Concrete

Mukutban plant incorporates state-of-the-art technology

Published

4 years ago

July 19, 2022

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Arvind Pathak, MD & CEO, Birla Corp, shares more on the Mukutban plant, its technological advancements and 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.

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 research and development, we tried to see if the setting time required with the fly-ash-based cement could more or 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 man hours 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 hired and took 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 Telangana. So, tomorrow, if we have to make an entry into Telangana, 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.

-Shriyal Sethumadhavan

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Concrete

ABB Extends Drive Lifespan at ACC Cement Plant Without Production Shutdown

Published

1 day ago

November 12, 2026

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ABB reconditions 25 drives at ACC’s Jamul cement plant, avoiding 16 tonnes of CO₂ emissions while improving reliability through predictive maintenance.
Chhattisgarh

ABB has signed a multi-year Motion OneCare service agreement with ACC Limited, part of the Adani Group, to modernise ageing industrial drives at its Jamul cement plant in Chhattisgarh, improving operational reliability while avoiding approximately 16 tonnes of carbon dioxide (CO₂) emissions without disrupting production.

Announced on 27 October 2026, the agreement combines scheduled drive reconditioning, digital condition monitoring and energy appraisals to extend equipment lifespan, improve plant uptime and optimise maintenance costs. The initiative marks a shift from conventional equipment replacement towards a more resource-efficient approach to industrial asset management.

The first phase, completed in April 2026, involved the on-site reconditioning of 25 ABB ACS800 variable speed drives without a major plant shutdown. By retaining the existing cabinets and restoring the drive modules rather than replacing entire panels, ABB helped ACC preserve capital investment, minimise material consumption and avoid approximately 16 tonnes of CO₂ emissions.

A second phase, covering an additional 25 ACS800 drive modules, is scheduled for the fourth quarter of 2026. The programme is designed to improve long-term equipment reliability while allowing maintenance activities to be aligned with the plant’s operational schedules.

The ACS800 drives, installed at Jamul in 2010, had delivered more than a decade of near-continuous service in demanding cement manufacturing conditions. However, ageing electrical components and changing fault patterns had begun to affect their ability to meet the plant’s reliability requirements.

Rather than opting for complete equipment replacement, ACC engaged ABB’s certified engineers to conduct a comprehensive asset health assessment. The evaluation found that the existing cabinets and enclosures remained structurally sound, making targeted reconditioning a technically viable and cost-effective alternative to full replacement.

Drawing on nearly two decades of experience with ACC’s equipment and operating requirements, ABB developed a maintenance framework tailored to the plant’s shutdown windows, budget cycles and production priorities.

The Motion OneCare agreement incorporates planned equipment restoration, condition-based monitoring and energy assessments, enabling ACC to adopt a more systematic approach to maintaining critical electrical infrastructure.

As part of the programme, ACC has implemented ABB Ability™ Digital Powertrain Insights to monitor drive performance and identify emerging operational issues before they result in equipment failures.

The digital platform provides continuous visibility into parameters such as temperature, current, vibration and fault patterns. These insights allow maintenance teams to detect early signs of equipment deterioration, schedule interventions more effectively and reduce the likelihood of unexpected downtime.

Amit Gupta, Local Division Manager, Motion Services, ABB India, said: “We know what unchecked wear costs over time: a small inefficiency that eats away at ROI for years. At Jamul, the evidence pointed clearly to assets with productive life still in them.”

“Our job was to restore them properly and give the team the tools to stay ahead of the next problem. At ABB, we don’t just fix what fails. We want to protect what works.”

The initiative also demonstrates the growing relevance of circular economy principles in cement manufacturing, where extending the service life of existing industrial equipment can reduce capital expenditure, material consumption and the environmental impact associated with manufacturing replacement components.

According to ABB, drive reconditioning can reduce lifecycle emissions by 50 to 80 per cent compared with complete equipment replacement. By preserving functional components and restoring critical modules, the process helps retain the economic and material value of existing industrial assets.

The addition of energy appraisals in subsequent phases will further expand the programme beyond equipment restoration, enabling ACC to assess drive performance, identify energy-saving opportunities and improve operating efficiency.

For cement manufacturers, variable speed drives play an important role in controlling motors and optimising energy consumption across production processes. Maintaining their reliability and efficiency is essential for minimising operational disruptions and managing electricity costs.

Vinod Bahety, CEO – Cement Business, Adani Group, said: “Moving from reactive firefighting to a structured maintenance plan was exactly what this operation needed. That kind of peace of mind doesn’t come easily. It comes from a partner that understands how your business runs.”

“We didn’t need a full system overhaul; we needed expert support, actionable insights, and a plan we could execute around our schedule. That’s what we got.”

The project supports ACC’s broader strategy to improve manufacturing efficiency through digital transformation, preventive maintenance and sustainable asset management.

