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Using AI to Achieve Operational Excellence

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Artificial Intelligence (Al) and Machine Learning (Ml) offer definite advantages in enhancing operational excellence of cement plants.
Dr SB Hegde, Professor, Jain University and Visiting Professor, Pennsylvania State University, USA, writes about the expanding and accelerating use of AI in the cement sector in a bid to reduce operating expenses while increasing yield, enhancing quality and lowering emissions.

The three main factors driving cement producers’ adoption of Artificial Intelligence (AI) are as follows:
computing power connected devices algorithms

In its daily operations, the cement industry faces a variety of difficulties related to profitability, cost control, quality versus throughput, emissions and environmental sustainability. Cement manufacturers can overcome these challenges thanks to the many benefits that AI offers. The game-changing technology that many cement producers have been waiting for is the ability to perform sophisticated data analytics and intelligent optimisation supported by AI. Artificial Intelligence is like a formula that achieves goals in new situations. The formula adapts to change rather than remain a static algorithm.

Cement manufacturers can achieve key performance indicators for operational excellence, connected workers, connected processes, and sustainability. Here are a few typical applications of AI in the manufacture of cement.

The following are the value drivers in a cement plant where AI and Machine Learning (ML) will be of great help and they are as follows:SustainabilityProcess performanceAsset performanceConnected workforceOperational excellence.

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ML, a subset of AI, is the principle that a machine can learn without human intervention, developing its own algorithm to improve the performance of a specific task. ML can only solve problems formulated for it. Not every optimisation method it learns from data makes sense in real life or delivers tangible benefits.

Deep Learning is a more sophisticated version of ML used to perform more complex tasks or to produce data needed for decision-making. It uses multi-layered neural networks for a more powerful way to filter and process information. Neural Networks is a set of algorithms loosely modelled on the way the human brain processes information.Ai and Sustainability
AI will be essential in achieving environmental sustainability goals, not just in terms of reducing emissions but also in terms of energy management and optimisation. As a result, operating costs and profit margins will immediately improve, and new business models for high-tech, low-CO2 cements will be possible. Cement plants are constantly working to stay within the daily SO2 emission limits and the hydrate consumption that goes along with them. They have a lot of process limitations to balance. Due to complex dynamics and the variability of feed and fuel sources, manual operators using PID control tend to keep ‘safe distances’ from process constraints, which reduces plant profitability.

Continuous Process Improvement

For plants to operate more profitably, traditional advanced process control (APC) solutions successfully address processes like clinker-to-cement ratio reduction, fuel switching and thermal efficiency. They include:
Increase feed by over 3 tph while reducing specific energy by 20 kcal/kgDeliver overall productivity increases of 4 per cent with better and more consistent cement quality.

Tying analytics and APC together will enable re-modelling and tuning in an automated way and optimising additional variables. Many technology suppliers are also working on utilising data collected through cement information management systems to address challenges that have not yet been tackled such as cement quality prediction.

Traditionally, cement strength is assessed after 28 days, which is obviously too late to make adjustments. As a result, plants frequently ‘over deliver’ on product specifications. On the day of sampling, technology providers are using ML and data-driven soft sensors to forecast 28-day strength, enabling quick process adjustments.

Setting new Blaines targets each day is required for this. Additionally, it means that cement plants will be able to sell more products with the proper specifications.

Asset Performance Management

Utilising AI for asset performance management (APM) is a significant improvement in how the maintenance and reliability team works with other departments. Depending on shifting production objectives, AI makes sure assets are available at the time and performance level required by the operations. Because complex systems interact in unexpected ways and are constantly changing, it is challenging to predict how assets will react and respond to different factors (like age or operating condition). Problems are frequently invisible to the human eye. AI/ML models can be continuously trained with pertinent datasets in order to provide precise target parameter predictions in close to real-time and to avoid failures. These datasets demonstrate in-depth knowledge of asset behaviour as well as cement processes.

