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Achieving Net Zero goals is a complex and long-term process

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Dr Arvind Bodhankar, Executive Director, ESG and CRO, Dalmia Bharat, brings to light the various measures undertaken for the production of green cement and the importance of incorporating sustainability in the manufacturing process.

Tell us about the importance of going green for the Indian cement industry?
The cement industry is one of the largest and most energy-intensive industries in India, accounting for a significant share of the country’s industrial emissions. Therefore, the importance of going green in the cement industry in India cannot be overstated. Here are some reasons why:

  • Environmental protection: Cement production is a major source of greenhouse gas emissions, including carbon dioxide, which contribute to global warming and climate change. By adopting green technologies and practices, the cement industry can reduce its carbon footprint and help protect the environment while doing cost optimisation.
  • Energy efficiency: The cement industry is highly energy-intensive, with most of the energy used in the manufacturing process coming from fossil fuels. By improving energy efficiency and using renewable energy sources, the industry can reduce its dependence on fossil fuels and lower its operating costs.
  • Compliance with regulations: Governments around the world are tightening regulations on industrial emissions, and India is no exception. By going green, cement companies can comply with environmental regulations and avoid fines and other penalties of regulations to be introduced in India in the future.
  • Consumer demand: Consumers are increasingly concerned about the environmental impact of the products they use and are demanding more sustainable and eco-friendly products. By going green, cement companies can meet this demand and differentiate themselves in the marketplace.
  • Hence, going green in the cement industry in India is essential for environmental protection, energy efficiency, regulatory compliance and meeting consumer demand for eco-friendly products.

Tell us about the cement blends or products from your organisation that are lower in their carbon content.
Blended cements are a type of cement that is composed of a blend of two or more materials, with at least one of them being a cementitious material such as Portland cement, fly ash, ground granulated blast furnace slag (GGBS), silica fume, or limestone. In India, the following types of blended cements are commonly used and also manufactured by

Dalmia Bharat:

  • Portland Pozzolana Cement (PPC): PPC is a blend of clinker and pozzolanic materials such as fly ash. It is known for its high strength and durability, and is commonly used in construction projects such as dams, bridges, and high-rise buildings.
  • Portland Slag Cement (PSC): PSC is a blend of Clinker and GGBS, which is a by-product of the iron and steel industry. PSC is known for its high strength, low heat of hydration, and resistance to sulfate and chloride attacks, making it suitable for use in marine and coastal structures. Dalmia Bharat is the largest manufacturer of PSC in India. This cement has the lowest carbon footprint.
  • Composite Cement: Composite cement is a blend of OPC/clinker and other cementitious materials such as fly ash or GGBS as well as other materials such as limestone or silica fume. Composite cement is commonly used in construction projects where high durability and strength are required.

We provide the blended cements with brand name of Dalmia INFRAPRO and Dalmia INFRAGREEN in various blended cement categories mentioned above. Other brands include Dalmia DSP and Konark Cement.

Tell us about your Net Zero Goals. How much have you achieved so far?
Net Zero goals refer to the target of achieving Net Zero carbon emissions, where the amount of carbon emissions produced is offset by the amount of carbon removed from the atmosphere. This can be achieved through a combination of reducing carbon emissions through efficient and sustainable manufacturing practices, as well as implementing carbon capture and storage technologies and investing in reforestation or other carbon removal projects.
Achieving Net Zero goals requires significant investments in research and development, process improvements, and alternative energy sources. Many cement manufacturers are exploring the use of alternative fuels and raw materials, as well as adopting technologies such as carbon capture and storage, to help reduce their carbon footprint. It is important to note that achieving Net Zero goals is a complex and long-term process that requires collaboration across the entire industry as well as support from governments, investors and consumers.
At the same time, Dalmia Cement has been doing its part and is the pioneer in setting up the target in the industry. We announced that we will become carbon negative by 2040. We are the first cement company globally to have such an ambitious target. And, we have been working in all spheres of its subject to meet our five-year interim targets. So far, we have been progressing well and ahead of our carbon negative roadmap targets. As compared to the target of 485 NetKgCO2/tonne of cementitious, we have already achieved 463 kgCO2/tonne of cementitious in FY23, which is more than 4.5 per cent reduction below the carbon negative target. All this has been taking place voluntarily without any regulatory push.

