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Looking Beyond the Low Hanging Fruits

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With the Net Zero targets looming in the near future and an imminent problem of emissions to contend with, the Indian cement manufacturing sector should no longer be satisfied with doing the bare minimum. Looking at innovative solutions, breakthrough technologies, automation and artificial intelligence, and most importantly, a change in mindset, is the need of the hour.

There is no denying the fact that cement being the second most consumed material after water in the world in terms of quantity, and by virtue of its inherent conversion process from limestone to clinker, the amount of CO2 emission from cement alone (7 per cent of all emissions) is one quarter of all industry emissions put together. Even in dollar terms the maximum CO2 per dollar of revenue industry-wide shows cement taking the top spot at 6.9 kg of CO2 per dollar.
The process of cement making has majorly two areas – raw material resources and clinker and cement manufacturing, where the emission needs to be segregated into its constituent elements, both from the point of view of energy consumption and also in terms of CO2 emissions. While two-thirds of the emissions stem from the calcination process, which is where the bulk of the thermal energy is consumed, the raw material extraction to feed generates negligible amounts of emissions and the cement grinding from clinker and logistics makes the bulk of the remaining emissions. The total emissions of 925 kg per tonne of cement production leaves a staggering 4 billion tonnes of CO2 generation each year, as the world produces 4.2 billion tonnes of cement annually.


The pathways through which the industry has progressed so far can be seen in the following areas:

  • Energy Efficiency
  • Alternative Fuel
  • Clinker Substitutes
  • New Technologies
  • Alternative Building Materials

If one goes into the analysis of each of these levers that the cement industry is currently using, the first three have remained the low hanging fruits where most of the attention and energy had been diverted to. These top three levers have so far fetched about 25 per cent of the CO2 emission reduction possibility into 2050, with energy efficiency showing a possibility of 7.2 per cent, alternative fuel a possibility of 10.5 per cent and clinker substitution 7 per cent. However, the investments needed for these and the abatement cost per tonne of CO2 would look very different for each. For example, alternative fuel would still need disposal cost, carbon capture and storage as well and the investments for these would make this category the highest in terms of abatement cost. The following table gives this as follows among all the levers:

So far, the cement industry has focused on the low hanging fruits, mostly clinker substitution after working on efficiency improvement levers, where the abatement costs were negative, giving economic benefits to the cement makers. Driven by the country’s landfill laws and pollution control norms, some of the advanced countries have outright rejected use of coal and PetCoke in cement kilns, replacing that with alternative fuel and biomass. However, these have to go through the abatement cost of Carbon Capture and Storage, which has been so far very high. Let us go through each category and see what is the current stage of development of these areas of focus.
Efficiency Improvement: The last step change for cement kiln technology was in the case of dry process replacing the wet process, thereafter the recent advancement has happened in the use of electrical energy instead of thermal energy for the kiln conversion process. This has been put to commercial use but till we use renewable energy in kilns, this does not give any advantage in terms of overall gain in emission. The replacement cost of thermal to electrical could be very high as well, so the future electrification of kilns, depends on use of renewables that must be part of a stable grid power, which raises many actions to be taken.
Clinker Substitution: Maximum gains have happened so far in reduction of emission by adopting various means to replace clinker with fly ash, slag etc., but the future could actually have very little of this available as generation of electricity moves to the renewable mode and the steel companies adopt more of the green technology that would generate far less waste eventually from the process.
Alternative Fuel: The availability of alternative fuels depends largely on the development of local supply chains that must wade through a number of constituencies like the local municipalities for the municipal wastes and the development of logistics systems have a lot to be desired. The only hope remains the use of biomass, which is the highest growing segment. The investments here include not only the platforms but also avenues of de-chlorination, etc.
Carbon Capture Use and Storage (CCUS): This method isolates and collects CO2 from industrial emissions and either recycles it for further industrial use or safely stores it underground. Once captured, a wide variety of potential uses for CO2 could be possible, such as in the production of glass, plastics, or synthetic fuels. Though carbon-capture technologies do exist commercially, they are utilised in very few plants—one example being natural-gas plants. Therefore, the progress of extensive decarbonisation will not only depend on the economic viability of storing and sequestering the carbon but also on the availability of CO2 marketplaces, through which the captured CO2 can be sold.
Carbon-cured Cement: This technology injects CO2 captured during cement production to accelerate the curing process and ‘lock in’ CO2 in the end product. Current low-carbon cement technologies can sequester up to 5 per cent of CO2, with the potential of 30 per cent. In fact, 60 million tonnes of CO2 per year are projected to be stored via carbon-cured concrete in 2050.
Alternative Building Materials: In the years to come, alternative building materials could shift demand away from cement. To date, cross-laminated timber (CLT) has attracted the most attention. Made by gluing wooden panels and boards together, CLT is an adequately fire-resistant building material that can reach large dimensions. Its application has recently increased and includes projects in Canada, Japan, and Sweden. Assuming a 10 per cent replacement of concrete—and considering the CO2 captured in the wood has been abated—would reduce the overall cement footprint by 25 per cent, as even more
CO2 is captured than avoided by reducing the cement production.
Recycled Concrete: Use of recycled concrete and demolition waste is the new development especially in Europe with the sources of limestone becoming limited in the future.
The potential reduction of 50 per cent of the CO2 emissions by 2050 depends on the progress of carbon capture and storage systems and technologies, where we have a few start-ups who have come up with very different processes. For example, one start-up uses a lower proportion of limestone in its cement, which results in fewer process and fuel emissions; this company’s process also locks in additional CO2, which is added before the concrete cures. Adding CO2 makes the concrete stronger and reduces the amount of cement needed. Carbon-cured concrete could also use CO2 captured during cement production. Today’s methods could sequester up to 5 per cent of the CO2 produced during production, but newer technologies could sequester 25 to 30 per cent. Products such as carbon-cured concrete, positioned differently, could earn a ‘green premium,’ potentially giving companies an edge among environmentally conscious buyers and greater pricing power.
The Indian cement industry must move steadily to these new innovations, after making the maximum gains from the low hanging fruits. Innovation remains the key word and investments in innovation, including the mindset, for cement is the first step in this journey.

-Procyon Mukherjee

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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Concrete

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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