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Technology prevents wastage of product

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Nitin Vyas, Managing Director and CEO, Beumer India, talks about how technology is the driving force behind the innovations in packaging, which will ultimately lead to more sustainable solutions and better efficiency.

Tell us about the loading systems and their impact on the energy efficiency of the cement manufacturing process.
If you break down the cement manufacturing processes into the raw and final product stages, about 25 per cent cost is sitting in the loading and packaging areas, which is part of the overall logistics. This is one of the most inefficient systems in the cement industry in the world, while the most efficient manufacturing systems are sitting in India. Unfortunately, a lot of focus has not come on the packing, loading and distribution of cement. Our machines not only function with respect to electro-mechanical loading efficiency or energy efficiency, they also are fully automatic. So, without any human intervention, a full truck can be loaded within 60 minutes. About 60 such machines are operational in 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.
If I look at the macro numbers, India’s overall logistics cost is around 14 per cent of the GDP, whereas a developed nation’s overall logistic cost is up to 10 per cent. We are aspiring to achieve these numbers. However, the cement industry holds a logistic cost of 25 per cent, which is very high. Therefore, going forward, packing, distribution etc need to be considered to bring down this logistics cost. Sustainability needs to be created end-to-end.
The United Nations has given sustainability goals and the cement industry needs to benchmark against the same as a measure for their sustainability goals. We need to look at sustainability not only from the view of energy efficiency but as the upliftment of a society and environment. For me, in a packaging plant the word society refers to the workers. The economic benefit lies in the reduced logistic cost and a lot more. Sustainability needs to be looked at in a total framework, only then it can be achieved.

Do you think the industry experiences a gap in policies and regulations in the packaging arena?
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.
We are hoping to implement more policies in the near future and there will be more transparency in policy and process in the days to come. Sustainability needs some push from the government, but eventually the onus is on the cement manufacturers to
follow through.

What is the role of technology in preventing wastage in packaging?
Anything that needs to be improved, needs to be measured. If you do not measure, you don’t know where you are standing. For example, your machine is supposed to produce 100 tonnes of cement in an hour, but in reality, it despatches only 80 tonnes in an hour, which should not be a satisfactory measure.
When the machines are technologically and digitally enabled, and the processes around them are made intelligent, too, then the measures are correct and precise. For a machine, system or line, manufacturers must measure Overall Equipment Effectiveness (OEE), to make it more efficient. This measurement will have an economic benefit, preventing wastage, by maximising the usage of the asset.
This enabling can work wonders in a cement packaging plant. For example, when a truck comes into the yard, enable it digitally by having a RF card, which the driver can scan and get to know his parking location and loading time. This saves time of filling out forms, reduces manual errors and saves cost. The truck can further get attached to machines, where packed bags can be loaded in a set weight and amount to have the most optimised loading of cement bags that can be despatched. Thus, technology prevents wastage of product, and it brings efficiency in terms of time and cost.

How important is data in building the kind of technology described by you?
Humans were originally hunters and gatherers. Our tools were bows and spears that were used for hunting. Then came the agricultural and industrial age when land was fuel and steel and coal were fuels, respectively. In today’s era, the digital age, data is the new fuel. Some of the data driven industries are richer than countries all together, because the new fuel for the economy is data. The first step to using data efficiently is to harvest it. Data is all over the place and data points need to be identified that should be harvested. People who use machines should understand the data points. Once the data is harvested it needs to be structured and put into categories and then start using it.
We do big data analytics for our machines. The objective is to improve the quality and efficiency of the machine. Data gives an opportunity to serve the existing market and improve existing machines while showcasing an opportunity to give economies of outcome. Thus, data is a powerful tool and one needs to identify and use it judiciously for their business and machines. It helps us better our technology by providing insights into the gaps as well as opportunities in the cement packaging sector.

What kind of innovations can be expected from your organisation in the near future?
We are working on a packaging machine that has a digital service attached to it. It comes with a smart glass, which will be given to the customer. So, whenever there is a breakdown or need for repair, there will not be a need for some person to come in. The personnel at the plant can wear these glasses. They have a camera and a screen that displays manuals and instructions. They can be heard and there is a facility to speak for help as well. All our machines are equipped with remote connectivity, which allows experts at the back office to take control of the machine and the person at the plant can show what is happening and get real time repair solutions, thus, saving on time and preventing longer downtimes.
This is one of many digital technologies that we plan to implement with our projects. For example, whenever we had a brown field on our existing plants, typically surveys were done manually, which used to take days. Now we are implementing 3D laser scanners, which will speed up the process at the plant. It beams the lasers around and with that we get the entire topography of the area, surface details and all required details to make modifications to our systems. All our machines now come digitally enabled. We also have apps to measure overall equipment effectiveness for plants and units to be more effective.

