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Bringing About a Green Change

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VN Balasubramanian, Director – Head BU Polysius India, thyssenkrupp Industries India (tkII), discusses the various factors challenging Indian cement sector’s fight against carbon emissions and the role technology partners play in the larger scheme of things.

BU Polysius has been in existence for over 150 years and has grown from a family-owned brand to a conglomerate. The philosophy of the Polysius group has always centred on quality, reliability and performance. India is a very price sensitive market, but as a group, thyssenkrupp Polysius is driven by the quality and ruggedness of German machinery. Their products may not be the cheapest in terms of price, but are amongst the best in quality. They do not believe in slashing their prices and compromising quality.
Major cement players from the Indian cement industry have relied on thyssenkrupp Polysius and have added multiple lines over the years. In addition, several new customers have also placed orders on Polysius in the recent past. Between 2010 and 2020, tkII Polysius have built 22 Pyro lines, which is a testimony to the reliability, quality of the equipment and service focus for the customer.

Reducing Carbon Footprint
Carbon footprint reduction in the Indian cement industry is not yet a mandatory norm like in the west but the mandates are round the corner. The Indian cement industry has strict guidelines on noise and dust emissions, which they have admirably complied with. There are guidelines on SOx and NOx emissions but no penalties yet for carbon emissions. But the awareness has surely increased. Outside India, BU Polysius have come up with a lot of green technology initiatives for reduction in use of fossil fuels, utilisation of activated clay etc. There are plants in Europe operating on 100 per cent alternative fuel and raw materials (AFR) with equipment supplied by BU Polysius. This has twin advantages of reduction of carbon emissions as well as operational cost advantages to the customers. Polysius offers a complete solution for AFR handling from the collection point to feeding in the calciner with assurance of total substitution rate (TSR) and throughput. The solution is field proven, with several operating references and highly beneficial to the customer and of course, the environment in the larger scheme of things.
In India, the AFR usage is around 15-25 per cent and is very fragmented. The main hurdle in achieving higher TSR rates is the supply chain to ensure continued availability of the waste of the right quality. Secondly, many plants are not AFR ready. However, this trend is changing for the better now with customers insisting on designing AFR-ready plants.
Apart from the standard ISO specifications that they adhere to and following the DIN standards for designs that are based out of Germany, all their equipment are initially designed in Germany and horizontally deployed in India. Hence, the thyssenkrupp India team does not copy, only improvise/ modify to match Indian conditions, get their approvals for BU Polysius and move forward. The vetting is a mandatory process for maintaining standards and reason for higher costs of their products. Every big and small equipment is DIN standard specified and over a period they are vetted. tkII workshops are approved by BU Polysius Germany Quality experts, who also carry out periodic inspections to ensure quality standards.
Customer Complaints at tKII are accorded top priority and resolution within a fixed period is an absolute must. They have a standard four-eyed principle for offer and design submission, vetted by a minimum of two people to avoid any errors.
thyssenkrupp BU Polysius India Global Engineering Centre is one of the two centres in the world, catering to plant design for BU Polysius Germany for their global projects. It comprises handpicked designers trained by Polysius Germany to deliver top class quality on rigid timelines. To maintain the high standards, German experts constantly evaluate and upgrade the skills of the team.

