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Integrating Sustainable Processes

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Primary and secondary packaging of cement is one of the most crucial stages of the manufacturing process, given the nature of the product. Faulty or cheap packaging can result in the cement turning solid due to moisture, by the time it is delivered on the site. At the turn of the century, the functionality of cement bags was not the only parameter to consider. Cement companies turned to innovation and recycling to implement sustainable bagging and packaging of their product. ICR looks at the current options available in the market and how cement brands can improve their packaging processes to reduce their carbon footprint.

Cement is a widely consumed and produced product. Its packaging, therefore, holds a lot of importance and needs to be done with care and precision. With the ongoing infrastructural development in the country, the demand for cement is ever rising. Similarly, India also exports a significant amount of cement.

PP woven bags are 100 per cent reusable and have
high durability making it the less pollutant product
compared to other packaging bags.


Packaging of cement plays a crucial role in the process of taking it from the makers to the consumers. Manufacturer’s source highest grade technology and packaging material to protect their product from damage, wastage and to reach the end user in an unharmed manner.
The process of packaging is at the last leg of the cement manufacturing process at the plant. Cement is extracted from the silo bottom by aeration and transported to electronic packing machines by air slides and bucket elevators. When it comes to filling cement bags at plants with valve fillers, the process is automated but the technicality is not simple. The product is pressed into the bag, while bags are made round so the maximum amount of product with air can be put inside. Then the bags are flattened so the air can escape through the many holes in the bag, and the bags can be stacked on a pallet. But this process does not work well with a closed plastic bag. The air leaving the product causes air to come in that cannot escape.

Materials and Quality Standards
Polypropylene is the chosen material for cement bags. The benefits of using this material are protection from moisture and strength to packaging. There are various categories of polypropylene bags available with coatings, linings etc.

  • PP Plain Woven Bags: These are simple bags made of plastic, stitched at the ends to hold cement in them.
  • PP Lined Woven Bags: These bags have an extra lining under the plastic outside that prevents cement from coming in contact with moisture.
  • Laminated PP Bags: These bags have an extra poly film layer over the polypropylene. They have a higher strength than the regular PP woven bags and provide a greater resistance from air that comes in contact with the bags. These also give way to better branding of the product when it is stored in uncovered settings.
  • BOPP Laminated Bags: The Biaxially Oriented Polypropylene (BOPP) laminated bags have a superior quality than other bags. An extra added layer enhances the durability of these bags and makes them more attractive for branding as well as prevent wear, tear and wastage while handling.


Cement makers, for the sake of sustainability, have been contemplating switching to paper bags. However, PP woven bags have various advantages when put in use for storing cement. They are highly chemical and weather resistant. They have high tear strength, which enables it to carry heavyweight materials. PP woven bags are 100 per cent reusable and have high durability making it the less pollutant product compared to other packaging bags. The element of recyclability and waste prevention because of the sturdiness of PP woven bags, they are the chosen material for cement packaging.
“Bags made of polypropylene can easily sustain harsh environments. Usually, we do not need to add any additives to retain the properties of the bags as in a normal case, cement is consumed within one to two months after it is produced and packed. But if there is a need to have longevity, we can add certain additives to the master batch to retain the properties of the bag. These additives allow the bags to sustain harsh conditions and environments, if exposed,
for up to a year,” says Nitesh Sharma, Director, ShriMaa Group.
Quality control for cement packaging is very important. The BIS (Bureau of Indian Standards) has set norms for cement packaging. As per Cl 9.2 of IS 455: 1989, the average net mass of cement per bag shall be 50 kg. The average net mass of cement per bag may also be 25 kg subject to tolerances and packed in suitable bags as agreed to between the purchaser and the manufacturer. Similarly, as per Cl 10.2 of IS 1489 (Part 1): 1991 and IS 1489 (Part 2): 1991, the average net mass of cement per bag shall be 50 kg. The average net mass of cement per bag may also be 25 kg subject to tolerances and packed in suitable bags as agreed to between the purchaser and the manufacturer. Also, as per IS 8112: 1989, the average net mass of cement per bag may also be 25 kg, 10 kg, 5 kg, 2 kg or 1 kg, subject to tolerances and packed in suitable bags as agreed to between the purchaser and the manufacturer.