ACC, a subsidiary of Ambuja Cements and part of the Adani Group, operates 20 cement manufacturing facilities and 119 ready-mix concrete plants across India. The company has been advancing initiatives focused on renewable energy, circular economy practices and technology-driven operational improvements.

Alongside Ambuja Cements, ACC is part of a large-scale building materials business committed to achieving net-zero emissions by 2050, with near-term and net-zero targets validated by the Science Based Targets initiative (SBTi).

The Jamul initiative aligns with these sustainability objectives by demonstrating how equipment life extension and digital monitoring can contribute to resource efficiency without requiring large-scale replacement of existing infrastructure.

ABB, a global technology company specialising in electrification and automation, brings more than 140 years of industrial expertise and employs approximately 110,000 people worldwide. Its Motion Services business supports industrial customers through equipment maintenance, modernisation, digital monitoring and lifecycle management solutions.

The agreement also reflects a wider shift in industrial maintenance practices, with manufacturers increasingly adopting predictive technologies to improve equipment availability, manage costs and reduce unplanned shutdowns.

With 25 drives already reconditioned and another 25 scheduled for restoration, ABB’s collaboration with ACC illustrates how targeted modernisation, digital monitoring and circular maintenance practices can extend the operational life of critical equipment while supporting more efficient and sustainable cement production.

Concrete

ABB Drives Digital Transformation at TCI MAX Cement Plant in J&K

Published

2 days ago

November 12, 2026

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ABB deploys advanced process control at TCI MAX’s Srinagar cement plant to improve clinker quality, energy efficiency and sustainable manufacturing.

Kashmir

ABB has deployed its advanced process control technology at TCI MAX Cement’s Srinagar facility in Jammu and Kashmir, marking the region’s first reported implementation of advanced process control (APC) in cement manufacturing and strengthening efforts towards more efficient, digitally enabled production.

Announced on 5 November 2026, the deployment of ABB Ability™ Expert Optimizer at the facility, operated by Trumboo Industries Pvt. Ltd., aims to improve process stability, clinker quality, energy efficiency and overall plant productivity. The implementation forms part of TCI MAX’s strategy to modernise its manufacturing operations through automation and digital technologies.

Following the integration of ABB’s advanced process control solution and supporting IT infrastructure, TCI MAX has reported improvements in operational productivity, product quality and sustainability-related performance indicators. The technology focuses on optimising the cement pyro process, a critical stage of production involving high-temperature processing and clinker formation.

Waseem Ahmed Trumboo, Director, Trumboo Industries Pvt. Ltd., said: “Introducing advanced process control at TCI MAX is an important step in how we are evolving our operations. Our focus is on improving the stability and efficiency of our processes while maintaining consistent clinker quality. We have been encouraged by the performance of the solution during commissioning and by the support from the ABB team, and we look forward to realizing its full potential.”

ABB Ability™ Expert Optimizer combines advanced process control, model predictive control (MPC) and artificial intelligence (AI) to continuously monitor and optimise manufacturing operations. By analysing process conditions, predicting operational behaviour and automatically adjusting key parameters, the system enables more consistent production while reducing process variability.

In cement manufacturing, maintaining stable pyro-processing conditions is essential for achieving uniform clinker quality and optimising thermal energy consumption. Fluctuations in operating parameters can affect fuel efficiency, production output and product consistency.

The deployment is designed to address these challenges through real-time process optimisation, helping operators maintain more stable kiln operations while improving the utilisation of fuel, electricity and raw materials.

Kapil Agarwal, Senior Vice President and Local Division Manager, Process Industries Division, ABB India, said: “Cement producers are increasingly looking to adopt digital technologies to achieve greater consistency and efficiency while addressing their sustainability priorities. ABB Ability™ Expert Optimizer brings advanced process control and deep cement process expertise together to help operators make their processes more stable and efficient. We are pleased to support TCI MAX as it takes this important step in its digital transformation.”

The technology also supports sustainability objectives by optimising fuel consumption, improving electrical energy efficiency and minimising process waste. More stable operations can contribute to lower energy intensity and reduced emissions associated with cement production.

For TCI MAX, the investment represents a move towards data-driven manufacturing, where automated control systems complement operator expertise to improve production performance and operational reliability.

The implementation is particularly significant for Jammu and Kashmir’s cement industry, as it introduces advanced process optimisation technology to a regional manufacturing facility. Its deployment could demonstrate the potential for wider adoption of digital automation across cement plants seeking to modernise their operations.

The project builds on ABB’s experience in delivering advanced process control solutions to cement manufacturers worldwide. Through the integration of industrial automation, predictive technologies and process engineering expertise, the company supports manufacturers in improving resource efficiency and maintaining consistent production quality.

As cement producers face increasing pressure to manage energy costs, improve productivity and reduce their environmental footprint, technologies such as AI-enabled process control and predictive optimisation are becoming important components of plant modernisation strategies.

