Concrete
From Grey to Green
Published
2 years agoon
By
admin
Green cement is no longer the future of the industry; it is the present. Manufacturing green cement is a complex process and the technical, economic and regulatory challenges involved are impregnable. However, they also provide the industry with a significant opportunity for innovation. ICR looks at the stumbling blocks and growth paths in the processing of green cement.
Green cement is a type of cement that is manufactured using eco-friendly and sustainable practices, with a focus on reducing carbon emissions and environmental impact. It is made by incorporating waste materials such as fly ash, slag and silica fumes, which are by-products of industrial processes, into the cement mixture. This process not only reduces the amount of waste that ends up in landfills but also reduces the carbon footprint of the cement manufacturing process.
In addition to reducing waste and carbon emissions, green cement also has other benefits over traditional cement. It has a lower water demand and a longer lifespan, which means it can be used for longer periods without needing to be replaced. Additionally, it can be manufactured using renewable energy sources such as solar and wind power, further reducing its environmental impact.

Waste from one industry is wealth for another as can be seen in the use of by-products such as fly ash, slag and silica fumes by the cement companies.
ROLE OF ALTERNATIVE FUELS
Alternative fuels play an important role in the cement manufacturing industry as they offer a more sustainable and eco-friendlier alternative to traditional fossil fuels such as coal and petroleum coke.
Alternative fuels, such as biomass, waste materials, and industrial by-products, have lower carbon content than traditional fossil fuels. By using these fuels, cement manufacturers can significantly reduce their carbon emissions and mitigate their impact on the environment. India is heavily dependent on imports for its fossil fuel requirements. By using alternative fuels, cement manufacturers can reduce their reliance on fossil fuels, which helps to promote energy security and reduce the country’s dependence on imports.
Cement manufacturers in India are using waste materials such as municipal solid waste, agricultural residues and industrial by-products as alternative fuels. This not only helps to reduce waste that would otherwise end up in landfills but also promotes a circular economy by utilising waste materials as a resource. Alternative fuels are often cheaper than traditional fossil fuels. By using alternative fuels, cement manufacturers can improve their
cost competitiveness and potentially lower their operating costs.
Kiran D Patil, Managing Director, Wonder Cement, says, “Our company is aligned with the country’s Net Zero policy and working towards achieving the targets through various initiatives such as using renewable energy, improving energy efficiency, and usage of industrial waste. Additionally, we are continuously working to reduce the environmental impact of our manufacturing process, including reducing water usage, minimising waste generation, and ensuring responsible sourcing of raw materials. We understand that sustainability is critical to the long-term success of our business and to the health of our plant. We are committed to doing our part to achieve a sustainable future. Our plan for the future is to use electrically operated vehicles for our plant operations.”
The use of alternative fuels in cement manufacturing in India offers numerous benefits, both in terms of sustainability and cost competitiveness. As such, the trend towards using alternative fuels is likely to continue and expand in the coming years.

SUPPLEMENTARY CEMENTITIOUS MATERIALS
Supplementary Cementitious Materials (SCMs) can make cement more environmentally friendly and lower in carbon content in several ways:
- Reduced clinker content: Clinker, the primary component of cement, is responsible for a significant amount of carbon emissions during the manufacturing process. By replacing a portion of the clinker with SCMs, such as fly ash, slag, or silica fume, the overall carbon footprint of cement can be reduced.
“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 adopt a higher percentage of alternative fuels in the process,” says D L Kantham, Director – Technical, Penna Cement. - Improved workability: SCMs can improve the workability of cement, which reduces the need for additional water or chemical admixtures. This not only improves the performance of the concrete but also reduces the carbon emissions associated with the production of these additives.
- Increased durability: SCMs can improve the durability of concrete by reducing the porosity and increasing the strength of the material. This reduces the need for maintenance and repairs, which in turn reduces the carbon emissions associated with these activities.
- Reduced waste: SCMs are often industrial by-products or waste materials that would otherwise be disposed of in landfills. By using these materials as a partial replacement for clinker, cement manufacturers can reduce waste and promote a circular economy.
- Improved thermal performance: SCMs can improve the thermal performance of concrete, which reduces the need for additional insulation and reduces the energy consumption associated with heating and cooling.

