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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

The primary high-power applications are fans and mills

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Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.

As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.

How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.

What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.

Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.

Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.

How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.

What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.

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Concrete

We conduct regular internal energy audits

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Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.

In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.

How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.

What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.

How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.

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Concrete

Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport

The airport is set to become Asia’s largest air connectivity hub.

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Enlight Metals has supplied 3,200 metric tonne of steel for the newly inaugurated Navi Mumbai International Airport, marking a major contribution to one of India’s largest infrastructure projects and reinforcing the company’s commitment to supporting national development.

The Navi Mumbai International Airport, developed under a Public-Private Partnership led by the Adani Group, was inaugurated today by Prime Minister Narendra Modi. The airport is set to become Asia’s largest air connectivity hub, enhancing regional connectivity, boosting economic growth, and expanding trade opportunities. Prime Minister Modi described the project as a “glimpse of Viksit Bharat,” highlighting its transformative impact on infrastructure and development in the region.

“The supply of 3,200 metric tonne of steel for this key project aligns with our focus on supporting critical infrastructure development through reliable and timely metal sourcing. Enlight Metals is committed to enhancing transparency and efficiency in the steel supply chain, contributing to projects integral to India’s growth objectives,” said Vedant Goel, Director, Enlight Metals.

Enlight Metals has implemented technology-driven solutions to strengthen supply chain efficiency, ensuring consistent availability of construction materials for large-scale projects nationwide. Its contribution to the Navi Mumbai International Airport underscores the company’s growing role in supporting India’s infrastructure development initiatives.

This milestone reflects Enlight Metals’ ongoing engagement in delivering quality materials and timely services for major national projects, further cementing its position as a reliable partner in India’s infrastructure sector

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