AI-enabled APM is the most economical

method for extending the life of older and newer assets and determining the best time for scheduled maintenance turnarounds (one of the biggest costs in cement plants). Cement plants may be able to operate more efficiently and with remote management thanks to predictive asset models. Operating a cement plant with three shifts of just three people would be possible at the time of writing, which is during the global COVID-19 pandemic. The remote teams working from their homes would have complete access to data that would inform them of the condition of all the assets in the plant if they used an APM solution powered by predictive asset models.

Connected Workforce as a Change Catalyst

By analysing how operators interact with control systems and how quickly they react to alarms, AI will increase workforce productivity. AI is able to learn which priority alarms call for quicker responses. The visibility of these alarms will then be improved by filtering and rationalising them to enhance performance.

The use of mobile technologies, smart glasses and human-centric control rooms will increase the industry’s appeal to the next generation of engineers. By enabling more people to access low-code/no-code solutions, enabling them to capture ‘tribal knowledge’ on a common platform, innovate, and produce better results, technology can aid cement manufacturers in the development of their employees’ AI capabilities.

Secret to Operational Excellence is Visibility

Companies can optimise production and find the best operating points to increase margins by transferring knowledge and process methodology from higher performing to lower performing facilities.

Future modular and prefabricated construction will require less cement, so AI will be crucial in restructuring operations to maintain profitability as cement demand declines. AI helps with better supply chain management planning by analysing previous procurement methods.

Enabling autonomous operation
Without a doubt, the digital revolution in the cement industry is driven by more and better data, which is collected directly from connected machinery, processes, soft sensor models and other systems.

The degree to which equipment, processes, plant operators and corporate management are connected by digital and automation technologies is unprecedented. The concept of an autonomous plant will eventually become a reality thanks to advanced data analytics and artificial intelligence.

Prospects for the Future

1. AI will collect data from a wider range of sources, such as sophisticated sensors, instruments, historians and databases. Even though data from 20 years ago may not be available, there will be more data available so that AI algorithms can advance.
2. As AI implementation becomes simpler, more cement producers will use AI to meet sustainability goals. Since manual setpoint adjustments alone are not sufficient to achieve those goals. The use of AI will help the cement industry become more reputable and reduce its carbon footprint.
3. Based on outside disturbances, unit area models will continuously retrain themselves. With increased confidence as a result of autonomous operations, cement companies will feel more at ease with having fewer human operators in a plant.
4. AI will help them become autonomous themselves. Core areas like operational excellence, process performance and asset performance will continue to provide value.

ABOUT THE AUTHOR
Dr SB Hegde is currently a visiting professor at Pennsylvania State University in the United States of America and a professor at Jain University in Karnataka, India. He had held ‘Leadership Positions’ in significant and top cement businesses both in India and abroad. He has more than 154 research papers that have been published in both national and international journals. Dr Hegde was also the recipient of the Global Visionary Award.

Concrete

Technology plays a critical role in achieving our goals

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Arasu Shanmugam, Director and CEO-India, IFGL, discusses the diversification of the refractory sector into the cement industry with sustainable and innovative solutions, including green refractories and advanced technologies like shotcrete.

