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The consistent goal in the cement industry is to use fewer natural resources

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Sanjay Joshi, Chief Manufacturing Officer, Nuvoco Vista, highlights the various supplementary cementitious materials that are used to make cement production more cost-effective and environmentally sustainable.

What are supplementary cementitious materials? Tell us more about their nature
of origin.

Cement products often have other materials incorporated that help increase the product’s strength and durability, reduce permeability, as well as help reduce the impact on the environment. These materials are known as supplementary cementitious materials.
The most used supplementary cementitious materials are fly ash or blast furnace slag. While fly ash is a by-product of thermal power generating stations, slag is a glassy, granular material formed during the smelting process of iron ore; it is quenched mostly by water sprays or immersion in water and then subsequently ground to cement fineness.
Gypsum is another cementitious material that is added to the cement. It is found naturally and as a by-product of chemical industries. Chemically, it is a sulphate of calcium (CaSO4.2H2O), which helps in delaying the setting time of cement and makes it workable.

Tell us about the supplementary cementitious materials and their composition used by your organisation.
We are using all the above-listed cementitious material as it is prevalent in the industry. The
C/K ratio (cement to clinker ratio) indicates the composition of cementitious materials used. We are operating at a level of ~1.8., which means we are producing ~1.8 tonnes of cement for every tonne of clinker consumed. It makes us the leading player in the industry, manufacturing products with high cementitious addition. We operate close to the 34-34.5 per cent fly ash addition in fly ash based cement. In slag-based cement, we are operating in the range of 55-65 per cent slag, based on the product requirement. Gypsum usage ranges from 3-5 per cent in all cement types, and it varies based on the requirement of
setting time.

Does the use of supplementary cementitious materials impact the process of cement manufacturing?
Yes, cementitious materials impact the energy consumption of cement manufacturing. These materials are easy to grind when compared to clinker which is the major constituent of cement. Thus, higher usage of cementitious materials helps in reducing energy consumption.
Also, clinker usage directly involves limestone consumption as a raw material. Therefore, by using higher cementitious materials in the cement-making process, we are preserving the limestone available naturally.
Another aspect of adding cementitious material is the change in equipment required. Slag and fly ash are abrasive in nature thus the equipment being used in cement manufacturing will wear out faster in the case of PPC and PSC making. This lower clinker consumption ultimately lowers CO2 emission/tonne of cement production.

What are the key advantages of using supplementary cementitious materials in the cement manufacturing process?
Cement manufacturing is a closed loop wherein all raw materials from limestone mining to clinker production remain fully under controlled process parameters. The company focuses on reducing clinker consumption by increasing the blended cement ratio. Using these SCM, Nuvoco is also aiming to save fossil fuel, along with the obvious reduction in carbon emissions. Additionally, SCM increase the strength and durability of the product and reduce permeability.

How does the use of supplementary materials increase the profitability of cement manufacturing for your organisation?
Clinker manufacturing is the main cost-intensive step of the cement manufacturing process. Thus, a higher percentage of clinker in cement leads to a higher cost of manufacturing. By using SCM to the maximum extent possible, we can make cement at a lower cost without impacting its key properties.

Tell us about the quality standards and checks implemented for the final product made using supplementary materials.
Nuvoco has a dedicated NABL-accredited Construction Development and Innovation Centre (CDIC) located in Mumbai. It serves as the incubation centre for innovative products and can conduct over 100 mechanical tests. Apart from that, it also offers third-party external testing services, offering products and solutions that have passed the highest standards and holds global validation.
Additionally, Nuvoco also exceeds/meets BIS standards for cement quality. We also have a robust internal quality check procedure for continuous monitoring and course correction if any.

What are the major challenges you face while using supplementary materials for cement manufacturing?
The major challenge would be ‘Procurement, Distribution, Quality and Cost’. If any of this gets compromised, it will result in increased cement costs. Cost plays an important role and is majorly affected by the lead distances and availability of cementitious material quality determines the level up to which we can optimise the addition of the cementitious material in consideration.

How does the use of cement made of supplementary materials impact its carbon footprint?
Taking care of our environment and being sustainable have always been our focus. The use of such SCM lowers the energy in the concrete and counterbalances almost a ton of carbon emissions for every ton of cement that is replaced.
The addition of cementitious material (fly ash and slag) in cement helps to reduce the carbon footprint in cement as waste from a different industry is utilised in products in the market. The second benefit is the reduction of clinker consumption which in itself is a carbon-intensive product as it requires the usage of fossil fuels and also consumes limestone which in turn requires mining and other processing activities.

How do you foresee the future of the global cement industry in terms of using alternative materials for cement manufacturing and running the race of decarbonisation?
With our sustainability initiatives, we are looking to create value for all our stakeholders.
Our outlook remains optimistic, both in the short-term and in the long-term, concerning India, the cement industry and Nuvoco, in particular. There are substantial opportunities for growth and impact.
The consistent goal in the cement industry is to use fewer natural resources. Limestone, the primary natural resource used in cement production, is reduced as blended cement production rises. This benefits not only the company but also the businesses that produce trash, such as the steel and power industries.

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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