Concrete
Our next target is to further reduce heat consumption
Published
3 years agoon
By
admin
AK Dembla, President & Managing Director, Humboldt Wedag India Pvt Ltd, sheds light on the positive effect of pyroprocessing and technology in cement production, and its ultimate impact on efficiency and profitability.
Tell us about the key areas where pyroprocessing has evolved since the 1950s?
In the 1950s, pyroprocessing was at a very nascent stage. There used to be wet process plants and heat consumption used to be around 1400 to 1600 kCal/kg clinker. In 1956, the first 4-stage preheater technology was developed and KHD was a pioneer in it. This reduced the heat consumption to 800 kCal/kg clinker and subsequently there was a development of the calciner technology which further optimised the heat consumption and increased the kiln productivity. The technology since then has been developing and we have now been able to bring down the heat consumption to 680 to 685 kCal/kg clinker. This has been a major step that has been achieved by the industry.
Our next target is to further reduce heat consumption either through substitution with alternative fuels or through some low temperature cements. We are trying to make this possible with the current methodologies in place. However, if there is a technological disruption, then the case may differ.
How is your technology helping reduce the carbon footprint?
As mentioned, in the area of heat consumption, we have been able to bring it down to almost half of what it was right at the beginning (early 1950) and that has been a major step in the reduction of carbon footprint. Another major step is the use of alternative fuel which is used on an average at
6 per cent in the Indian cement industry, some plants even use it up to 20 per cent. So, whatever alternative fuel we use, equivalent heat we calculate because it comes through a circular economy. And that much heat is saved, thus, reducing the carbon footprint
as well.
The industry is also working on reducing
the clinker factor in cement. Initially there was a demand for OPC, but when PPC started being popularised in early 2000 (July 2000) when the government had allowed up to 35 per cent flyash as additive in blended cement, the clinker factor substantially reduced, thus, majorly reducing the carbon footprint of the industry. Similarly, more blended cements started getting introduced by the cement makers to reduce the carbon footprint and with advancement of technology and research, the industry is gearing up to achieve net zero in concrete (final product from cement) by 2050.
How has your equipment adapted to the changing raw mix and fuels?
The good thing about using alternative fuels is that if its use is planned initially, then the process can be designed/ adapted for it. The limitation of using alternative fuel in an existing plant is to use extra equipment like shredders, preparation units for plastic waste or municipal waste or agriculture waste or hazardous waste etc. Another limitation is that the amount of alternative fuel that can be fed in the existing system can go up to 20 per cent, beyond that there is a need to modify the calciner system or add equipment for proper combustion of waste apart from the problem of bypassing minor constituents like chloride etc. For new plants that plan to use alternative fuels, we provide them with additional equipment like combustion chamber, pyro-rotor etc. that helps cement makers accommodate a higher percentage (more than 80 per cent of calciner fuel) of alternative fuels in their manufacturing process. We also investigate environmental aspects like emission of NOx and handling of minor constituents in initial design.
How has your equipment impacting the profitability for cement manufacturers?
It is our endeavour to design our equipment on parameters that are industry standard with
state-of-the-art technology. We ensure that the power consumption and use of thermal energy should be at a minimum and the productivity of the pyro-system and the grinding systems should be at its best.
Apart from design of the system and abiding by the industry standards, we do a cost comparative analysis for coal versus alternative fuels for the manufacturer, we research on layouts to bring low civil and mechanical consumption weight-wise. There are multiple efforts taken by suppliers like us to optimise the system on all fronts as it is a competitive market. Our target is to help cement makers have a lesser capital investment to ease their financial repayments and plant operations are better in productivity and output.
What is the role of automation and technology in your workings for the pyroprocessing system?
The pandemic era nudged us to explore the use of lesser manpower and include automations in our systems. There were mainly two issues: dependency on manpower and misconception that automation means a higher cost. However, that is not true. If automation is included in systems, moving towards artificial intelligence, digitisation and Industry 4.0 Standards, experts have concluded that data can be retrieved on the go and optimise processes in real time which saves costs.
In recent years, automation and technology has become a big part of the industry with equipment and sensors being installed to get data that goes through the cloud to experts and is available globally for analysis and feedback in real time. This is helping the industry increase its productivity and reducing downtime by understanding and anticipating the attention required in a particular process at a particular time. This trend is expected to mature further with time throughout the cement industry.
How do you envision the future of the cement industry with your technology
and equipment?
At present, we are putting in a lot of effort on research and development in the area of reducing carbon footprint. The main equipment and system that we are currently installing in cement plants support alternative fuels, wastes as raw material, cogeneration and blended cements. The future holds the use of solar energy and wind energy as the source of substantial power for the cement plants. The industry must also look towards having the process of calcination without fossil fuels and with the use of electrical energy produced from green hydrogen, and use of technology like oxyfuel etc. A lot of research is on-going, which may take about 5 to 15 years to be implemented, but the alternative energy sources like green hydrogen and use of oxyfuel etc., shall have been made possible to bring down the carbon footprint to zero in concrete is a big ambition for the industry. Researchers are also working on the technology where carbon can be captured, stored, and re-used.
With our processes and systems also adapting to continuous research and evolving technology, together with the cement industry we shall build solutions that ensure sustainability and reduce carbon footprint. This is what I envision for the future.
Concrete
Adani’s Strategic Emergence in India’s Cement Landscape
Published
3 days agoon
September 16, 2025By
admin
Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.
India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.
Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:
- September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
- December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
- August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
- April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
- Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
- Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
- Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
- Orient Cement: It would serve as a principal manufacturing facility following the merger.
Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:
- By FY 2026: Reach 118 MTPA
- By FY 2028: Target 140 MTPA
These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).
Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.
Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.
Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.
Challenges potentially include:
- Integration challenges across systems, corporate cultures, and plant operations
- Regulatory sanctions for pending mergers and new capacity additions
- Environmental clearances in environmentally sensitive areas and debt management with input price volatility
When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.
Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.
About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.
Concrete
Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series
Published
1 month agoon
August 16, 2025By
admin
PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.
Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.
Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.
Beyond energy efficiency, the retrofit significantly improved operational parameters:
- Lower thermal stress on equipment
- Extended lubricant drain intervals
- Reduction in CO2 emissions and operational costs
These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.
Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:
- Enhanced component protection
- Extended oil life under high loads
- Stable performance across fluctuating temperatures
By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.
Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.
A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

Adani’s Strategic Emergence in India’s Cement Landscape

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

Driving Measurable Gains

Reshaping the Competitive Landscape

CCU testbeds in Tamil Nadu

Adani’s Strategic Emergence in India’s Cement Landscape

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

Driving Measurable Gains

Reshaping the Competitive Landscape