Tell us about your company, it being India’s first refractory all Indian MNC.
IFGL Refractories has traditionally focused on the steel industry. However, as part of our diversification strategy, we decided to expand into the cement sector a year ago, offering a comprehensive range of solutions. These solutions cover the entire process, from the preheater stage to the cooler. On the product side, we provide a full range, including alumina bricks, monolithics, castables, and basic refractories.
In a remarkably short span of time, we have built the capability to offer complete solutions to the cement industry using our own products. Although the cement segment is new for IFGL, the team handling this business vertical has 30 years of experience in the cement industry. This expertise has been instrumental in establishing a brand-new greenfield project for alumina bricks, which is now operational. Since production began in May, we are fully booked for the next six months, with orders extending until May 2025. This demonstrates the credibility we have quickly established, driven by our team’s experience and the company’s agility, which has been a core strength for us in the steel industry and will now benefit our cement initiatives.
As a 100 per cent Indian-owned multinational company, IFGL stands out in the refractory sector, where most leading players providing cement solutions are foreign-owned. We are listed on the stock exchange and have a global footprint, including plants in the United Kingdom, where we are the largest refractory producer, thanks to our operations with Sheffield Refractories and Monocon. Additionally, we have a plant in the United States that produces state-of-the-art black refractories for critical steel applications, a plant in Germany providing filtering solutions for the foundry sector, and a base in China, ensuring secure access to high-quality raw materials.
China, as a major source of pure raw materials for refractories, is critical to the global supply chain. We have strategically developed our own base there, ensuring both raw material security and technological advancements. For instance, Sheffield Refractories is a leader in cutting-edge shotcreting technology, which is particularly relevant to the cement industry. Since downtime in cement plants incurs costs far greater than refractory expenses, this technology, which enables rapid repairs and quicker return to production, is a game-changer. Leading cement manufacturers in the country have already expressed significant interest in this service, which we plan to launch in March 2025.
With this strong foundation, we are entering the cement industry with confidence and a commitment to delivering innovative and efficient solutions.
Could you share any differences you’ve observed in business operations between regions like Europe, India, and China? How do their functionalities and approaches vary?
When it comes to business functionality, Europe is unfortunately a shrinking market. There is a noticeable lack of enthusiasm, and companies there often face challenges in forming partnerships with vendors. In contrast, India presents an evolving scenario where close partnerships with vendors have become a key trend. About 15 years ago, refractory suppliers were viewed merely as vendors supplying commodities. Today, however, they are integral to the customer’s value creation chain.
We now have a deep understanding of our customers’ process variations and advancements. This integration allows us to align our refractory solutions with their evolving processes, strengthening our role as a value chain partner. This collaborative approach is a major differentiator, and I don’t see it happening anywhere else on the same scale. Additionally, India is the only region globally experiencing significant growth. As a result, international players are increasingly looking at India as a potential market for expansion. Given this, we take pride in being an Indian company for over four decades and aim to contribute to making Aatma Nirbhar Bharat (self-reliant India) a reality.
Moving on to the net-zero mission, it’s crucial to discuss our contributions to sustainability in the cement industry. Traditionally, we focused on providing burnt bricks, which require significant fuel consumption during firing and result in higher greenhouse gas emissions, particularly CO2. With the introduction of Sheffield Refractories’ green technology, we are now promoting the use of green refractories in cement production. Increasing the share of green refractories naturally reduces CO2 emissions per ton of clinker produced.
Our honourable Prime Minister has set the goal of achieving net-zero emissions by 2070. We are committed to being key enablers of this vision by expanding the use of green refractories and providing sustainable solutions to the cement industry, reducing reliance on burnt refractories.

Technology is advancing rapidly. What role does it play in helping you achieve your targets and support the cement industry?
Technology plays a critical role in achieving our goals and supporting the cement industry. As I mentioned earlier, the reduction in specific refractory consumption is driven by two key factors: refining customer processes and enhancing refractory quality. By working closely as partners with our customers, we gain a deeper understanding of their evolving needs, enabling us to continuously innovate. For example, in November 2022, we established a state-of-the-art research centre in India for IFGL, something we didn’t have before.
The primary objective of this centre is to leverage in-house technology to enhance the utilisation of recycled materials in manufacturing our products. By increasing the proportion of recycled materials, we reduce the depletion of natural resources and greenhouse gas emissions. In essence, our focus is on developing sustainable, green refractories while promoting circularity in our business processes. This multi-faceted approach ensures we contribute to environmental sustainability while meeting the industry’s demands.