-Kanika Mathur

Concrete

Cement Sector Faces Sluggish Growth in First Half of FY27

April Price Hikes Unlikely To Offset Margin Decline

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Nuvama Institutional Equities has warned that India’s cement industry is expected to record subdued volume growth in the first half of fiscal year 2026-27 before a recovery in the second half. The brokerage assessed that price increases implemented in April 2026 will be insufficient to offset an overall decline in sector profitability. It attributed the outlook to weak demand and fresh capacity additions scheduled during fiscal years 2026-27 and 2027-28 that are likely to keep prices under pressure.

The report noted that demand was sluggish in April and May 2026 owing to global uncertainty, labour shortages, heatwaves, constraints in raw materials and unseasonal rainfall. Producers raised prices across regions in April to mitigate rising petcoke costs and higher packaging expenses, but the increases proved short lived. Nuvama reported that standard petcoke prices rose to USD153/t, around USD41/t higher than in the third quarter of fiscal year 2025-26.

Price correction followed weaker demand, limiting the net increase to about Rs 10-12 per bag by the end of the quarter. Imported petcoke prices have since fallen to USD132/t from a recent peak of USD168/t, although they remained roughly USD20/t higher quarter on quarter. The brokerage expected the higher input cost impact to begin reflecting from late quarter one of FY27 and to continue into early quarter two.

Nuvama also estimated that crude linked increases were likely to raise packaging costs by about Rs 120-150/t and to exert upward pressure on freight. It warned that soft demand combined with significant new supply coming on stream in FY27-28 would keep pricing under strain and constrain near term margin recovery. The report concluded that volume growth was likely to be sluggish in the first half of FY27 before recovering in the second half.

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Concrete

Nuvoco Vistas launches Limla cement plant, expands Gujarat footprint

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Nuvoco Vistas opens a 2 MMTPA grinding unit at Limla, entering Gujarat and advancing its target of 35 MMTPA capacity by FY 2028.

Surat (Gujarat)

Nuvoco Vistas Corporation Ltd, a part of Nirma Group and one of India’s leading building materials company, has inaugurated the Limla Cement Plant in Surat (Gujarat), one of Vadraj Cement Limited’s (VCL) principal manufacturing facilities. The commissioning represents a key milestone in Nuvoco’s acquisition and restoration of VCL, while supporting the company’s expansion across the Western Indian cement market.

Vadraj Cement Limited is a subsidiary of Nuvoco Vistas Corporation Limited and has installed cement capacity of 6 MMTPA across its assets. The Limla inauguration therefore represents the first operational step in the acquired platform’s wider revival, while the Kutch facilities provide clinker supply, mineral security and coastal logistics support for the western business.

Nuvoco completed its acquisition of Vadraj Cement Limited, then under the Corporate Insolvency Resolution Process, after paying a consideration of Rs 1,800 crore in June 2025. VCL’s asset portfolio comprises a clinker unit at Kutch and a grinding unit at Limla in Surat. It also includes high-quality captive limestone reserves and a captive jetty at Kutch, supporting more efficient logistics. Following the takeover, Nuvoco began an extensive programme of restoration, refurbishment and expansion at both locations, leading to the commissioning of the Limla plant.

The Limla Cement Plant is expected to support a phased increase in sales volumes across Gujarat. It will also help Nuvoco supply neighbouring markets in Western Maharashtra and release cement capacity from its northern plants, which can consequently be redirected towards markets in North India. The plant will manufacture a full portfolio comprising Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. It will additionally produce the complete Nuvoco Duraguard range, including the premium Nuvoco Duraguard Microfibre product. The acquisition is also expected to generate operational synergies with Nuvoco’s existing plants at Nimbol and Chittorgarh in Rajasthan, improving logistics optimisation and market reach across important regional markets.