Indian cement industry is committed to reducing its CO2 emissions intensity by 35 per cent by 2030, compared to 2005 levels
The use of supplementary cementitious materials in cement manufacturing can significantly reduce the carbon footprint of the cement and promote sustainable practices. By using these materials, cement manufacturers can reduce waste, improve the durability and workability of the concrete and promote a circular economy.
ROLE OF AUTOMATION AND TECHNOLOGY
Automation and technology can play a significant role in manufacturing eco-friendly cement by reducing the energy consumption and carbon emissions associated with traditional cement production processes.
Dr S B Hegde, Professor, Jain University and Visiting Professor, Pennsylvania State University, USA, in his article Using AI to Achieve Operational Excellence mentions, “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.”
“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,” he adds.
One way that automation and technology can achieve this is through the use of alternative fuels and raw materials. For example, the use of waste materials such as fly ash, slag and rice husk ash can significantly reduce the amount of CO2 emitted during cement production. Automation can help to monitor and control the process of adding these materials to the cement mix, ensuring consistent quality and reducing waste.
Additionally, automation can be used to optimise the cement manufacturing process, reducing the energy consumption and CO2 emissions associated with traditional methods. This can include using advanced sensors and control systems to monitor and adjust the temperature, pressure, and other key parameters in the production process, optimising the use of energy and resources.
Another way that automation and technology can contribute to eco-friendly cement production is through the use of digital tools such as machine learning and artificial intelligence. These tools can help to predict and prevent equipment failures, optimise energy usage, and improve overall process efficiency.
“Data Analytics has been there in the cement industry for quite some time. The industry is quite standardised with different product lines. The overall process is extremely complex: you have mines, conveyor belts moving raw materials, stockyards, kilns, grinding and so on. Various customers, especially the big players, have had solutions in place to
provide data analytics,” says Manish Chordia, Regional Sales Manager – Cement, South Asia and Africa, ABB.
“When you move to the next step of AI, we have solutions relating to assets and asset reliability. We collect various data like device temperatures, loading patterns, ambient temperatures and the happenings inside the cabinets to do AI-based analytics,”
he adds.
Overall, automation and technology have the potential to have a significant effect on the production of eco-friendly cement, reducing the environmental impact of this important industry while also improving efficiency and quality.
NET ZERO JOURNEY
The Indian cement industry is one of the largest and most energy-intensive industries in the country, accounting for around seven per cent of the world’s total cement production. Cement manufacturing is a highly carbon-intensive process that involves burning fossil fuels, emitting large amounts of CO2 and other GreenHouse Gases. However, the Indian cement industry has been making significant efforts towards achieving Net Zero carbon emissions and promoting green cement.
The Net Zero journey of the Indian cement industry started with the launch of the Cement Sustainability Initiative (CSI) by the World Business Council for Sustainable Development (WBCSD) in 2002. The initiative aimed to reduce CO2 emissions from cement production by improving energy efficiency, using alternative fuels, and developing low-carbon cements.
In 2018, the Indian cement industry committed to reducing its CO2 emissions intensity by 35 per cent by 2030, compared to 2005 levels, through the use of alternative fuels, waste heat recovery, and other innovative technologies. This commitment was made under the Cement Sustainability Initiative’s ‘Getting the Numbers Right’ (GNR) framework.
Dr Arvind Bodhankar, Executive Director, ESG and CRO, Dalmia Bharat, says, “Dalmia Cement has been doing its part and is the pioneer in setting up the target of Net Zero 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,” he adds.
To achieve this target, the Indian cement industry has been implementing various measures, such as use of alternative fuels, energy efficiency, carbon capture and utilisation and more.
The Indian cement industry’s efforts towards Net Zero carbon emissions and promoting green cement have gained significant momentum in recent years. Several cement companies in India, such as Dalmia Cement, ACC and UltraTech Cement, have set ambitious targets for achieving Net Zero carbon emissions by 2050.
GOVERNMENTAL REGULATIONS
The Indian government has introduced various regulations and policies to promote sustainable practices and reduce carbon emissions and waste in the cement manufacturing industry. Here are some of the key regulations that cement manufacturers in India need to comply with:
- PAT Scheme: The Perform, Achieve and Trade (PAT) Scheme is a market-based mechanism that aims to improve energy efficiency in energy-intensive industries such as cement manufacturing. Under this scheme, cement manufacturers are required to meet specific energy consumption targets, failing which they may have to pay penalties.
- National Action Plan on Climate Change: The National Action Plan on Climate Change (NAPCC) aims to mitigate the impacts of climate change by reducing greenhouse gas emissions. The cement manufacturing industry is included in this plan, and cement manufacturers are required to reduce their carbon emissions and implement sustainable practices.
- Solid Waste Management Rules: The Solid Waste Management Rules (2016) require industries to promote the principles of reduce, reuse, and recycle in their operations. Cement manufacturers are required to use alternative fuels such as biomass, agricultural waste, and municipal solid waste as a fuel source in their kilns.
- Cement Industry Standards: The Bureau of Indian Standards (BIS) has introduced standards for cement manufacturing, including requirements for energy consumption, quality, and emissions. Cement manufacturers are required to comply with these standards to ensure that their operations are sustainable and eco-friendly.
- Emission Standards for Cement Plants: The Ministry of Environment, Forest and Climate Change has introduced emission standards for cement plants, including requirements for particulate matter, sulphur dioxide and nitrogen oxides emissions. Cement manufacturers are required to comply with these standards to minimise their impact on the environment.
- The Indian government has introduced a range of regulations and policies to promote sustainable practices in the cement manufacturing industry, including reducing carbon emissions and waste. Cement manufacturers are required to comply with these regulations to ensure that their operations are sustainable and eco-friendly.
In conclusion, green cement has emerged as a crucial solution to address the environmental impact of cement production, which is one of the most carbon-intensive industrial processes. The use of alternative fuels and alternative raw materials, along with the implementation of carbon capture and utilisation technologies, are some of the key strategies that are being adopted by the cement industry to reduce its carbon footprint. Government policies and regulations aimed at promoting the use of green cement and achieving Net Zero emissions are expected to play a critical role in accelerating this transition. As the global demand for cement continues to rise, the adoption of sustainable and eco-friendly practices such as green cement will become increasingly important to ensure a more sustainable future for the construction industry.
-Kanika Mathur