Technology of Cement Packaging
Packing and bagging of cement is the last leg of the cement manufacturing process, after which the end product is loaded into its transport and sent across for sales and distribution. This process of packaging is mechanised and precision needs to be maintained to attain uniform results in packaging.
The packing machines can be classified as a fixed type and a rotary type. The fixed type usually has 1 to 4 cement discharging nozzles while the rotary type machine has 6 to 14 nozzles, which operates in a rotating way for automated cement bag filling.
With this machinery, cement bags are filled continuously through the discharging mouth by the impeller running at high speed. A weight is set for the filling and when the cement reaches that set weight, a signal is transmitted to the main system and the filling is stopped. This process is electronically controlled; however, bags of the desired size are manually fed to the machine. Automation of the bag filling process has various advantages like
having a stable operation, giving uniformity and structure to the bags, clean and hygienic filling of cement bags, ease of maintenance and lesser mechanical faults.

Growth of the Packaging Market
According to research conducted by Future Market Insights, the cement packaging market is expected to record a CAGR of 3.9 per cent during the forecast period 2022-2032, up from US$ 344.5 Billion in the year 2022 to reach a valuation of US$ 488.4 Billion by 2032. This growth shall be credited to the increasing demand from construction industry, surging application of paper bags as it provides ease of printability and replacement of conventional plastic bags. On the other hand, evolution of advanced products will further create new and ample opportunities for the growth of cement packaging market in the above-mentioned forecast period. This will also be seen in the sustainable packaging solutions vertical over the years to come as that demand is growing in most sectors related to cement.
Moreover, the market is flooded with duplicated and adulterated construction materials. So, the manufacturers of cement are aiming to reduce instances of counterfeiting by incorporating sophisticated branding impressions on their packaging solutions. These factors are expected to drive the sales of cement packaging solutions in the global industrial packaging market.

Sustainability in Packaging

The advantage of automated bag filling is uniformity and structure of the bag along with reduction of wastage.


Decision makers of the cement industry have taken conscious steps towards sustainability in their manufacturing process. Cement bags and packaging also play a crucial role as they eventually become waste by-products of cement and end up in landfills or waterbeds.
According to Nitin Vyas, Managing Director and CEO, Beumer India, “Looking at the larger picture and speaking about sustainability, our cement bags are a problem. They have a high porosity. The only two countries using these bags are India and China, where China will stop using these bags going forward as they are huge pollutants. When the bag is thrown, a lot of dust is generated. The cement industry needs to become responsible and not look at saving a miniscule amount of money per bag and rather look at the bigger picture and save the environment. Approximately Rs 2 per 50 kg bag needs to be spent to improve the quality, which will result in a better environment and better health conditions for the loader as well.”
“There are no hard policies for packaging. There are no strict regulations on what kind of bags need to be used for packaging, what is the pollution limit in a packing plant etc. Sustainability is treated as fashion in today’s time, but it needs to be looked at more seriously, especially in the packaging and logistics domain,” he adds.

Cement bags and packaging play a crucial role in
the approach towards sustainability and eventually
become waste by-products of cement and end up in
landfills or wat


Recycling of cement bags has been taken up as a major step towards the conservation of resources and prevention of wastage. Primarily made of polypropylene or plastic, there are two product outcomes while recycling cement sacks, i.e., recycled polymer (polypropylene) and calcium carbonate (CaCo3). The most common method of cleaning the sacks is by water; this allows agglomeration of cement (lumps) that is left in the bag. Hence, 80-85 per cent of recycled polypropylene is churned out in grey (not white) and the remaining 15-20 per cent is calcium carbonate formed from the cement already available in the sack. While washing with air is another option, it is not widely used given its high cost. The output is the same-coloured polymer and less calcium carbonate. The reason behind these polymers being coloured is due to the use of masterbatch or UV coating while making them.
The recycled polymers are sent to regions where the blow-moulding industry is predominant for conversion. In India, Dhoraji, Ahmedabad in Gujarat is the recycling ‘hub’ for all plastic scrap. Other regions include Aurangabad in Maharashtra and Hyderabad in Telangana. Nearly 30 per cent of the cement sacks are cleaned and re-used by farmers and small-scale industry manufacturers to collect/pack manure, waste, by-product, scrap etc.
The Bureau of Indian Standards (BIS) allows 15 per cent calcium carbonate and only 10 per cent recycled polymers while making cement sacks. The reason for lesser use of recycled polymer is because the handling system in India is mostly manual involving 8-10 people across the supply chain. This increases the scope for breakage and tearing. There is a bursting system that indicates the number of cement sacks that can be stacked atop of one cement sack; its breakage is tested depending on the number of sacks that are stacked before the bottom sack could burst. In China, the bursting standards are 7:1 i.e., 7 cement sacks stacked upon 1 whereas in India it is 5:1. Baling of cement sacks would spread the risk of breakage.
Cement industry in India and globally is growing. And so is the requirement of its bagging and packaging. This comes with its own set of challenges; however, the advancing automation and technology is making the process precision and waste free. Recycling of the polypropylene bags has been identified as a key solution to avoid wastage and pollution of the environment. Efforts are being made by the industry to make their brand stand out with quality packaging as well as in the direction of sustainability to build a better tomorrow.