How do you incorporate sustainability in your cement manufacturing process?
Here is how sustainability is incorporated in our cement manufacturing process:
Sustainability is an important consideration for cement manufacturing. One way to promote sustainability is by using alternative raw materials and fuels in the manufacturing process. Some key alternative raw materials include fly ash and slag. The use of alternative fuels such as biomass and industrial byproducts can also help to reduce emissions and lower the carbon footprint of cement manufacturing. Dalmia Bharat has been enhancing their use to reduce natural minerals consumption. In addition, sustainable mining practices are being implemented to reduce the environmental impact of mining activities. This includes minimising water usage, using eco-friendly mining techniques, restoring mined land and protecting biodiversity in the surrounding areas.
Water conservation is another important aspect of our sustainability. We are implementing measures such as recycling and reusing water, optimising processes to reduce water usage, and using rainwater harvesting to reduce dependence on freshwater sources. We are more than 14 times water positive organisation on account of water harvesting and saving activities.
Air emissions are another significant concern in cement manufacturing. Technology upgrades, alternative fuels and regular monitoring and reporting of emissions is helping us to reduce emissions and improve air quality within our plants and surrounding areas. To address fugitive emissions, we have implemented several measures, such as using enclosed conveyors, installing dust collection systems, and regularly maintaining equipment to prevent leaks. Additionally, proper training and awareness programs are helping employees to identify and report any fugitive emissions.
Finally, health and safety, people management and community engagement are another set of important considerations for promoting sustainability in our group and manufacturing process. Ensure the safety and well-being of the employees and engagement with local communities helps maintain the smooth relationships with key stakeholders.
By incorporating these measures, we have been progressing on the sustainability journey and reducing our environmental impacts while demonstrating a commitment to responsible business practices.

What is the role of automation and technology in making cement an eco-friendly product?
Automation and technology play a crucial role in making cement manufacturing a more eco-friendly and sustainable process. The use of advanced technologies and automation systems can help cement manufacturers to reduce energy consumption, increase efficiency and minimise waste generation.
One of the significant advantages of automation and technology is that they can help in optimising the cement manufacturing process, thus reducing energy consumption and greenhouse gas emissions. For example, automated kiln control systems can help to maintain precise temperature and pressure conditions in the kiln, leading to more efficient and cleaner burning of fuels. Moreover, the use of advanced technologies, such as artificial intelligence and machine learning, can help in real-time monitoring of the manufacturing process and identification of any inefficiencies or areas of improvement. This can help manufacturers to optimise their operations and reduce waste and emissions.
Predictive maintenance is another key aspect of automation and technology in the cement industry. It involves the use of sensors and data analytics to predict when maintenance will be required on equipment and machinery, allowing for timely repairs and replacements to be made. By implementing a predictive maintenance system, cement plants can reduce the likelihood of equipment breakdowns
and minimise the need for reactive maintenance, which can be time-consuming and expensive.
This can lead to increased efficiency, reduced downtime, and improved overall productivity, while also reducing the environmental impact of the manufacturing process.
Another important aspect of technology in cement manufacturing is the use of digital solutions for tracking and reporting sustainability metrics. This can help manufacturers to monitor their environmental performance and identify areas of improvement to achieve their sustainability goals.

