Concrete

Technology prevents wastage of product

Published

3 years ago

January 16, 2023

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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

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Concrete

JSW Cement Begins Production At Nagaur Rajasthan Plant

Greenfield integrated cement plant begins operations in Rajasthan

Published

14 hours ago

March 23, 2026

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JSW Cement has started production at a new greenfield integrated cement plant in Nagaur, Rajasthan, marking its first integrated facility in north India. The commissioning advances its national expansion and raises cement grinding capacity to 24.1 million tonnes per annum (MTPA) and clinker manufacturing capacity to nine point seven four MTPA including joint venture capacity. The plant is strategically located to serve high growth markets in Rajasthan, Haryana, Punjab and the National Capital Region.

The Nagaur plant comprises a three point three MTPA clinkerisation unit and a two point five MTPA cement grinding unit, with an additional one MTPA grinding unit under construction. The facility’s capacity additions enable it to meet regional demand and support infrastructure development. The project was funded by equity and long term debt and the company allocated Rs 8 bn from IPO proceeds to part finance the unit.

Company leadership said commissioning was completed within 21 months and that the expansion advances its aim to become a pan India player, with a mid term target of 41.85 MTPA and a long term vision of 60 MTPA. The plant includes sustainability features such as co processing of alternative fuels and a seven kilometre overland belt conveyor to transport limestone from the mines, reducing road transport impacts. The operation is expected to support economic growth and provide supplies for construction projects across the north.

The site will incorporate a 16 megawatt (MW) Waste Heat Recovery System to capture and reuse process heat, reducing the carbon footprint. JSW Cement’s operations include eight plants in India and a clinker unit in the UAE through a joint venture, providing a presence across the building materials value chain. The company emphasised use of industrial by products in manufacture and focus on producing eco friendly building materials.

Concrete

MAPEI India Celebrates 15 Years of Building Excellence

MAPEI India celebrates 15 years with growth, expansion and CSR impact

Published

14 hours ago

March 23, 2026

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MAPEI India marks its 15th anniversary, celebrating a journey defined by innovation, trust, and continuous growth. Beginning in 2011 with just four employees and a single manufacturing facility in Bengaluru, the company has evolved into a key player in India’s construction chemicals industry, now employing over 380 professionals across the country. Over the past 15 years, MAPEI India has delivered strong performance with a sales CAGR of 31 per cent. From zero production in its early years, the company shipped 1,71,000 metric tonnes of materials in 2025, demonstrating robust operational capabilities and rising market acceptance.

To support expanding demand, MAPEI India has steadily scaled its manufacturing footprint. Following the Bengaluru plant in 2011, new facilities were launched in Vadodara in 2016 and Kosi (Mathura) in 2022. A fourth facility in Kharagpur is set to go live in 2026, strengthening the company’s nationwide supply network.

As part of its commitment to global standards, MAPEI India operates under an Integrated Management System (IMS) certified for ISO 9001 (Quality), ISO 14001 (Environment) and ISO 45001 (Health & Safety). These certifications reinforce its dedication to delivering safe, sustainable, and high quality solutions.

With a diverse portfolio of over 20 product lines, MAPEI India has supported iconic projects such as the Atal Tunnel, the Statue of Unity, and major airport and metro developments. The company has also invested Rs 3.2 crore in CSR initiatives focused on education, women’s empowerment, and rehabilitation. As it steps into the future, MAPEI India remains committed to excellence, sustainability, and customer trust.

Mapei hai to bharosa hai.

Concrete

Material Flow Efficiency

Published

6 days ago

March 18, 2026

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We explore how material handling systems are becoming strategic assets in cement plants, enabling efficient movement of raw materials, clinker and finished cement. Advanced conveying, automation and digital technologies are improving plant productivity while supporting energy efficiency and sustainability goals.