Of course, this all sounds promising, but there must be challenges you’re facing along the way. Could you elaborate on those?
One challenge we face is related to India’s mineral resources. For instance, there are oxide deposits in the Saurashtra region of Gujarat, but unfortunately, they contain a higher percentage of impurities. On the magnesite side, India has deposits in three regions: Salem in Tamil Nadu, Almora in Uttarakhand, and Jammu. However, these magnesite deposits also have impurities. We believe the government should take up research and development initiatives to beneficiate these minerals, which are abundantly available in India, and make them suitable for producing high-end refractories. This task is beyond the capacity of an individual refractories company and requires focused policy intervention. While the government is undertaking several initiatives, beneficiation of minerals like Indian magnesite and Indian oxide needs to become a key area of focus.
Another crucial policy support we require is recognising the importance of refractories in industrial production. The reality is that without refractories, not even a single kilogram of steel or cement can be produced. Despite this, refractories are not included in the list of core industries. We urge the government to designate refractories as a core industry, which would ensure dedicated focus, including R&D allocations for initiatives like raw material beneficiation. At IFGL, we are taking proactive steps to address some of these challenges. For instance, we own Sheffield Refractories, a global leader in shotcrete technology. We are bringing this technology to India, with implementation planned from March onwards. Additionally, our partnership with Marvel Refractories in China enables us to leverage their expertise in providing high-quality refractories for steel and cement industries worldwide.
While we are making significant efforts at our level, policy support from the government—such as recognising refractories as a core industry and fostering research for local raw material beneficiation—would accelerate progress. This combined effort would greatly enhance India’s capability to produce high-end refractories and meet the growing demands of critical industries.

Could you share your opinion on the journey toward achieving net-zero emissions? How do you envision this journey unfolding?
The journey toward net zero is progressing steadily. For instance, even at this conference, we can observe the commitment as a country toward this goal. Achieving net zero involves having a clear starting point, a defined objective, and a pace to progress. I believe we are already moving at an impressive speed toward realising this goal. One example is the significant reduction in energy consumption per ton of clinker, which has halved over the past 7–8 years—a remarkable achievement.
Another critical aspect is the emphasis on circularity in the cement industry. The use of gypsum, which is a byproduct of the fertiliser and chemical industries, as well as fly ash generated by the power industry, has been effectively incorporated into cement production. Additionally, a recent advancement involves the use of calcined clay as an active component in cement. I am particularly encouraged by discussions around incorporating 12 per cent to 15 per cent limestone into the mix without the need for burning, which does not compromise the quality of the final product. These strategies demonstrate the cement industry’s constructive and innovative approach toward achieving net-zero emissions. The pace at which these advancements are being adopted is highly encouraging, and I believe we are on a fast track to reaching this critical milestone.

– Kanika Mathur

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ARAPL Reports 175% EBITDA Growth, Expands Global Robotics Footprint

Affordable Robotic & Automation posts strong Q2 and H1 FY26 results driven by innovation and overseas orders

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Affordable Robotic & Automation Limited (ARAPL), India’s first listed robotics firm and a pioneer in industrial automation and smart robotic solutions, has reported robust financial results for the second quarter and half year ended September 30, 2025.
The company achieved a 175 per cent year-on-year rise in standalone EBITDA and strong revenue growth across its automation and robotics segments. The Board of Directors approved the unaudited financial results on October 10, 2025.

Key Highlights – Q2 FY2026
• Strong momentum across core automation and robotics divisions
• Secured the first order for the Atlas AC2000, an autonomous truck loading and unloading forklift, from a leading US logistics player
• Rebranded its RaaS product line as Humro (Human + Robot), symbolising collaborative automation between people and machines
• Expanded its Humro range in global warehouse automation markets
• Continued investment in deep-tech innovations, including AI-based route optimisation, autonomy kits, vehicle controllers, and digital twins
Global Milestone: First Atlas AC2000 Order in the US

ARAPL’s US-based subsidiary, ARAPL RaaS (Humro), received its first order for the next-generation Atlas AC2000 autonomous forklift from a leading logistics company. Following successful prototype trials, the client placed an order for two robots valued at Rs 36 million under a three-year lease. The project opens opportunities for scaling up to 15–16 robots per site across 15 US warehouses within two years.
The product addresses an untapped market of 10 million loading docks across 21,000 warehouses in the US, positioning ARAPL for exponential growth.

