constructed in time using fly ash-based cement. We wanted to demonstrate that this product can be as efficiently used for speedy construction as OPC.
With regard to cement production in this plant, will the consumption of slag and fly ash be scaled up?
Going forward, our endeavour would be to have 100 per cent blended cement, be it with the use of slag or fly ash. Delivery is key. We need to educate the market and our customers and, if we can offer the benefit of speed of construction, we could expect to see demand.
The pandemic’s impact on the world economy, the cement industry in India and major disruptions on account on COVID-19 must have led to several challenges, such as logistics, labour shortages and stoppage of work. How did you build this plant in these tough circumstances?
We did two things that helped. In hindsight, the infrastructure facilities created for the contractor’s workmen were far superior to what is normally found on construction sites. This resulted in hygiene, and good health and comfort of all employees working with us. Along with excellent facilities, we provided an online mechanism or toll-free lines where their family members could reach out for help. With this, they were individually satisfied with the infrastructure they had and, relatively, had some comfort that their families were being attended to. With these efforts, though we could not mitigate the challenges 100 per cent, the impact was reduced to a large extent, enabling us to complete this project without huge delay despite three waves of COVID.
Also, achieving 10 million manhours of construction with zero accidents and the completion of the entire project without a single major accident or fatality is a unique achievement in the cement industry. How was this achieved?
It was a concentrated effort. We did hire and take the help of an external agency. This ensured that all systems and processes were followed and no deviations permitted. We also ensured extensive training for everybody who entered the project site. This training was reinforced time and again to ensure everyone was always up to the mark. Some refresher courses were also extended. Last, our protocols for every typical job – having a hazard review and then taking appropriate measures under the expert guidance of our consultants – yielded significant results.
How do you see this plant further supporting your footprint in western India?
At Birla Corporation, we normally prefer expanding the market adjoining the unit where we operate. If we are operating in Madhya Pradesh, in some parts of Rajasthan, it does make logical sense to us to move in a continuous direction till we go pan India. Maharashtra being an important State, we felt we should move our footprint in this direction. From the Maharashtra plant, we will be selling cement to Telengana. So, tomorrow, if we have to make an entry into Telengana, there will be some base that will always exist there. Such is our approach.
The geopolitical scenario has had its share of impact on cement and steel prices. How has the company been addressing this situation?
While production has not been affected much, the cost of production has certainly been impacted. Amid this scenario, we have been innovating some ways of working. And if you can keep ahead of your competitors, it does not hit us that badly. In absolute terms, yes; but in relative terms, it may not. Ultimately, if this is going to be the scenario going forward, or some amount of this increases, we will mitigate it through some innovative measures.
A significant portion of the cost is especially because of fuel and power. Power is also nothing but coal. With the rise in coal prices, the Ukraine war, the quantum of coal we require and the power crises in our country, the only silver lining we see is that we already have one coal mine. We are expecting to start one more before year-end. This is a testing time for us for the next six to seven months. Once these two coal mines are in operation, we will be covering 40 to 50 per cent of our fuel requirement.
Please tell us about your products.
We have one of the largest product bouquets in the industry. As we have been selling in Maharashtra for quite some time, we know the requirements of the State. What we are offering today is superior to other products within the same bracket available in the market. What we bring to the customer is value for money.

Concrete
Adani’s Strategic Emergence in India’s Cement Landscape
Published
2 weeks agoon
September 16, 2025By
admin
Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.
India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.
Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:
- September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
- December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
- August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
- April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
- Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
- Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
- Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
- Orient Cement: It would serve as a principal manufacturing facility following the merger.
Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:
- By FY 2026: Reach 118 MTPA
- By FY 2028: Target 140 MTPA
These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).
Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.
Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.
Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.
Challenges potentially include:
- Integration challenges across systems, corporate cultures, and plant operations
- Regulatory sanctions for pending mergers and new capacity additions
- Environmental clearances in environmentally sensitive areas and debt management with input price volatility
When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.
Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.
About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.
Concrete
Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series
Published
1 month agoon
August 16, 2025By
admin
PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.
Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.
Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.
Beyond energy efficiency, the retrofit significantly improved operational parameters:
- Lower thermal stress on equipment
- Extended lubricant drain intervals
- Reduction in CO2 emissions and operational costs
These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.
Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:
- Enhanced component protection
- Extended oil life under high loads
- Stable performance across fluctuating temperatures
By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.
Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.
A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

Adani’s Strategic Emergence in India’s Cement Landscape

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

Driving Measurable Gains

Reshaping the Competitive Landscape

CCU testbeds in Tamil Nadu

Adani’s Strategic Emergence in India’s Cement Landscape

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

Driving Measurable Gains

Reshaping the Competitive Landscape