Material handling systems form the operational backbone of cement plants, enabling the efficient movement of raw materials, clinker and finished cement across complex production networks. With India’s cement industry producing over 391 million tonnes of cement in FY2024 and possessing an installed capacity of around 668 mtpa, according to the CRISIL Research Industry Report, 2025, efficient material logistics have become critical to maintaining plant productivity and cost competitiveness. At the same time, cement production is highly energy intensive and contributes around 7 per cent to
8 per cent of global CO2 emissions, making efficient material flow and logistics optimisation essential for reducing operational inefficiencies and emissions states the International Energy Agency Cement Technology Roadmap, 2023. As plants scale capacity and integrate digital technologies, modern material handling systems, ranging from automated conveyors to intelligent stockyards, are increasingly recognised as strategic assets that influence plant stability, energy efficiency and environmental performance.

Strategic role of material handling
Material handling is no longer viewed as a secondary utility within cement plants; it is now recognised as a strategic system that directly influences production efficiency and process stability.
Cement manufacturing involves the continuous movement of large volumes of limestone, clay, additives, clinker and finished cement across multiple production stages. Even minor disruptions in conveying systems or storage infrastructure can lead to kiln feed fluctuations, production delays and significant financial losses. According to Indian Cement Industry Operational Benchmarking Study, 2024, unplanned downtime in large integrated cement plants can cost between Rs.15–20 lakh per hour, highlighting the economic importance of reliable material handling systems.
Modern cement plants are therefore investing in advanced mechanical handling systems designed for high throughput and operational reliability. Large integrated plants can process over 10,000 tonnes per day of clinker, requiring highly efficient conveying systems and automated stockyards to maintain continuous material flow, suggests the International Cement Review Industry Analysis, 2024. Efficient material handling also reduces spillage, minimises dust emissions and improves workplace safety. As cement plants become larger and more technologically advanced, the role of material handling is evolving from simple transport infrastructure to a critical operational system that supports both productivity and sustainability.

From quarry to plant
The transport of raw materials from quarry to processing plant represents one of the most energy-intensive stages of cement production. Traditionally, limestone and other raw materials were transported using diesel-powered trucks, which resulted in high fuel consumption, dust generation and increased operational costs. However, modern plants are increasingly adopting long-distance belt conveyors and pipe conveyors as a more efficient alternative. These systems allow continuous material transport over distances of 10–15 kilometres, significantly reducing fuel consumption and operating costs while improving environmental performance, states the FLSmidth Cement Industry Technology Report, 2024.
Milind Khangan, Marketing Manager, Vertex Market Research & Consulting, says, “Efficient and enclosed handling of fine materials such as cement, fly ash and slag requires modern pneumatic conveying systems. By optimising the air-to-material ratio, these systems can reduce energy consumption by 10 per cent to 15 per cent while ensuring smooth material flow. Closed-loop conveying further minimises dust loading and improves the performance of bag filters, supporting cleaner plant operations. In addition, flow-regulated conveying lines help prevent clogging and maintain reliable dispatch performance. Overall, automation in pneumatic conveying delivers immediate operational benefits, including improved equipment uptime, lower energy use, reduced material spillage and more stable kiln and mill performance.”
Pipe conveyor systems are particularly gaining traction because they provide a completely enclosed transport system that prevents material spillage and dust emissions. According to global cement engineering studies, conveyor-based transport can reduce energy consumption by up to 30 per cent compared to truck haulage, while also improving operational reliability. Several cement plants in India have already implemented such systems to stabilise quarry-to-plant logistics while reducing carbon emissions associated with diesel transport.

Stockyard management and homogenisation
Stockyards play a critical role in maintaining raw material consistency and stabilising kiln feed quality. Modern cement plants use advanced stacker and reclaimer systems to ensure efficient storage and blending of raw materials before they enter the grinding and pyroprocessing stages. Automated stacking methods such as chevron or windrow stacking enable uniform distribution of materials, while bridge-type or portal reclaimers ensure consistent extraction during kiln feed preparation. These systems are essential for maintaining stable chemical composition of raw meal, which directly influences kiln efficiency and clinker quality. The Cement Plant Operations Handbook, 2024 indicates that advanced homogenisation systems can reduce raw mix variability by up to 50 per cent, significantly improving kiln stability and energy efficiency. Integrated stockyard management systems also incorporate sensors for monitoring bulk density, moisture levels and stockpile volumes, enabling real-time control over material blending processes.