Concrete
Adani’s Strategic Emergence in India’s Cement Landscape
Published
2 weeks agoon
September 16, 2025By
admin
Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.
India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.
Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:
- September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
- December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
- August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
- April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
- Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
- Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
- Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
- Orient Cement: It would serve as a principal manufacturing facility following the merger.
Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:
- By FY 2026: Reach 118 MTPA
- By FY 2028: Target 140 MTPA
These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).
Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.
Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.
Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.
Challenges potentially include:
- Integration challenges across systems, corporate cultures, and plant operations
- Regulatory sanctions for pending mergers and new capacity additions
- Environmental clearances in environmentally sensitive areas and debt management with input price volatility
When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.
Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.
About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.
Concrete
Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series
Published
1 month agoon
August 16, 2025By
admin
PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.
Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.
Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.
Beyond energy efficiency, the retrofit significantly improved operational parameters:
- Lower thermal stress on equipment
- Extended lubricant drain intervals
- Reduction in CO2 emissions and operational costs
These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.
Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:
- Enhanced component protection
- Extended oil life under high loads
- Stable performance across fluctuating temperatures
By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.
Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.
A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

Adani’s Strategic Emergence in India’s Cement Landscape

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

Driving Measurable Gains

Reshaping the Competitive Landscape

CCU testbeds in Tamil Nadu

Adani’s Strategic Emergence in India’s Cement Landscape

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

Driving Measurable Gains

Reshaping the Competitive Landscape