-Kanika Mathur

Concrete

Driving Sustainability Through Innovation

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The 15th Cement Expo 2025 will spotlight India’s cement industry’s growth, innovation, and sustainability, showcasing cutting-edge solutions for a greener future.

The cement industry in India, the second-largest in the world, is on the cusp of remarkable growth as it continues its transition toward sustainability, innovation, and expansion. The 15th Cement Expo 2025, scheduled for November 12-13, 2025, at the Yashobhoomi Convention Centre in Delhi, will be the premier event where the industry’s foremost stakeholders converge to explore state-of-the-art technologies and solutions.
Co-located with the 11th Indian Cement Review Conference and the 9th Indian Cement Review Awards, the expo promises to be a pivotal event for professionals in the cement, construction, and infrastructure sectors. This year’s theme, “Driving Sustainability Through Technology,” highlights the sector’s commitment to decarbonisation, efficiency, and technological advancement. With India poised to add 80 to 100 million tonnes of cement capacity by 2024-25, the event will address the urgent need for sustainable, low-carbon solutions to meet the growing demand.
Before we look ahead to the 15th Cement Expo, let’s reflect on the remarkable success of the Cement Expo Forum 2025, held on March 5-6, 2025, in Hyderabad. The event attracted over 500 industry professionals and featured groundbreaking discussions on sustainability, logistics, and decarbonisation. Key sponsors and partners, such as ABB, Gebr Pfeiffer, JK Cement, and Flender Drives, showcased their latest innovations, contributing to the forum’s success.
Pratap Padode, Founder and President of First Construction Council, spoke at the event, noting, “The PPP pipeline is complemented by a provision of Rs 1.5 trillion in interest-free loans to states, earmarked for capital expenditure. With this, we have a solid plan in place. What needs to be done is to ensure that the PPP actually takes off as envisaged. To make this happen, trust must be established, and policies must be investor-friendly. Telangana, in this regard, has demonstrated ease of doing business exceptionally well.”
He added, “These financial injections into the infrastructure sector are expected to create a ripple effect, driving demand for cement as a key material in construction and development projects. The growing demand for cement is evident as infrastructure projects continue to rise across the country.”
The forum also provided invaluable networking opportunities, with attendees gaining insights from over 35 distinguished speakers and connecting with more than 50 exhibitors. The event laid a strong foundation for the upcoming Expo, showcasing the significant strides the cement industry is making toward a greener, more efficient future.
The 15th Cement Expo 2025 will focus on advancing the industry’s next big step toward sustainable growth. With India’s cement sector making significant progress in decarbonisation, a key focus will be on technologies and innovations that support carbon capture, low-carbon cement production, and energy-efficient solutions.
The expo will feature over 50 exhibitors representing all aspects of the cement industry. Whether you are a manufacturer, raw material supplier, technology provider, or logistics partner, the Cement Expo 2025 offers an ideal platform to showcase your products and solutions. Attendees will have the opportunity to explore the latest advancements in cement production technology, automation, logistics, and environmental solutions, all geared toward building a greener and more sustainable future.
Exhibitor profiles will include cement manufacturers, raw material suppliers, technology and automation solutions providers, environmental and sustainability solutions providers, cement packaging and logistics, construction equipment manufacturers, admixtures and chemical suppliers, and concrete reinforcement and structural systems.

11th Indian Cement Review Conference

Held alongside the Expo, the 11th Indian Cement Review Conference will offer delegates invaluable insights into the latest trends and innovations shaping the cement industry. Focusing on sustainability, the conference will address critical issues such as energy efficiency, plant design, and emerging technologies like carbon capture and automation.
Industry leaders will share their expertise in technical forums, while specialised activities, such as plant tours and energy audits, will provide practical guidance on improving operations and efficiency. This is a prime opportunity to network with industry stakeholders, gain hands-on experience with new technologies, and acquire actionable knowledge to enhance your business.