Financial Performance – Q2 FY2026 (Standalone)
Net Revenue: Rs 25.7587 million, up 37 per cent quarter-on-quarter
EBITDA: Rs 5.9632 million, up 396 per cent QoQ
Profit Before Tax: Rs 4.3808 million, compared to a Rs 360.46 lakh loss in Q1
Profit After Tax: Rs 4.1854 lakh, representing 216 per cent QoQ growth
On a half-year basis, ARAPL reported a 175 per cent rise in EBITDA and returned to profitability with Rs 58.08 lakh PAT, highlighting strong operational efficiency and improved contribution from core businesses.
Consolidated Performance – Q2 FY2026
Net Revenue: Rs 29.566 million, up 57% QoQ
EBITDA: Rs 6.2608 million, up 418 per cent QoQ
Profit After Tax: Rs 4.5672 million, marking a 224 per cent QoQ improvement

Milind Padole, Managing Director, ARAPL said, “Our Q2 results reflect the success of our innovation-led growth strategy and the growing global confidence in ARAPL’s technology. The Atlas AC2000 order marks a defining milestone that validates our engineering strength and accelerates our global expansion. With a healthy order book and continued investment in AI and autonomous systems, ARAPL is positioned to lead the next phase of intelligent industrial transformation.”
Founded in 2005 and headquartered in Pune, Affordable Robotic & Automation Ltd (ARAPL) delivers turnkey robotic and automation solutions across automotive, general manufacturing, and government sectors. Its offerings include robotic welding, automated inspection, assembly automation, automated parking systems, and autonomous driverless forklifts.
ARAPL operates five advanced plants in Pune spanning 350,000 sq ft, supported by over 400 engineers in India and seven team members in the US. The company also maintains facilities in North Carolina and California, and service centres in Faridabad, Mumbai, and San Francisco.

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M.E. Energy Bags Rs 490 Mn Order for Waste Heat Recovery Project

Second major EPC contract from Ferro Alloys sector strengthens company’s growth

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M.E. Energy Pvt Ltd, a wholly owned subsidiary of Kilburn Engineering Ltd and a leading Indian engineering company specialising in energy recovery and cost reduction, has secured its second consecutive major order worth Rs 490 million in the Ferro Alloys sector. The order covers the Engineering, Procurement and Construction (EPC) of a 12 MW Waste Heat Recovery Based Power Plant (WHRPP).

This repeat order underscores the Ferro Alloys industry’s confidence in M.E. Energy’s expertise in delivering efficient and sustainable energy solutions for high-temperature process industries. The project aims to enhance energy efficiency and reduce carbon emissions by converting waste heat into clean power.

“Securing another project in the Ferro Alloys segment reinforces our strong technical credibility. It’s a proud moment as we continue helping our clients achieve sustainability and cost efficiency through innovative waste heat recovery systems,” said K. Vijaysanker Kartha, Managing Director, M.E. Energy Pvt Ltd.

“M.E. Energy’s expansion into sectors such as cement and ferro alloys is yielding solid results. We remain confident of sustained success as we deepen our presence in steel and carbon black industries. These achievements reaffirm our focus on innovation, technology, and energy efficiency,” added Amritanshu Khaitan, Director, Kilburn Engineering Ltd

With this latest order, M.E. Energy has already surpassed its total external order bookings from the previous financial year, recording Rs 138 crore so far in FY26. The company anticipates further growth in the second half, supported by a robust project pipeline and the rising adoption of waste heat recovery technologies across industries.

The development marks continued momentum towards FY27, strengthening M.E. Energy’s position as a leading player in industrial energy optimisation.

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