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Supporting Technology with Regulation

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Sridhar S Sundaram, Vice President, Head of Global Product Line – Grinding and Gears, FLSmidth explains the role of technology in enhancing cement manufacturing processes to enable bigger and faster strides towards net zero targets.

Productivity growth through automation in the cement industry has grown from use of technology in the old physiological days to Artificial Intelligence (AI) powered softwares today. Cement plants operate in an automated way but there are still manual interventions that happen in an operating plant. These variations are also controlled now with AI powered softwares. This is helping customers have minimum manual intervention in the operation of the cement plants and increase production up to 5 per cent. However, when productivity increases, the energy consumption also decreases since the systems are automated to use only the optimum amount of energy. FLSmidth has an optimisation software called Process Expert Controller (PXC), which does the trick for cement manufactures and helps them enhance their production and productivity levels.
Data is meant to enable better decision making. There is a control system, optimisation software and apart from these systems, there is also an application called Site Connect. Data from the control system is available at the head office in a monitor, tablet and mobile phone that enables better decision making and managerial interventions, which in due course of time better production and profits. This kind of digitalisation is at a nascent stage. The aim is to get as many plants connected as possible. Data from this software goes to the cloud, then back to the stakeholders i.e., FLSmidth headquarters, customer headquarters, and to all those who need the data to make better decisions.
Work is also in progress on the backend algorithms for data collection. Based on these algorithms, there can be alarms, flags etc., enabling predictive interventions of plant maintenance.

No Alternative to Safety
There are quite a few experts who have spoken about how to reduce CO2. OxyRich fuel and Green Hydrogen are the next generation topics as we exhaust the existing alternative fuel options. When we go from the present 15 per cent use of alternative fuels to 50 to 60 per cent use of alternative fuels, that itself will take care of the sustainability aspect of the cement industry. Beyond this, when CO2 capture is thought of then OxyRich and Green Hydrogen come into play. This technology is evolving and will eventually benefit all industries that have a high emission rate.
The industry must use alternative fuels. Agriculture wastes can contribute up to 10 per cent of alternative fuels. Now, the industry is targeting 30 to 50 per cent use of alternative fuels, which comes out as waste derived fuels. Feedback that has come from the cement plants states that the odour and other problems associated with these fuels could be hazardous to the health. While it is encouraged for cement plants to use alternative fuels, the challenge is to safeguard every employee at the plant and surroundings with the other harmful effects of the waste derived fuels. The approach towards the use of waste derived fuels should be in a manner that all aspects of its use and safety should be taken care of before its implementation.

Technology at its best
The industry has an intention to reduce its carbon footprint and make cement production friendly for the environment. However, without governance and regulation, the implementation will be a challenge and there will be no standard practice. If you go back 30 years when stacks in cement plants had a lot of dust, it was the government that made the norms and kept making them stricter, which has led to a highly reduced dust emission from cement plants. Similarly, usage of technology for reduction of carbon footprint will require intervention and regulation for cement players.
In Europe, there is a penalty known as carbon tax while the talk of Indian industry is Sustainability Incentive. Either way, there needs to be an intervention to bring down emission levels in any industry.

Future Collaborations
FLSmidth is always with its customers. And the company has a mission zero roadmap, too. The strategy and aim are to design a plant with zero emission by 2030. There are steps involved to this.
The first step is to modernise old plants, which will have a huge impact on reducing carbon emission and energy consumption. Second step would be to collaborate with new technologies and make them available in the market in an accelerated manner. For this, a deal has been signed with Dalmia Cement that both companies will collaborate in pushing the sustainability agenda at a much larger scale than before. With Dalmia Cement as a partner, FLSmidth can immediately test its new technologies. Once that is successful, it can be taken to the market faster than before.
The company is looking at partnerships with leading players to help bring better technology to the industry. Their role, too, is key in bringing a change and FLSmidth is looking forward to collaborating with all players of the Indian cement industry.

ABOUT THE AUTHOR:


Sridhar S Sundaram, VP & Head of Global Product Lines – Grinding and Gears, holds managerial expertise with varied and international experience in Technical, Sales and O&M functions.

Concrete

Nuvoco commissions Surat grinding unit

Nuvoco posts 20 per cent rise in Q1 PAT

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Nuvoco Vistas Corp. has announced its financial results for the quarter ended June 30, 2026, reporting growth in volumes, earnings and profitability while advancing its expansion plans in western India.
The company inaugurated a 2-million-tonnes-per-annum (MTPA) grinding unit at its Limla Cement Plant in Surat on July 11, 2026, ahead of schedule. The facility, part of the Vadraj Cement assets, is expected to strengthen Nuvoco’s presence in western India while freeing up capacity at its Rajasthan plants to cater to demand in northern markets.
Progress at the Kutch project remains on track, with phased commissioning scheduled to begin in the third quarter of FY27. The company has also commenced work on a bulk cement terminal at Viramgam, Sachana, Gujarat, featuring a dedicated railway siding. The terminal is expected to become operational by the second quarter of FY28 and will support distribution across Gujarat. These projects form part of Nuvoco’s capacity expansion programme, which is expected to increase its total cement capacity to 35 MTPA by FY28.
During Q1 FY27, the company recorded cement sales volumes of 5.3 million tonnes, up 5 per cent year-on-year. Consolidated total income rose 9 per cent to Rs 31.29 billion, while EBITDA increased 7 per cent to Rs 5.72 billion, marking the company’s highest-ever first-quarter EBITDA. Profit after tax grew 20 per cent year-on-year to Rs 1.60 billion.
Commenting on the results, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp., said the company delivered improved business performance despite macroeconomic and geopolitical challenges. He attributed the results to disciplined execution, cost optimisation and operational efficiencies, while highlighting the early commissioning of the Surat grinding unit as a key milestone in the company’s expansion strategy.
He added that the company remains focused on prudent procurement, supply chain efficiency and cost discipline while monitoring geopolitical developments that could affect industry supply chains and input costs.

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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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