9th Indian Cement Review Awards

The 9th Indian Cement Review Awards will recognise the fastest-growing cement companies and industry leaders for their outstanding contributions to the sector. This prestigious event will serve as a platform to honour the pioneers of innovation, sustainability, and performance within the cement industry, highlighting the sector’s commitment to growth and environmental responsibility.
As we look forward to the 15th Cement Expo 2025, we invite you to join us for two exciting days of networking, learning, and innovation. This event offers a unique opportunity to be part of the next wave of growth and sustainability in the global cement sector.

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Concrete

Transforming Interior Spaces: Trendy Wall Putty Designs to Enhance Your Home

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When it comes to interior design, walls are more than just structural elements—they serve as the canvas for self-expression, setting the mood and personality of a space. While paint and wallpaper have long been the go-to choices for wall finishes, wall putty is emerging as a game-changer in home décor. With its smooth finish, durability, and versatility, wall putty opens a world of creative possibilities. In this article, we explore trendy wall putty designs that can elevate your interiors, turning ordinary walls into extraordinary design statements.
Wall Putty is a Must-Have in Modern Homes
Wall putty is no longer just a preparatory material for painting; it plays a significant role in modern home aesthetics. It enhances the finish of walls, making them smoother, stronger, and resistant to cracks and moisture. Additionally, high-quality putty like Birla White Wall Putty ensures better paint adhesion, resulting in long-lasting vibrancy.
Beyond its functional benefits, wall putty allows homeowners to experiment with textures and patterns, giving walls a designer touch without the hassle of high-maintenance materials like stone or wood. Whether you’re aiming for a minimalist, rustic, or ultra-modern aesthetic, wall putty designs can help achieve the look effortlessly.
Trendy Wall Putty Designs for Stunning Interiors
1. Textured Wall Putty for a Tactile Appeal
Textured walls are a popular interior trend, adding depth and dimension to living spaces. By using wall putty, homeowners can create a variety of textures, including:
  • Rustic Texture: Mimicking natural stone or aged plaster for an earthy, vintage feel.
  • Wave Patterns: Adding a sense of movement and fluidity to walls, perfect for living rooms and entryways.
  • Sand Finish: A subtle grainy effect that provides a sophisticated touch.
Textured putty walls work exceptionally well in accent areas, such as behind a television unit or as a backdrop for artwork.
2. Sleek and Smooth Walls for a Luxurious Look
For those who prefer a refined and elegant aesthetic, a smooth putty finish is ideal. A flawlessly smooth wall creates a premium appearance, amplifying the impact of high-quality paints. Opting for a high-performance putty like Birla White WallCare Putty ensures a glass-like finish that complements modern and contemporary interiors.
This design is perfect for:
  • Monochrome interiors where walls serve as a sleek backdrop.
  • High-gloss or matte-painted walls that need a seamless base.
  • Spaces with minimal décor where the walls themselves make a statement.
3. Geometric & Abstract Patterns for a Contemporary Edge
Wall putty can be artistically applied to create striking geometric or abstract patterns, adding a unique character to interiors.
Popular designs include:
  • Chevron or Herringbone: A dynamic, sophisticated look that pairs well with both modern and mid-century décor.
  • 3D Raised Panels: Using putty to craft subtle raised patterns, adding a sculptural effect to the wall.
  • Asymmetrical Shapes: For a bold and avant-garde touch.
  • These patterns work best in bedrooms, study areas, or accent walls in open spaces.
4. Venetian Plaster for a Luxe European Aesthetic
Venetian plaster, an age-old technique, is making a grand comeback in modern interiors. With wall putty, you can achieve this exquisite marble-like effect, which exudes luxury and timeless charm.
This design works well for:
  • Statement walls in living rooms and foyers.
  • Elegant dining areas where a touch of opulence is desired.
  • Boutique-style bedrooms with a rich, textured finish.
A high-quality white cement-based putty can replicate this effect beautifully, making the walls look naturally luminous.
5. Dual-Tone or Ombre Walls for a Soft Gradient Effect
The ombre effect, a gradient transition between two colors, is a trendy and artistic way to enhance interiors. When applied over a smooth wall putty base, the gradient blends seamlessly, offering a dreamy, watercolor-like appeal.
This style is perfect for:
  • Children’s rooms or play areas, creating a fun and dynamic atmosphere.
  • Bedrooms with a soothing pastel gradient for a calming effect.
  • Dining spaces where a bold color fade adds character.
6. Metallic & Glossy Finishes for a Chic Look
For homeowners who love glamour and sophistication, combining wall putty with metallic paints or glossy finishes can create a high-end appeal. The smooth base of putty enhances the reflective qualities of metallic shades like gold, silver, or bronze, resulting in an opulent and dramatic effect.
Best suited for:
  • Luxurious master bedrooms and dressing areas.
  • Accent walls in dining rooms or home bars.
  • Commercial spaces like boutiques and salons.
How to Achieve the Best Wall Putty Designs
  • Choose the Right Putty: Opt for a premium wall putty like Birla White WallCare Putty to ensure durability, a smooth finish, and long-lasting appeal.
  • Prepare the Surface: Ensure the walls are clean, dry, and free from loose particles before application.
  • Apply in Layers: Depending on the design, putty can be applied in single or multiple layers for the desired effect.
  • Use the Right Tools: Trowels, spatulas, sponges, or patterned rollers help create specific textures and patterns.
  • Seal with Paint or Polish: Once the putty is dry, finishing it with paint, polish, or protective coatings enhances its aesthetic and durability.
Conclusion
Wall putty has evolved beyond its traditional role, now serving as a medium for creative interior design. Whether you prefer textured finishes, sleek smooth walls, or artistic patterns, wall putty designs can elevate your home’s aesthetics while offering durability and elegance. By selecting the  best putty for wall and application technique, you can transform your interior walls into stunning masterpieces, setting the perfect backdrop for your lifestyle.
For high-quality wall finishes that stand the test of time, Birla White WallCare Putty ensures both beauty and performance, making your dream interiors a reality.