Role of Automation and Technology
Operating costs are constantly on the rise. The goal is to reduce the production cost to the best possible extent for the customers. In the former days, there used to be about 800 people working in a cement plant and today it has been reduced to less than 250 in India. Similar plants overseas operate with less than 100 personnel. This has been possible largely due to digitalisation and automation. The trend is gradually gaining pace in the Indian cement industry as well. Manual intervention in inspection and operation not only increases the cost but also the probability of errors. Today automation is not just a buzzword but the need of the day.
For example, their R&D Centre in Germany can evaluate the real time performance of a Polysius plant in India or any corner in the world without physically visiting. It, of course, comes at a price but with proper planning in the early stages of the project, the cost is negligible. It is possible even in operating plants of any make. The cost incurred vis-à-vis advantages of an automated solution is a no brainer.
Developing a digitalised solution for improving operational efficiency is a challenge, and there are many players in the market but with thyssenkrupp Polysius, the added advantage is the knowledge
of process technology that comes along. Thus, the output from their automation solutions are more precise and accurate, which are accompanied by precise recommendations.
Regarding polab® laboratory automation, Polab stands for POLYSIUS Laboratory. It is one of the most automated and reliable products in the market today. It is a step towards the future where it cuts out personal and human intervention. With the POLAB, samples are collected automatically from every stage of the production line, transported to the lab and results delivered within a few minutes and correction is carried out online.
Earlier cement plant laboratories used to have 6-8 people in a shift and at least 10-12 in the lab for the physical and chemical testing. Now, the POLAB carries out the tests automatically with a robot that does all the testing, and usually operates with just one person per shift to oversee the operation. The total design and supply of crucial components are from Germany. Another USP is the assembly and trial of the entire system in our R&D centre in Germany before being shipped out to the plant location. thyssenkrupp BU Polysius specialises in this kind of automation.
In India, Wonder Cement has four pyro processing lines from BU Polysius through tkII. The association started with the first line and with each new Pyro line, modules added subsequently. The entire system is fully integrated and operational. The key components in all lines are manufactured and assembled in Germany. The quality control at every stage is excellent and very precise. It contributes to the image of Wonder cement. The return on investment is high in this scenario. There are other players also in the market but very few bring with them the technology that is akin to BU Polysius.
polab® is yet another equipment that the company is proud of. They are thinking of steps to further indigenise some components to optimise costs and work on the lines of ‘Make in India’ initiative so that over a period of time, it becomes more affordable for all cement players in India, without any compromise on quality. For the past two years, India has been one of the most fiercely expanding economies and top of the order in terms of capex investments in the cement sector.
A few years ago, thyssenkrupp India used to execute 2-3 pyro lines in a financial year. But in the past couple of years, they are executing on at least five pyro lines with 10-12 raw grinding units simultaneously without any big-time increase in headcount. This has been possible due to the proactive support from the parent organisation in Germany and excellent work of the young and exuberant team in the BU Polysius India. It would not have been possible without them.
With the tremendous thrust on infrastructure in the recent budgets, the Government of India has opened floodgates of opportunity for the cement sector. Hence, the bullish trend should continue for a few more years but will continue to be severely price competitive. Hence, the key lies in optimising design and cost without compromising quality. Indian cement plants are amongst the most efficient worldwide in terms of fuel and power consumption but we are not yet there in terms of emissions and cost competitiveness.
The Government of India and the cement industry are putting efforts in that direction. But, given the size of India and its diversities, the task is daunting. They are optimistic that change will happen soon and tkII BU Polysius with the technology back up is prepared to partner the cement makers to bring this green change to cement manufacturing, which will not only help the current generation but also the future generations.

Kanika Mathur

Concrete

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

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FORNNAX TECHNOLOGY has appointed industry veteran Dieter Jerschl as its new sales partner in Germany to strengthen its presence across Central Europe. The partnership aims to accelerate the adoption of FORNNAX’s high-capacity, sustainable recycling solutions while building long-term regional capabilities.

FORNNAX TECHNOLOGY, one of the leading advanced recycling equipment manufacturers, has announced the appointment of a new sales partner in Germany as part of its strategic expansion into Central Europe. The company has entered into a collaborative agreement with Mr. Dieter Jerschl, a seasoned industry professional with over 20 years of experience in the shredding and recycling sector, to represent and promote FORNNAX’s solutions across key European markets.

Mr. Jerschl brings extensive expertise from his work with renowned companies such as BHS, Eldan, Vecoplan, and others. Over the course of his career, he has successfully led the deployment of both single machines and complete turnkey installations for a wide range of applications, including tyre recycling, cable recycling, municipal solid waste, e-waste, and industrial waste processing.

Speaking about the partnership, Mr. Jerschl said,
“I’ve known FORNNAX for over a decade and have followed their growth closely. What attracted me to this collaboration is their state-of-the-art & high-capacity technology, it is powerful, sustainable, and economically viable. There is great potential to introduce FORNNAX’s innovative systems to more markets across Europe, and I am excited to be part of that journey.”

The partnership will primarily focus on Central Europe, including Germany, Austria, and neighbouring countries, with the flexibility to extend the geographical scope based on project requirements and mutual agreement. The collaboration is structured to evolve over time, with performance-driven expansion and ongoing strategic discussions with FORNNAX’s management. The immediate priority is to build a strong project pipeline and enhance FORNNAX’s brand presence across the region.

FORNNAX’s portfolio of high-performance shredding and pre-processing solutions is well aligned with Europe’s growing demand for sustainable and efficient waste treatment technologies. By partnering with Mr. Jerschl—who brings deep market insight and established industry relationships—FORNNAX aims to accelerate adoption of its solutions and participate in upcoming recycling projects across the region.

As part of the partnership, Mr. Jerschl will also deliver value-added services, including equipment installation, maintenance, and spare parts support through a dedicated technical team. This local service capability is expected to ensure faster project execution, minimise downtime, and enhance overall customer experience.

Commenting on the long-term vision, Mr. Jerschl added,
“We are committed to increasing market awareness and establishing new reference projects across the region. My goal is not only to generate business but to lay the foundation for long-term growth. Ideally, we aim to establish a dedicated FORNNAX legal entity or operational site in Germany over the next five to ten years.”

For FORNNAX, this partnership aligns closely with its global strategy of expanding into key markets through strong regional representation. The company believes that local partnerships are critical for navigating complex market dynamics and delivering solutions tailored to region-specific waste management challenges.

“We see tremendous potential in the Central European market,” said Mr. Jignesh Kundaria, Director and CEO of FORNNAX.
“Partnering with someone as experienced and well-established as Mr. Jerschl gives us a strong foothold and allows us to better serve our customers. This marks a major milestone in our efforts to promote reliable, efficient and future-ready recycling solutions globally,” he added.

