Concrete

From Grey to Green

Published

3 years ago

May 12, 2023

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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

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Concrete

Refractory demands in our kiln have changed

Published

1 day ago

February 20, 2026

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Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, points out why performance, predictability and life-cycle value now matter more than routine replacement in cement kilns.

As Indian cement plants push for higher throughput, increased alternative fuel usage and tighter shutdown cycles, refractory performance in kilns and pyro-processing systems is under growing pressure. In this interview, Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, shares how refractory demands have evolved on the ground and how smarter digital monitoring is improving kiln stability, uptime and clinker quality.

How have refractory demands changed in your kiln and pyro-processing line over the last five years?
Over the last five years, refractory demands in our kiln and pyro line have changed. Earlier, the focus was mostly on standard grades and routine shutdown-based replacement. But now, because of higher production loads, more alternative fuels and raw materials (AFR) usage and greater temperature variation, the expectation from refractory has increased.
In our own case, the current kiln refractory has already completed around 1.5 years, which itself shows how much more we now rely on materials that can handle thermal shock, alkali attack and coating fluctuations. We have moved towards more stable, high-performance linings so that we don’t have to enter the kiln frequently for repairs.
Overall, the shift has been from just ‘installation and run’ to selecting refractories that give longer life, better coating behaviour and more predictable performance under tougher operating conditions.

What are the biggest refractory challenges in the preheater, calciner and cooler zones?
• Preheater: Coating instability, chloride/sulphur cycles and brick erosion.
• Calciner: AFR firing, thermal shock and alkali infiltration.
• Cooler: Severe abrasion, red-river formation and mechanical stress on linings.
Overall, the biggest challenge is maintaining lining stability under highly variable operating conditions.

How do you evaluate and select refractory partners for long-term performance?
In real plant conditions, we don’t select a refractory partner just by looking at price. First, we see their past performance in similar kilns and whether their material has actually survived our operating conditions. We also check how strong their technical support is during shutdowns, because installation quality matters as much as the material itself.
Another key point is how quickly they respond during breakdowns or hot spots. A good partner should be available on short notice. We also look at their failure analysis capability, whether they can explain why a lining failed and suggest improvements.
On top of this, we review the life they delivered in the last few campaigns, their supply reliability and their willingness to offer plant-specific custom solutions instead of generic grades. Only a partner who supports us throughout the life cycle, which includes selection, installation, monitoring and post-failure analysis, fits our long-term requirement.

Can you share a recent example where better refractory selection improved uptime or clinker quality?
Recently, we upgraded to a high-abrasion basic brick at the kiln outlet. Earlier we had frequent chipping and coating loss. With the new lining, thermal stability improved and the coating became much more stable. As a result, our shutdown interval increased and clinker quality remained more consistent. It had a direct impact on our uptime.

How is increased AFR use affecting refractory behaviour?
Increased AFR use is definitely putting more stress on the refractory. The biggest issue we see daily is the rise in chlorine, alkalis and volatiles, which directly attack the lining, especially in the calciner and kiln inlet. AFR firing is also not as stable as conventional fuel, so we face frequent temperature fluctuations, which cause more thermal shock and small cracks in the lining.
Another real problem is coating instability. Some days the coating builds too fast, other days it suddenly drops, and both conditions impact refractory life. We also notice more dust circulation and buildup inside the calciner whenever the AFR mix changes, which again increases erosion.
Because of these practical issues, we have started relying more on alkali-resistant, low-porosity and better thermal shock–resistant materials to handle the additional stress coming from AFR.

What role does digital monitoring or thermal profiling play in your refractory strategy?
Digital tools like kiln shell scanners, IR imaging and thermal profiling help us detect weakening areas much earlier. This reduces unplanned shutdowns, helps identify hotspots accurately and allows us to replace only the critical sections. Overall, our maintenance has shifted from reactive to predictive, improving lining life significantly.

How do you balance cost, durability and installation speed during refractory shutdowns?
We focus on three points:
• Material quality that suits our thermal profile and chemistry.
• Installation speed, in fast turnarounds, we prefer monolithic.
• Life-cycle cost—the cheapest material is not the most economical. We look at durability, future downtime and total cost of ownership.
This balance ensures reliable performance without unnecessary expenditure.

What refractory or pyro-processing innovations could transform Indian cement operations?
Some promising developments include:
• High-performance, low-porosity and nano-bonded refractories
• Precast modular linings to drastically reduce shutdown time
• AI-driven kiln thermal analytics
• Advanced coating management solutions
• More AFR-compatible refractory mixes

These innovations can significantly improve kiln stability, efficiency and maintenance planning across the industry.

Concrete

Digital supply chain visibility is critical

Published

1 day ago

February 20, 2026

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MSR Kali Prasad, Chief Digital and Information Officer, Shree Cement, discusses how data, discipline and scale are turning Industry 4.0 into everyday business reality.