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?
Measuring the impact of green cement on the environment and society requires a comprehensive approach that considers the entire life cycle of the product. We have been taking several steps to measure the impact of our cement on the environment
and society:

  • Environmental Impact Assessment (EIA): We conduct an Environmental Impact Assessment to evaluate the environmental impacts of our Cement production. This includes assessing the impact of raw material extraction, transportation, and manufacturing processes, as well as the energy and water usage and the carbon footprint of
    the product.
  • Social Impact Assessment (SIA): We also evaluate the social impact of Cement production on local communities, including employment opportunities, labour practices and community development. This is done through stakeholder engagement and local knowledge.
  • Life Cycle Assessment (LCA): We have also started conducting Life Cycle Assessment to measure the overall environmental impact of Cement from raw material extraction to disposal. This can help identify areas where improvements can be made to reduce environmental impact. The LCA has potential to identify hotspots or stages in the life cycle where the most environmental impact occurs.
  • Environmental Reporting: We regularly report on environmental performance and progress towards sustainability goals. This includes reporting on carbon emissions, water usage, waste generation, and other key sustainability indicators. Environmental reporting can be done through sustainability reports, annual reports, and other public disclosures. This helps our stakeholders informed and our performance as well as targets checked from independent assurance providers.
  • Stakeholder Engagement: We engage with stakeholders, including local communities, NGOs and regulators, to understand their concerns and perspectives on the impact of cement production. This can help identify opportunities for improvement and build support for sustainability initiatives. Stakeholder engagement also helps in development of sustainability strategies that are aligned with stakeholder expectations.

To continuously improve sustainability, cement, we are taking the following steps:

  • Research and Development: We invest in research and development to develop new low-carbon technologies and processes that reduce environmental impact. This involves developing new materials, improving manufacturing processes, and exploring alternative fuels and energy sources.
  • Efficiency Improvements: We are continuously improving the efficiency of manufacturing processes to reduce energy and water usage and improve environmental performance. This is done through process optimisation, equipment upgrades and energy management systems.
  • Green Procurement: We source raw materials from sustainable and responsible sources, including recycled materials and renewable resources.
  • This helps reduce the environmental impact of raw material extraction and supports
  • sustainable development.
  • Certification: We have third-party certifications to demonstrate the sustainability performance of green cement products under various categories. We also have third party certified plants for management systems. Certification helps us build credibility with customers and investors and it can differentiate green cement products in the market.
  • Collaboration: We collaborate with other companies and stakeholders to share best practices and develop sustainability initiatives that benefit the entire industry including us. This has evolved as associations, collaborating with supplier sand customers, and partnering with NGOs and other stakeholders.

– Kanika Mathur

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The primary high-power applications are fans and mills

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October 10, 2025

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Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.

As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.

How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.

What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.

Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.

Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.

How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.

What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.

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We conduct regular internal energy audits

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Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.

In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.

How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.

What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.

How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.

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Concrete

Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport

The airport is set to become Asia’s largest air connectivity hub.

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October 10, 2025

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Enlight Metals has supplied 3,200 metric tonne of steel for the newly inaugurated Navi Mumbai International Airport, marking a major contribution to one of India’s largest infrastructure projects and reinforcing the company’s commitment to supporting national development.

The Navi Mumbai International Airport, developed under a Public-Private Partnership led by the Adani Group, was inaugurated today by Prime Minister Narendra Modi. The airport is set to become Asia’s largest air connectivity hub, enhancing regional connectivity, boosting economic growth, and expanding trade opportunities. Prime Minister Modi described the project as a “glimpse of Viksit Bharat,” highlighting its transformative impact on infrastructure and development in the region.

“The supply of 3,200 metric tonne of steel for this key project aligns with our focus on supporting critical infrastructure development through reliable and timely metal sourcing. Enlight Metals is committed to enhancing transparency and efficiency in the steel supply chain, contributing to projects integral to India’s growth objectives,” said Vedant Goel, Director, Enlight Metals.

Enlight Metals has implemented technology-driven solutions to strengthen supply chain efficiency, ensuring consistent availability of construction materials for large-scale projects nationwide. Its contribution to the Navi Mumbai International Airport underscores the company’s growing role in supporting India’s infrastructure development initiatives.

This milestone reflects Enlight Metals’ ongoing engagement in delivering quality materials and timely services for major national projects, further cementing its position as a reliable partner in India’s infrastructure sector

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