This collaboration further strengthens FORNNAX’s commitment to environmental stewardship, innovation, and sustainable waste management, supporting the transition toward a greener and more circular future.

 

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Budget 2026–27 infra thrust and CCUS outlay to lift cement sector outlook

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Higher capex, city-led growth and CCUS funding improve demand visibility and decarbonisation prospects for cement

Mumbai

Cement manufacturers have welcomed the Union Budget 2026–27’s strong infrastructure thrust, with public capital expenditure increased to Rs 12.2 trillion, saying it reinforces infrastructure as the central engine of economic growth and strengthens medium-term prospects for the cement sector. In a statement, the Cement Manufacturers’ Association (CMA) has welcomed the Union budget 2026-27 for reinforcing the ambitions for the nation’s growth balancing the aspirations of the people through inclusivity inspired by the vision of Narendra Modi, Prime Minister of India, for a Viksit Bharat by 2047 and Atmanirbharta.

The budget underscores India’s steady economic trajectory over the past 12 years, marked by fiscal discipline, sustained growth and moderate inflation, and offers strong demand visibility for infrastructure linked sectors such as cement.

The Budget’s strong infrastructure push, with public capital expenditure rising from Rs 11.2 trillion in fiscal year 2025–26 to Rs 12.2 trillion in fiscal year 2026–27, recognises infrastructure as the primary anchor for economic growth creating positive prospects for the Indian cement industry and improving long term visibility for the cement sector. The emphasis on Tier 2 and Tier 3 cities with populations above 5 lakh and the creation of City Economic Regions (CERs) with an allocation of Rs 50 billion per CER over five years, should accelerate construction activity across housing, transport and urban services, supporting broad based cement consumption.

Logistics and connectivity measures announced in the budget are particularly significant for the cement industry. The announcement of new dedicated freight corridors, the operationalisation of 20 additional National Waterways over the next five years, the launch of the Coastal Cargo Promotion Scheme to raise the modal share of waterways and coastal shipping from 6 per cent to 12 per cent by 2047, and the development of ship repair ecosystems should enhance multimodal freight efficiency, reduce logistics costs and improve the sector’s carbon footprint. The announcement of seven high speed rail corridors as growth corridors can be expected to further stimulate regional development and construction demand.

Commenting on the budget, Parth Jindal, President, Cement Manufacturers’ Association (CMA), said, “As India advances towards a Viksit Bharat, the three kartavya articulated in the Union Budget provide a clear context for the Nation’s growth and aspirations, combining economic momentum with capacity building and inclusive progress. The Cement Manufacturers’ Association (CMA) appreciates the Union Budget 2026-27 for the continued emphasis on manufacturing competitiveness, urban development and infrastructure modernisation, supported by over 350 reforms spanning GST simplification, labour codes, quality control rationalisation and coordinated deregulation with States. These reforms, alongside the Budget’s focus on Youth Power and domestic manufacturing capacity under Atmanirbharta, stand to strengthen the investment environment for capital intensive sectors such as Cement. The Union Budget 2026-27 reflects the Government’s focus on infrastructure led development emerging as a structural pillar of India’s growth strategy.”

He added, “The Rs 200 billion CCUS outlay for various sectors, including Cement, fundamentally alters the decarbonisation landscape for India’s emissions intensive industries. CCUS is a significant enabler for large scale decarbonisation of industries such as Cement and this intervention directly addresses the technology and cost requirements of the Cement sector in context. The Cement Industry, fully aligned with the Government of India’s Net Zero commitment by 2070, views this support as critical to enabling the adoption and scale up of CCUS technologies while continuing to meet the Country’s long term infrastructure needs.”

Dr Raghavpat Singhania, Vice President, CMA, said, “The government’s sustained infrastructure push supports employment, regional development and stronger local supply chains. Cement manufacturing clusters act as economic anchors across regions, generating livelihoods in construction, logistics and allied sectors. The budget’s focus on inclusive growth, execution and system level enablers creates a supportive environment for responsible and efficient expansion offering opportunities for economic growth and lending momentum to the cement sector. The increase in public capex to Rs 12.2 trillion, the focus on Tier 2 and Tier 3 cities, and the creation of City Economic Regions stand to strengthen the growth of the cement sector. We welcome the budget’s emphasis on tourism, cultural and social infrastructure, which should broaden construction activity across regions. Investments in tourism facilities, heritage and Buddhist circuits, regional connectivity in Purvodaya and North Eastern States, and the strengthening of emergency and trauma care infrastructure in district hospitals reinforce the cement sector’s role in enabling inclusive growth.”

CMA also noted the Government’s continued commitment to fiscal discipline, with the fiscal deficit estimated at 4.3 per cent of GDP in FY27, reinforcing macroeconomic stability and investor confidence.

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Concrete

Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

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Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

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