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Automation leads to significant gains through optimal raw mix

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D L Kantham, Director – Technical, Penna Cement, discusses the use of alternative raw materials and fuels in making green cement, along with the use of technology and automation, to ensure that the industry moves towards Net Zero goals.

Tell us about the importance of going green for the Indian cement industry.
Globally cement production capacity stands at 4.2 billion tonnes per annum. Cement production, a source of anthropogenic CO2, accounts for 8 per cent of global emissions. Indian production capacity currently stands at about 550 million tonnes per annum with annual production of around 370 million tons per annum. Annual cement production is expected to reach about 480 million tons annually by 2028-29. Hence, the cement industry in India must ‘Go Green’ to be aligned with the Net Zero Target by 2050. This target is aligned with the Paris Agreement to limit global warming to 1.50C.

What are the key alternative raw materials used to manufacture green cement?
We use fly ash, slag and other pozzolanic materials as key alternative raw materials to manufacture greener cement.

What is the role of fuel in making cement green? How does the use of alternative fuels impact the productivity and efficiency of the manufacturing process?
Using alternative fuels like pharma wastes and municipal solid wastes, leads to reduced fossil fuel (coal) usage, thereby reducing carbon emission. Alternative fuel utilisation in the cement industry reduces production costs and reduces CO2 emissions in the atmosphere.

Tell us about the cement blends or products from your organisation that are lower in their carbon content.
Penna Power (Portland Pozzolana Cement) conforming to IS 1489:2015 (32-35 per cent fly ash blended), Penna Suraksha (Portland Slag Cement) conforming to IS 455:2015 (38-48 per cent GGBS Blended) and Concrete Guard, a premium blended product conforming to IS: 1489:2015 aimed to motivate and supply 100 per cent blended cement in retail markets satisfying the customer requirements in IHB market segments.

Tell us about your Net Zero goals. How much have you achieved so far?
Our Net Zero goal is to increase our blended cement production ratio to 75 per cent from the 40 per cent level in 2015. Currently, blended cement production constitutes about 55 per cent.

How do you incorporate sustainability in your cement manufacturing process

  • Increasing Clinker to Cement Ratio (Higher use of PFA/GGBS in the mix).
  • Alternative fuels like pet coke, pharma waste and municipal waste.
  • Energy efficiency technologies, such as Waste Heat Recovery to reduce fossil fuel requirements and adaptation of better cement grinding systems (Roller Press), grinding aids, etc.

What is the role of automation and technology in making cement an eco-friendly product?
Automation leads to significant gains through optimal raw mix, better product output in quantity and quality through minimal human involvement and saves time in decision making on end product quality by quicker analysis of raw materials.

What are the major challenges in reducing the carbon content of cement manufacturing, and how can they be resolved?
Two key areas for reducing the carbon content from cement include:
Reduction in clinker to cement ratio through greater uptake of blended cement in all the key consumption segments – housing, government projects, precast cement products and ready-mix concrete. This involves developing new blended cement to suit the requirements in segments where OPC is still preferred for specific reasons, and to adapt to a higher percentage of alternative fuels in the process.
Following actions may be taken to improve greater uptake of blended cements, which leads to a reduction in the clinker cement ratio:

  • We need to enhance market awareness and acceptability because users are reluctant to select blended cement over portland cement in some regions, though substantial progress has happened in India over the past two decades.
  • Need to involve all the key stakeholders – cement manufacturers, government policymakers – national standards, consultants, key end users, and related allied products, e.g., chemical admixtures used in concrete production for exchange of experience on reducing clinker to cement ratio, promote training events with national standardisation bodies and accreditation institutes etc.
  • Independent organisations to develop cement and concrete standards and codes that allow the widespread use of blended cements while ensuring product reliability and durability at final applications to promote the use of blended cement. For example, additional types of blended cement with a higher blending ratio for specific end applications.
  • Government to promote blended cement in sourcing and public procurement policies and the private big project consultants.
  • Industries and universities conduct R&D into processing techniques for potential cement blending materials that cannot be used due to quality constraints, for example, rice husk ash.
  • Introducing a freight subsidy for transporting supplementary cementitious materials from surplus areas to cement clusters is desirable where SCM availability is limited.
  • Deploying innovative technologies (including carbon capture, usage and storage (CCUS)). Government can stimulate investment and innovation in these areas through funding for R&D.

Broadly, CCUS prevents CO2 from being released into the atmosphere by capturing it and either using it or injecting it in geological formations for permanent storage. CCUS will be crucial to reduce cement sector CO2 emissions, particularly the process emissions released during limestone calcination. While the commercial deployment of CCUS is currently limited, several innovative efforts have been underway in recent years.

How do you measure the impact of your green cement on the environment and society, and what steps do you take to continuously improve its sustainability?
Resource and environmental protection agencies use specific indicators to track and enforce
changes. Today, one of the critical measurement techniques is footprint evaluation. The three common footprint indicators are carbon, ecological, water and soil footprint.
Green concrete produced from green cement has been proven to have enhanced the structure’s durability. This ensures a reduction in demand for natural resources (limestone in particular), thereby improving the sustainability, associated energy consumption, and a corresponding decrease in GHG (GreenHouse Gas) emissions.
Additional cement product profiles, for example, Composite Cement and LC3 Cement (Limestone Calcined Clay Cement), are being researched and developed to suit the market requirement, which will help us further improve on sustainability.

-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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