ABB’s Expert Optimizer provides a platform for addressing these priorities by enabling automated adjustments based on changing process conditions, reducing reliance on manual intervention and supporting more efficient plant operation.

ABB, a global technology company specialising in electrification and automation, has more than 140 years of industrial experience and approximately 110,000 employees worldwide. Its Automation business employs around 26,000 people and provides technologies and services across process, hybrid and maritime industries.

The TCI MAX deployment reinforces ABB’s growing role in the digital transformation of cement manufacturing in India, where improving process efficiency and reducing energy consumption remain critical to the industry’s long-term sustainability.

With the advanced process control system now implemented at its Srinagar facility, TCI MAX aims to build on the initial operational improvements and further optimise production efficiency, clinker consistency and environmental performance.

Concrete

Ramco Cements’ Hard Worker Wins Eight Awards at ‘Love of Advertising Awards 2026’

Published

2 days ago

November 12, 2026

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Ramco Cements’ Hard Worker brand wins eight awards for excellence in advertising, packaging and brand identity at the Love of Advertising Awards 2026.

Hyderabad

The Ramco Cements Limited’s construction chemicals brand, Hard Worker, has secured eight awards at the Love of Advertising Awards 2026, recognising its creative excellence across television, digital advertising, packaging design and brand identity.

Organised by the Advertising Club of Trivandrum, the awards were presented at a ceremony held at The Leela Raviz, Kovalam, on 24 October 2026. The recognition highlights Hard Worker’s integrated marketing strategy and its efforts to establish a distinctive presence in India’s competitive construction chemicals market.

The eight awards span multiple creative categories, reflecting the brand’s approach to combining product-focused communication with engaging storytelling, humour and innovative design. Through its campaigns, Hard Worker has sought to simplify technical product benefits and make construction chemicals more accessible and relatable to consumers and construction professionals.

Built around the philosophy of “Hard-working products for hardworking people”, the brand focuses on communicating practical product advantages through memorable advertising narratives while maintaining a consistent identity across different marketing platforms.

Its campaigns for Ramco Hard Worker Eco Plaster and Tile Fix have been central to this approach. The Eco Plaster campaign highlights water conservation through the product’s self-curing properties, positioning it as a solution that supports more efficient construction practices. Meanwhile, Tile Fix promotes specialised tile-fixing solutions by presenting their practical benefits through relatable situations and creative storytelling.

Beyond advertising, Hard Worker has invested in distinctive packaging and brand identity development to improve product recognition and maintain consistency across customer touchpoints. This integrated approach has helped the brand differentiate itself in a category where marketing communication has traditionally focused on technical specifications and functional performance.

A V Dharmakrishnan, CEO, Ramco Cements, said, “Winning eight awards at the Love of Advertising Awards is a proud moment for Ramco Cements and the Hard Worker team. We believe that building a strong brand requires not only quality products but also the ability to communicate their value in a compelling and differentiated manner. Hard Worker’s journey reflects our commitment to combining product performance with innovative marketing to create meaningful connections with our customers and strengthen our presence in the construction chemicals market.”

The recognition comes as building materials manufacturers increasingly focus on brand differentiation, product awareness and customer engagement to strengthen their position in the construction chemicals segment.

By using humour and storytelling to explain product applications and benefits, Hard Worker aims to bridge the communication gap between technical construction solutions and the practical requirements of contractors, applicators and end-users.

Balaji K. Moorthy, Executive Director – Marketing, Ramco Cements, said, “Hard Worker was conceived to bring a fresh perspective to the construction chemicals category, where product communication has traditionally been functional and technical. Our endeavour has been to break through the clutter with distinctive ideas, humour and storytelling, while keeping the product proposition at the heart of every campaign. The recognition across TV and digital advertising, packaging design and brand identity design demonstrates our integrated approach to building the brand. These eight awards are an encouraging recognition of the creative thinking and collaborative effort behind Hard Worker’s marketing initiatives.”

The awards add to Hard Worker’s growing portfolio of creative recognitions and reinforce Ramco Cements’ emphasis on integrating product innovation with strategic marketing.

The brand’s communication initiatives also reflect a wider shift in the construction materials industry, where manufacturers are increasingly adopting consumer-focused marketing strategies to improve product understanding and strengthen relationships with construction professionals.

With its portfolio of construction chemicals, Hard Worker aims to address evolving requirements for durability, application efficiency and construction quality. Its marketing efforts seek to complement these product attributes by building stronger awareness and encouraging the adoption of specialised construction solutions.

Ramco Cements, one of India’s established cement manufacturers, operates across cement and allied building solutions. Through Hard Worker, the company is expanding its presence in the construction chemicals segment with products designed to enhance performance, quality and durability in modern construction applications.

The latest recognition strengthens Hard Worker’s brand visibility and underscores the growing importance of creative communication in promoting technical building materials. Ramco Cements intends to continue combining product development with distinctive marketing initiatives to support the brand’s growth in India’s construction chemicals market.