Over the past five years, digitalisation in Indian cement manufacturing has moved decisively beyond experimentation. Today, it is a strategic lever for cost control, operational resilience and sustainability. In this interview, MSR Kali Prasad, Chief Digital and Information Officer, Shree Cement, explains how integrated digital foundations, advanced analytics and real-time visibility are helping deliver measurable business outcomes.

How has digitalisation moved from pilot projects to core strategy in Indian cement manufacturing over the past five years?
Digitalisation in Indian cement has evolved from isolated pilot initiatives into a core business strategy because outcomes are now measurable, repeatable and scalable. The key shift has been the move away from standalone solutions toward an integrated digital foundation built on standardised processes, governed data and enterprise platforms that can be deployed consistently across plants and functions.
At Shree Cement, this transition has been very pragmatic. The early phase focused on visibility through dashboards, reporting, and digitisation of critical workflows. Over time, this has progressed into enterprise-level analytics and decision support across manufacturing and the supply chain,
with clear outcomes in cost optimisation, margin protection and revenue improvement through enhanced customer experience.
Equally important, digital is no longer the responsibility of a single function. It is embedded into day-to-day operations across planning, production, maintenance, despatch and customer servicing, supported by enterprise systems, Industrial Internet of Things (IIoT) data platforms, and a structured approach to change management.

Which digital interventions are delivering the highest ROI across mining, production and logistics today?
In a capital- and cost-intensive sector like cement, the highest returns come from digital interventions that directly reduce unit costs or unlock latent capacity without significant capex.
Supply chain and planning (advanced analytics): Tools for demand forecasting, S&OP, network optimisation and scheduling deliver strong returns by lowering logistics costs, improving service levels, and aligning production with demand in a fragmented and regionally diverse market.
Mining (fleet and productivity analytics): Data-led mine planning, fleet analytics, despatch discipline, and idle-time reduction improve fuel efficiency and equipment utilisation, generating meaningful savings in a cost-heavy operation.
Manufacturing (APC and process analytics): Advanced Process Control, mill optimisation, and variability reduction improve thermal and electrical efficiency, stabilise quality and reduce rework and unplanned stoppages.
Customer experience and revenue enablement (digital platforms): Dealer and retailer apps, order visibility and digitally enabled technical services improve ease of doing business and responsiveness. We are also empowering channel partners with transparent, real-time information on schemes, including eligibility, utilisation status and actionable recommendations, which improves channel satisfaction and market execution while supporting revenue growth.
Overall, while Artificial Intelligence (AI) and IIoT are powerful enablers, it is advanced analytics anchored in strong processes that typically delivers the fastest and most reliable ROI.

How is real-time data helping plants shift from reactive maintenance to predictive and prescriptive operations?
Real-time and near real-time data is driving a more proactive and disciplined maintenance culture, beginning with visibility and progressively moving toward prediction and prescription.
At Shree Cement, we have implemented a robust SAP Plant Maintenance framework to standardise maintenance workflows. This is complemented by IIoT-driven condition monitoring, ensuring consistent capture of equipment health indicators such as vibration, temperature, load, operating patterns and alarms.
Real-time visibility enables early detection of abnormal conditions, allowing teams to intervene before failures occur. As data quality improves and failure histories become structured, predictive models can anticipate likely failure modes and recommend timely interventions, improving MTBF and reducing downtime. Over time, these insights will evolve into prescriptive actions, including spares readiness, maintenance scheduling, and operating parameter adjustments, enabling reliability optimisation with minimal disruption.
A critical success factor is adoption. Predictive insights deliver value only when they are embedded into daily workflows, roles and accountability structures. Without this, they remain insights without action.

In a cost-sensitive market like India, how do cement companies balance digital investment with price competitiveness?
In India’s intensely competitive cement market, digital investments must be tightly linked to tangible business outcomes, particularly cost reduction, service improvement, and faster decision-making.
This balance is achieved by prioritising high-impact use cases such as planning efficiency, logistics optimisation, asset reliability, and process stability, all of which typically deliver quick payback. Equally important is building scalable and governed digital foundations that reduce the marginal cost of rolling out new use cases across plants.
Digitally enabled order management, live despatch visibility, and channel partner platforms also improve customer centricity while controlling cost-to-serve, allowing service levels to improve without proportionate increases in headcount or overheads.
In essence, the most effective digital investments do not add cost. They protect margins by reducing variability, improving planning accuracy, and strengthening execution discipline.

How is digitalisation enabling measurable reductions in energy consumption, emissions, and overall carbon footprint?
Digitalisation plays a pivotal role in improving energy efficiency, reducing emissions and lowering overall carbon intensity.
Real-time monitoring and analytics enable near real-time tracking of energy consumption and critical operating parameters, allowing inefficiencies to be identified quickly and corrective actions to be implemented. Centralised data consolidation across plants enables benchmarking, accelerates best-practice adoption, and drives consistent improvements in energy performance.
Improved asset reliability through predictive maintenance reduces unplanned downtime and process instability, directly lowering energy losses. Digital platforms also support more effective planning and control of renewable energy sources and waste heat recovery systems, reducing dependence on fossil fuels.
Most importantly, digitalisation enables sustainability progress to be tracked with greater accuracy and consistency, supporting long-term ESG commitments.