The grinding unit at the Limla Cement Plant was completed ahead of schedule, with 2 MMTPA of capacity now inaugurated to expand Nuvoco’s operating scale and customer reach. After Vadraj Cement’s assets become fully operational, plants in North and West India are expected to account for nearly 40 per cent of Nuvoco’s total cement capacity. This will broaden the company’s manufacturing network, strengthen access to high-growth markets and support its plan to increase consolidated cement capacity to 35 MMTPA by FY 2028, reinforcing its longer-term growth strategy.

Commenting on the development, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said: “The inauguration of the Limla Grinding Unit in Surat is an important milestone in Nuvoco’s growth journey and demonstrates our commitment to disciplined, value-accretive expansion. Gujarat is strategically significant for Nuvoco, with substantial opportunities arising from infrastructure investment, industrial growth, rapid urbanisation and continuing demand from the housing and construction sectors. The facility strengthens our regional footprint, improves operational flexibility and increases our ability to serve customers across northern and western markets with greater reliability and efficiency.”

He added: “Through the Vadraj acquisition, we have refurbished and restarted a strategically important asset, returning it to operations in record time through strong execution and collaboration between teams. The achievement demonstrates our ability to create value from acquired assets, fulfil our commitments and retain the confidence of stakeholders. It also highlights the strength of our project delivery capabilities and our continued focus on building sustainable, profitable growth over the long term.”

Nuvoco Vistas Corporation Limited is a building materials company whose vision is to build a safer, smarter and more sustainable world. It is among the leading players in East India and has a significant presence across North and West India. Nuvoco began operations in 2014 with a greenfield cement plant at Nimbol, Rajasthan. It later acquired Lafarge India Limited, which had entered India in 1999, followed by Emami Cement Limited in 2020 and Vadraj Cement Limited in April 2025. The company has also announced an expansion in eastern India through a new grinding mill at the Arasmeta Cement Plant, supported by several debottlenecking programmes involving equipment upgrades, process improvements and internal capacity initiatives. These developments place Nuvoco on track to achieve total cement capacity of approximately 35 MMTPA. The company reported total income of Rs 11,362 crore in FY 2025-26, reflecting its continuing growth trajectory.

Nuvoco operates a diversified portfolio across three segments: Cement, Ready-Mix Concrete and Modern Building Materials. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem, covering Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. Its pan-India RMX business provides value-added products under Concreto for performance concrete, Artiste for decorative concrete, InstaMix for ready-to-use bagged concrete, X-Con covering M20 to M60 grades, and Ecodure for specialised green concrete. Nuvoco has supplied materials to projects including the Mumbai-Ahmedabad Bullet Train, Birsa Munda Hockey Stadium in Rourkela, Aquatic Gallery at Science City in Ahmedabad, and metro railway projects in Delhi, Jaipur, Noida and Mumbai.

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Concrete

Cement Prices To Hold Steady Amid Monsoon Slump

Centrum report says demand weakness will limit hikes

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Centrum, a financial services firm, has reported that cement prices are likely to remain largely unchanged in July as weak demand during the monsoon season constrains pricing power. The report noted that construction activity remained subdued in the first quarter of fiscal year 2027 owing to labour shortages and slower execution of government projects. While June showed some volume recovery driven by delayed monsoons and quarter end sales, dealers are cautious about sustaining any price increases.

The analysis suggested that seasonal slowdown related to monsoon will prolong demand and pricing challenges through the second quarter. Dealers saw most recent attempts at price hikes as protective measures rather than genuine shifts in market fundamentals. They signalled that pockets of demand in select regions could prompt isolated adjustments but that broad based increases were unlikely while construction activity remained weak. Market participants therefore expected a cautious stance on pricing.

The report highlighted that despite intermittent recovery in shipments during June, the underlying demand trajectory remained muted as monsoon hampered site level activity and logistics. Commercial builders and retail dealers both reported constrained order books and slower payment cycles, which in turn reduced room for margin expansion among manufacturers. Analysts noted that unless government project execution accelerates markedly, demand improvement would be gradual. Price setters were thus likely to focus on protecting market shares rather than pursuing aggressive increases.

Market watchers said the near term outlook would be shaped by monsoon progress and fiscal spending patterns, with any acceleration in public works offering the most tangible support. Traders expected that regional variations would persist and that trade flows between surplus and deficit centres would determine local price movements. The report concluded that stakeholders should prepare for a period of subdued pricing until demand signals strengthen.

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