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Only cement has the ability to enhance the viscosity of concrete

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ICR engages Anirudh Dani, Grinding Unit Head, JK Cement Works, Jharli, in a discussion about the grinding processes at the plant.

Explain the grinding process in cement manufacturing.
Cement is a core ingredient in construction and is also the most widely used construction material because only cement has the ability to enhance the viscosity of concrete, which in return provides a better locking result of sand and gravel together in a concrete mix.
Fresh feed along with the coarse material from the separator is fed back into the grinding system. Fines from separator i.e. the product passes from the bag house through a fan. The material collected at the bottom of the bag house is transported through a set of air slides and bucket elevator to the cement silo.

Tell us about the equipment used for grinding raw material and clinker.
A closed circuit Ball Mill, VRM, Roller Press or a combination of these are used for the grinding of raw materials and clinker. At JK Cement works, Jharli Roller press and ball mill combo are used for cement grinding, which has a capacity of 2.0 MTPA.
Mills are selected according to the type, which is most suitable in terms of variables like desired capacity, investment, space availability and grinding efficiencies based on relevant raw materials. In our organisation, we are using all three available combinations at various locations. All available technologies of cement grinding have their own benefits and drawbacks. Looking at the advancement of technology we prefer the Roller Press with Ball Mill and VRM. Several types of separators are also used in mill circuits and there are numerous variations of each type available in the market.

What are the key functionalities that are looked at while installing a cement grinding plant in your organisation?
In general, cement grinding plants are installed with the clinkerisation plant. But cement grinding is also installed at different locations on the basis of various strategic variables like nearby market locations and raw material sources. By installing cement grinding at different locations, the cement industry is effectively utilising the ‘Hub and Spoke Model’.
Major key technical functionalities are production capacity, cement grade, special energy consumption, maintenance cost, construction cost etc., for the installation of the grinding unit.
Further major key strategic deciding factors are land availability, market demand, logistics optimisation, geographical analysis and raw material availability for the finalisation of the cement grinding location.

What is the contribution of the grinding unit in making the cement grinding process efficient and productive?
Cement grinding is an integral part of the cement manufacturing process. The main function of cement clinker grinding is to provide a finished cement product with a certain particle composition. The dispersion of cement can be expressed by fineness and specific surface area. Cement grinding is required for inter grinding of various raw materials like clinker, gypsum, fly ash, slag and performance improvers. Efficient cement grinding contributes to enhancing the quality of the cement by better particle size distribution.

How do cement grinding /grinding units contribute to profitability of the cement making process?
Cement grinding cost is 40 to 45 per cent of the variable cost of cement production. By effective control measures and minuscule innovations, we can achieve a significant impact on profit maximisation with environmental sustainability.
Major KPIs of cement grinding units are clinker factor, specific power consumption, MTBF and maintenance cost to contribute for the profit maximisation.
Clinker factor has a pivotal role in profit maximisation with GHG reduction that is environmentally sustainable. For example, the clinker factor in PPC varies from 55 per cent to 65 per cent at various plants.
In general, as an industry, we are more concerned about the reduction in heat consumption during the clinkerisation process but concerted efforts to optimise the clinker factor will give more benefits in a shorter time. For example, 1 per cent reduction in clinker factor achieves higher environmentally sustainable gain, compared to 1.5 per cent reduction of specific heat consumption in clinker.
Specific energy consumption of grinding varies from 18.5 Kwh/MT to 30 Kwh/MT in the industry. Optimisation of grinding efficiency helps us in increasing the profitability of the cement-making process. Earlier we were on the higher side of energy consumption however by optimisation and innovations we have surpassed the industry benchmark and achieved higher profitability and environmental sustainability.
Further logistics costs also can be optimised by placing cement grinding on the basis of various strategic variables as already explained.

What are the materials and equipment that aid in the process of cement grinding?
Other than the standard raw materials, grinding aids and performance improvers play an important role in cement grinding. Grinding aids are effective chemicals that are utilised for various applications like increasing the flow ability of cement, higher early/later mortar strength and higher concrete strengths. Grinding aids for cement are like ‘Few drops can make a huge impact’.
Weigh feeders, VFD, screw conveyors, high efficiency separators, bag houses, compressors and hot air generators are the types of equipment used in the cement grinding process.
How do you ensure standards in the process? How often is the same monitored?
We ensure that our processes are BIS and ISO compliant. Further, we have also well-established internal norms by benchmarking the global data.
Chemical analysis of cement, product fineness, blaine surface and 45-micron residue, cement sulphur trioxide (SO3), percentage of grinding aid usage, moisture percentage, production rate, specific power consumption (SPC) and MTBF are also continuously monitored.
To ensure we meet quality standards, we leverage various digital platforms for taking real time action. We have an expert control system, world class laboratory, energy management system, lab automation and mobile applications that are well placed for continuous monitoring of the same.

What challenges do you face in the cement process of grinding?
Largely, availability of good quality raw materials, periodic variation in composition and size of materials, low availability of fly ash, power outage, optimum utilisation of alternative raw materials like wet fly ash, chemical gypsum, mould gypsum, and flue gas desulphurisation (FGD) gypsum are the major challenges in cement grinding. But as we have seen several times, challenges present opportunities whereby we can become more efficient in our operations. The cement industry is looking at alternatives and gearing up to handle these challenges through innovative solutions.

What are the innovations you would like to see in the technology of the grinding process and grinding aids?
Innovation is a continuous journey and grinding technology is continuously evolving and has modernised since its inception. We like to see innovations like low-weight grinding media/liners in ball mill, low maintenance-based rollers, high-efficiency separators of more than 95 per cent of efficiency, spares having less maintenance and higher life, brushless direct current motor based air conditioners, low clinker-based cement like limestone calcined clay cement, online real-time quality monitoring equipment etc.
Currently, various grinding aids are available in the market claiming high early/later strength, flowability of cement, higher concrete strength etc. We have seen continuous innovation happening in this area and there’s ongoing research on some materials like graphene to increase the impact on the cement strength by 15 per cent to 20 per cent. Further, we would also like to see the grinding aids, which will reduce the water demand drastically in the cement manufacturing process.

-Kanika Mathur

Concrete

Adani’s Strategic Emergence in India’s Cement Landscape

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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.

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Concrete

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

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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.

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Driving Measurable Gains

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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.

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