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Technology should be used along with traditional safety protocols

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Kanishk Khanna, CEO, Elion Technologies and Consulting, sheds light on the auditing of safety and compliance procedures at cement plants.

Tell us about your process of auditing a cement plant for its safety and compliance.
The process of auditing a cement plant for safety and compliance typically involves several steps, including:

  • Planning: The auditor will develop an audit plan that outlines the scope of the audit, the areas that will be evaluated and the resources that will be needed.
  • Preparation: The auditor will gather information about the cement plant, including its
  • operations, safety procedures and any relevant regulatory requirements.
  • On-site assessment: The auditor will visit the plant and conduct a thorough examination of the facility, including inspecting equipment
  • and machinery, observing operations and interviewing employees.
  • Documentation review: The auditor will review the plant’s safety records and documentation, including training records, incident reports and safety inspection records.
  • Reporting: The auditor will prepare a report that summarises the findings of the audit and makes recommendations for improvements to the plant’s safety and compliance.
  • Follow-up: The auditor will follow up with the plant management to ensure that any issues identified during the audit are addressed and to verify that the recommended improvements have been implemented.

What is the importance of safety audits?
Safety audits are important for several reasons:

  • Compliance: Safety audits help ensure that a facility is meeting all relevant safety regulations and standards, which can help prevent fines, penalties and legal action.
  • Risk management: Audits help identify potential safety hazards and risks, which can be addressed before they lead to accidents or injuries.
  • Continuous improvement: Safety audits can help identify areas where a facility can improve its safety practices and procedures, which can lead to a safer work environment and fewer incidents over time.
  • Reputation management: Having a good safety record can help to improve a company’s reputation and can attract customers, investors and employees.
  • Legal and insurance: Safety audits can help reduce the risk of legal action and insurance claims, which can also save a company money in the long run.

Overall, safety audits are an essential tool for maintaining a safe and compliant workplace, protecting employees and ensuring that a company is meeting its legal and moral obligations to provide a safe
work environment.

How often do you conduct cement plant safety audits? What is the recommended timeline?
In general, it is a good practice to conduct safety audits at least once a year, but some companies may choose to conduct them more frequently. Cement plants possess multiple hazards so it is also important to conduct safety audits following any significant changes to the facility or its operations, such as new equipment or processes or after any incidents
or accidents.
Annual Safety Audits are also mandatory as per factory rules. For these audits, the rules vary from state to state.

What role does data and technology play in ensuring plant safety?
Data and technology can play an important role in ensuring plant safety by providing real-time monitoring, analysis and reporting capabilities that can help to identify and address potential hazards before they lead to accidents or injuries. However, it’s important to keep in mind that technology should be used along with traditional safety protocols and procedures, and the companies should have a well-structured plan on how to use these technologies.

Tell us about the key safety concerns you have observed at cement plants.
Cement plants have many safety concerns due to the nature of the materials and processes involved. The major hazards exist not only during running operation but also during the shutdown activities. The major hazards/incidents that have been identified include accidents in heavy machinery and equipment.
Explosions and fires have occurred especially in the mining area. Cement plants have many areas that are classified as confined spaces, and employees working in these areas are at risk of suffocation or other hazards. This needs special attention especially during the shutdown.

It is also important to ensure proper Job Safety Analysis, Training and PPE for the works being performed specially for the mechanical works.
It’s important for cement plant management to ensure that all safety concerns are addressed and to implement safety protocols and procedures to protect employees and the environment. Regular safety audits and inspections, employee training, and proper maintenance of equipment are some ways to mitigate these safety concerns.

What safety equipment do you recommend Indian cement plants to use?
Few examples of safety equipment that may be recommended for use in Indian cement plants:

  • Respirators and dust masks: To protect employees from inhaling dust and particulate matter.
  • Earplugs or earmuffs: To protect employees from excessive noise levels.
  • Fire extinguishers and fire suppression systems: To protect against explosions and fires.
  • Personal protective equipment (PPE): Hard hats, safety glasses, gloves, and steel-toed boots help protect employees from accidents and injuries.
  • Confined space equipment: Harnesses, ladders and gas monitors to help protect employees who are working in confined spaces.
  • Emergency eyewash and shower stations: To provide quick and easy access to emergency treatment in case of chemical spills or exposure.
  • Safety signs and labels: To help identify potential hazards and provide instructions for safe operation of equipment and machinery.
  • Traffic safety equipment: Traffic cones, barriers and warning lights help to protect employees and visitors from vehicle and traffic hazards.
  • Slips, trips and fall protection equipment: Non-slip mats, handrails, and guardrails help to protect employees from slips, trips and falls.

It is important to note that these are just examples of safety equipment that may be recommended for use in Indian cement plants, and the specific equipment required will depend on the layout and operations of the specific plant.

Tell us about the key challenges in safety audits and how can the cement industry help you overcome the same?
Safety audits require a significant investment of time and money, and some companies are not willing to provide the resources to conduct them on a regular basis. At many times the staff on the field feels like an audit is a fault finding procedure and tries to suppress the facts. The industry can invest in safety audits by providing the necessary funding and personnel. The audit activity should be given importance and management should encourage the site staff to proactively participate in the audit activities.

-Kanika Mathur

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

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