Clinker and cement conveying technologies
Once clinker is produced in the kiln, it must be efficiently transported to storage silos and subsequently to grinding and packing units. Modern cement plants rely on high-capacity belt conveyors, bucket elevators and pneumatic conveying systems to manage this stage of material flow. Steel-cord belt bucket elevators are now capable of lifting materials to heights exceeding 120 metres with capacities reaching 1,500 tonnes per hour, making them suitable for large-scale clinker production lines, states the European Cement Engineering Association Technical Paper, 2023.
For fine materials such as cement, fly ash and slag, pneumatic conveying systems provide a reliable and dust-free solution. These systems transport powdered materials using controlled airflow, ensuring enclosed and contamination-free movement between grinding units, silos and packing stations. Optimised pneumatic systems can reduce energy consumption by 10 per cent to 15 per cent compared to older conveying technologies, while also improving plant cleanliness and environmental compliance, according to the Global Cement Technology Review, 2024.

Automation and digitalisation
Digitalisation is transforming material handling systems by introducing real-time monitoring, predictive maintenance and automated control. Advanced sensors and Industrial Internet of Things (IIoT) platforms enable plant operators to track conveyor health, stockpile levels and equipment performance in real time. Predictive maintenance systems analyse vibration patterns, temperature fluctuations and equipment load data to detect potential failures before they occur. According to McKinsey’s Industry 4.0 Manufacturing Report, 2023, for heavy industries, digital monitoring and predictive maintenance technologies can reduce equipment downtime by up to 30 per cent and increase productivity by 10 per cent to 15 per cent. Digital control centres also integrate data from conveyors, stacker reclaimers and dispatch systems, enabling centralised management of material flows from quarry to dispatch.

Handling of AFR
The growing adoption of Alternative Fuels and Raw Materials (AFR) has introduced new challenges and opportunities for material handling systems in cement plants. AFR materials such as refuse-derived fuel (RDF), biomass and industrial waste often have irregular particle sizes, variable moisture content and lower bulk density compared to conventional fuels. As a result, specialised storage, dosing and feeding systems are required to ensure consistent kiln combustion. According to the Cement Sector Decarbonisation Roadmap published by NITI Aayog in 2026, increasing the use of AFR could enable India’s cement sector to achieve thermal substitution rates of around 20 per cent in the coming decades. To support this transition, plants are investing in automated receiving stations, shredding units, drying systems and precision dosing equipment to stabilise AFR supply and combustion performance.

Energy efficiency and dust control
Material handling systems also play a crucial role in improving plant energy efficiency and environmental performance. Modern conveyor systems equipped with variable speed drives and energy-efficient motors can significantly reduce electricity consumption. Permanent magnet motors used in conveyor drives can deliver 8 per cent to 12 per cent energy savings compared to conventional induction motors, improving overall plant energy efficiency according to the IEA Industrial Energy Efficiency Study, 2023. Dust control is another major concern in cement plants, particularly during material transfer and storage operations. Enclosed conveyors, dust extraction systems and advanced bag filters are widely used to minimise particulate emissions and improve workplace safety.

Future trends in material handling
The future of material handling in cement plants will be shaped by automation, digitalisation and sustainability considerations. Emerging technologies such as AI-driven logistics optimisation, autonomous mobile equipment and digital twins are expected to further improve plant efficiency and operational visibility. Digital twin models allow engineers to simulate material flow patterns, optimise stockyard operations and predict equipment performance under different operating conditions. According to the International Energy Agency Digitalisation and Energy Report, 2024, the adoption of advanced digital technologies could improve industrial energy efficiency by up to 20 per cent in heavy industries such as cement manufacturing. As cement plants expand capacity and adopt low-carbon technologies, intelligent material handling systems will play a critical role in maintaining productivity and reducing environmental impact.

Conclusion
Material handling systems have evolved from basic transport infrastructure into strategic operational systems that directly influence plant efficiency, reliability and sustainability. From quarry transport and automated stockyards to digital dispatch platforms and advanced conveying technologies, modern material handling solutions enable cement plants to manage large production volumes while maintaining process stability.
As India’s cement industry continues to expand to meet infrastructure and urban development demands, investments in advanced material handling technologies will become increasingly important. By integrating automation, digital monitoring and energy-efficient systems, cement manufacturers can improve operational performance while supporting the industry’s long-term sustainability and decarbonisation goals.