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Concrete

Dalmia Bharat to add 6 MnTPA Cement Capacity in Maharashtra and Karnataka

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  • Investment in alignment with the strategic goal of becoming a PAN India company and achieving 75 MnT capacity by FY28
  • Increases capacity primarily to meet growing demand in Western India along with existing regions

Dalmia Bharat Limited, one of India’s leading cement companies, through its subsidiaries, has announced a strategic investment of approximately Rs 3,520 Crore in the states of Maharashtra and Karnataka. As part of this initiative, the company will establish a 3.6 MnTPA clinker unit and a 3 MnTPA grinding unit at its existing Belgaum plant, Karnataka coupled with a new greenfield split grinding unit with a capacity of 3 MnTPA in Pune, Maharashtra. The capex will be funded through a combination of debt and internal accruals. With this expansion, Dalmia Bharat’s total installed cement capacity will increase to 55.5 MnTPA, after considering the ongoing expansion of 2.9 MnT at Assam and Bihar. These new units are expected to be commissioned by Q4 FY27.

The Belgaum Grinding Unit will cater to the underserved Southern Maharashtra markets while enhancing share in the existing region by improving penetration. On the other hand, Pune Grinding Unit will entirely cater to the untapped Western Maharashtra markets. The initiative is a part of the company’s vision to be a PAN India player and achieve 75 MnTPA capacity by FY28 and 110-130 MnT by 2031.

Speaking on the development, Mr. Puneet Dalmia, Managing Director & CEO, Dalmia Bharat Limited, said, “This investment is a significant step in our Phase II expansion strategy, bringing us closer to strengthen our position as a pan-India player and to reach intermittent goal of 75 MnT capacity by FY28. The increase in our production capacity is primarily to meet the growing infrastructure demand in Western India.” He further added, “We remain committed in realising our goals of capacity expansion, while staying focused on operational excellence and creating long-term value for our stakeholders. The capacity additions will also continue to be in line with Dalmia Bharat’s sustainability-driven approach and its commitment to supporting India’s infrastructure and development goals.”

About Dalmia Bharat: Founded in 1939, Dalmia Bharat Limited (DBL) (BSE/NSE Symbol: DALBHARAT) is one of India’s pioneering cement companies headquartered in New Delhi. With a growing capacity, currently pegged at 46.6 MnT, Dalmia Bharat Limited (including its subsidiaries) is the fourth-largest cement manufacturing company in India by installed capacity. Spread across 10 states and 15 manufacturing units.  Dalmia Cement (Bharat) Limited, a subsidiary of Dalmia Bharat Limited, prides itself at having one of the lowest carbon footprint in the cement world globally. It is the first cement company to commit to RE100, EP100 and EV100 (first triple joiner) – showing real business leadership in the clean energy transition by taking a joined-up approach.

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