Concrete
Our major focus is on green power
Published
3 years agoon
By
admin
The scope of reducing energy consumption in a cement plant brings into play optimum use of technology and automation. Kiran Patil, Managing Director, Wonder Cement, shares details about his company’s endeavour in harnessing green power sources and the promising outcome of these efforts.
What is the energy consumption in one cycle of the cement manufacturing process? Which process is the most energy-intensive?
The energy consumption in the cement industry depends on the process, design, layout, equipment selection, the product being manufactured in wet or dry process plants, 5 stage or 6 stage preheaters, OPC or PPC, slag cement, etc. The basic raw material required for manufacturing any type of cement is clinker. Our current power consumption is closer to 42 to 43 units per tonne of clinker. Power consumption per tonne of cement varies with the type of cement being manufactured and the percentage usage of cementitious material in the blended cement.
Again power consumption per ton of cement depends on co-grinding or separate grinding. For example, while manufacturing slag cement, separate grinding is economical as compared to co-grinding. Power consumption also depends on the hardness of the material.
The grinding circuit is the most energy-intensive process in cement making.
What are the sources of energy used for cement manufacturing in your organisation?
Power and fuel are the most important cost drivers in cement plants. Hence, there is a lot of thrust to optimise the cost. We, at Wonder Cement, use all types of electrical energy, such as grid, solar, wind, thermal, and waste heat recovery (WHR) systems. Whichever source of energy is available, we use it to operate the plant. But our major focus is on green power. We have a WHR system for all the plants, which are in operation and our new unit, currently under construction, also has a waste heat recovery system.
As I mentioned, fuel is a part of energy, hence, sourcing the right quality of fuel at optimal cost to suit the raw mix to produce a good quality clinker is very important. So, we use different types of fuels like pet coke, bituminous coal, and alternative fuels. Use of alternate fuel, alternate raw material, and green power is our vision towards sustainability.
How does automation and technology help in optimising the use of energy in cement plants?
The role of automation in the cement industry is very high. If we look back, the cement plants in the later part of 1970 or early 1980s used to have local substations or local control systems. But today with automation, plants are operated and controlled from a single location (CCR). The control room operator can see the entire plant operation from a single monitor. Functions like start or stop, alarms, process interlocks etc., are major benefits of automation that a cement plant experiences.
As mentioned earlier, energy is a very important cost driver. We have a strong energy monitoring system that gives accurate real-time consumption reports for control purposes.
Further, industries have used robotics in the plant, and Wonder Cement is one of the cement plants to have robotics for quality control. In this digital world, we cannot be behind and so, we are working towards the implementation of digitalisation in operation and maintenance to get better efficiency.
What are the major challenges your organisation faces in managing the energy needs of the cement manufacturing process?
Normally, all cement plants operate on a continuous basis. Hence, it is important to have an uninterrupted power supply from the cheapest source. During the initial period, grid power was the only source of power supply to operate the plant without interruption (except breakdown). Then the cement industry started becoming captive of thermal power plants, which were cheaper than the grid. Now, we have moved to green power which again is cheaper than grid and thermal.
Green power is not only cheaper but it is good for the environment and reduces emission levels.
However, its availability on a continuous basis is a major challenge. Power Load Function (PLF) of solar and wind power is very low and not continuously available. Again, the same for wind energy also depends upon climatic conditions. Cement plants are process plants and operate 24×7, hence, they can’t be stopped when solar or wind power is not available. In spite of challenges, Wonder Cement is fully committed to maximising green power and renewable energy to protect the environment and promote sustainability.
Another challenge is the steep increase in the coal price, which leads to an increase in the cost of thermal energy, which in turn is the cost of cement.
Tell us about the compliance and standards followed by you to maintain energy use and efficiency in the organisation?
The government always encourages plants that consume less power. There are some regulations by the government that a certain percentage of power consumed should be green power.
There are regulations for not using pet coke in thermal power plants. Compliance towards the SOx and NOx, ambient air quality and stack emissions are very important and are being monitored online. We follow it very strictly. We have one of the best operating plants, free from pollution and greenery in and around the plant. Being a modern cement plant with latest technology equipment and machinery installed, our energy consumption is the best in the industry with 100 per cent compliances.
How often are audits done to ensure optimum use of energy? What is the suggested duration for the same?
Auditing is a regular phenomenon in our company. As far as energy audits are concerned, we have both internal and external audits at a regular frequency. Dedicated teams with certified engineers are stationed in the plant to have regular meetings on energy conservation. Audit findings and its compliance are discussed in the meeting. Audits by external agencies and their implementation help us for further improvement in energy consumption.
In our daily production meeting, after safety, the major discussion is on energy consumption. We strongly suggest to have half-yearly internal audits and at least one audit by external agencies per year.
How does energy conservation impact the profitability of the organisation? What impact does it have on the productivity of the process?
Of course, there is an impact on the profitability of the organisation when a cheaper source of power is made available for plant operation. As mentioned, green power is the cheapest source of power. But again, it depends on its availability. Cement kilns can›t be switched on or off based on power availability, they need a continuous power supply.
But grinding mills can be optimised based on market demand. One has to look at overall profitability by balancing production vs utilisation of cheaper power.
What percentage of your carbon emission reduction target are you set to achieve by 2030?
In the cement industry, one of the major activities for minimising carbon emission is to maximise blended cement so that clinker consumption per tonne of cement is reduced. This is achieved with PPC or PSC (slag cement). The second activity is to use green power.
We are located in a region where there is no availability of blast furnace slag (waste generated from steel plants). It is one of the most important ingredients for making Portland Slag Cement (PSC).
Mostly, it is available in the central or eastern part of the country. Thus, making PSC is not possible for us at Wonder Cement at the moment. So, the option is to maximise PPC (blended cement). By maximising the production of PPC and maximising the percentage usage of fly ash, we can further reduce carbon emissions.
Normally, 950kg of carbon dioxide is emitted while manufacturing per ton of OPC. Approximately 600 to 650kg of carbon dioxide is emitted while manufacturing per ton of PPC. What is important for us is to maximise the blended cement with maximum usage of fly ash. Again it all depends on which market we serve. We cannot simply push the cement we manufacture and expect customers to use it.
With all the initiatives and actions, Wonder Cement has an ambitious plan to maximise green power in the coming days for the existing as well as future projects. We are discussing the same with major renewable power suppliers to have long-term PPA. Also, have plans to set up solar power plants in the existing unit.
In what areas can the cement manufacturers drastically reduce their energy consumption and how?
Grinding is one process that consumes maximum power. In the old technology, clinkers were ground in ball mills with high power consumption. With new technology, we now have roller presses, vertical mills and a combination of mills with a V separator has reduced the power consumption drastically.
Adapting this new technology has helped to bring down power consumption. The power consumption today in roller presses and vertical roller mills are less than 20 to 22 units per tonne of cement.
Still, there is a lot of scope to optimise power in the grinding circuit
What kind of innovations in the area of energy consumption do you wish to see in the cement industry?
There is a tremendous scope of reducing energy consumption. At the start of my career the power consumption used to be 120 units per tonne of cement produced. Now it has come down in the range of 55 to 60 units per ton of cement.
Plants that have reached maturity level with full capacity utilisation, the scope of reduction is lesser.
But the older plants with old technology have a lot of scope for reduction in power consumption. Here digitalisation will play an important role. We need to optimise the operation with the latest technology with energy-efficient equipment, variable frequency drives, and optimisers for processes. Periodic audits and implementation of actionable points will further reduce energy consumption in the cement industry with strong follow-up.
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