What role does digital supply chain visibility play in managing demand volatility and regional market dynamics in India?
Digital supply chain visibility is critical in India, where demand is highly regional, seasonality is pronounced, and logistics constraints can shift rapidly.
At Shree Cement, planning operates across multiple horizons. Annual planning focuses on capacity, network footprint and medium-term demand. Monthly S&OP aligns demand, production and logistics, while daily scheduling drives execution-level decisions on despatch, sourcing and prioritisation.
As digital maturity increases, this structure is being augmented by central command-and-control capabilities that manage exceptions such as plant constraints, demand spikes, route disruptions and order prioritisation. Planning is also shifting from aggregated averages to granular, cost-to-serve and exception-based decision-making, improving responsiveness, lowering logistics costs and strengthening service reliability.

How prepared is the current workforce for Industry 4.0, and what reskilling strategies are proving most effective?
Workforce preparedness for Industry 4.0 is improving, though the primary challenge lies in scaling capabilities consistently across diverse roles.
The most effective approach is to define capability requirements by role and tailor enablement accordingly. Senior leadership focuses on digital literacy for governance, investment prioritisation, and value tracking. Middle management is enabled to use analytics for execution discipline and adoption. Frontline sales and service teams benefit from
mobile-first tools and KPI-driven workflows, while shop-floor and plant teams focus on data-driven operations, APC usage, maintenance discipline, safety and quality routines.
Personalised, role-based learning paths, supported by on-ground champions and a clear articulation of practical benefits, drive adoption far more effectively than generic training programmes.

Which emerging digital technologies will fundamentally reshape cement manufacturing in the next decade?
AI and GenAI are expected to have the most significant impact, particularly when combined with connected operations and disciplined processes.
Key technologies likely to reshape the sector include GenAI and agentic AI for faster root-cause analysis, knowledge access, and standardisation of best practices; industrial foundation models that learn patterns across large sensor datasets; digital twins that allow simulation of process changes before implementation; and increasingly autonomous control systems that integrate sensors, AI, and APC to maintain stability with minimal manual intervention.
Over time, this will enable more centralised monitoring and management of plant operations, supported by strong processes, training and capability-building.

Concrete

Redefining Efficiency with Digitalisation

Published

1 day ago

February 20, 2026

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Professor Procyon Mukherjee discusses how as the cement industry accelerates its shift towards digitalisation, data-driven technologies are becoming the mainstay of sustainability and control across the value chain.

The cement industry, long perceived as traditional and resistant to change, is undergoing a profound transformation driven by digital technologies. As global infrastructure demand grows alongside increasing pressure to decarbonise and improve productivity, cement manufacturers are adopting data-centric tools to enhance performance across the value chain. Nowhere is this shift more impactful than in grinding, which is the energy-intensive final stage of cement production, and in the materials that make grinding more efficient: grinding media and grinding aids.

The imperative for digitalisation
Cement production accounts for roughly 7 per cent to 8 per cent of global CO2 emissions, largely due to the energy intensity of clinker production and grinding processes. Digital solutions, such as AI-driven process controls and digital twins, are helping plants improve stability, cut fuel use and reduce emissions while maintaining consistent product quality. In one deployment alongside ABB’s process controls at a Heidelberg plant in Czechia, AI tools cut fuel use by 4 per cent and emissions by 2 per cent, while also improving operational stability.
Digitalisation in cement manufacturing encompasses a suite of technologies, broadly termed as Industrial Internet of Things (IIoT), AI and machine learning, predictive analytics, cloud-based platforms, advanced process control and digital twins, each playing a role in optimising various stages of production from quarrying to despatch.

Grinding: The crucible of efficiency and cost
Of all the stages in cement production, grinding is among the most energy-intensive, historically consuming large amounts of electricity and representing a significant portion of plant operating costs. As a result, optimising grinding operations has become central to digital transformation strategies.
Modern digital systems are transforming grinding mills from mechanical workhorses into intelligent, interconnected assets. Sensors throughout the mill measure parameters such as mill load, vibration, mill speed, particle size distribution, and power consumption. This real-time data, fed into machine learning and advanced process control (APC) systems, can dynamically adjust operating conditions to maintain optimal throughput and energy usage.
For example, advanced grinding systems now predict inefficient conditions, such as impending mill overload, by continuously analysing acoustic and vibration signatures. The system can then proactively adjust clinker feed rates and grinding media distribution to sustain optimal conditions, reducing energy consumption and improving consistency.

Digital twins: Seeing grinding in the virtual world
One of the most transformative digital tools applied in cement grinding is the digital twin, which a real-time virtual replica of physical equipment and processes. By integrating sensor data and
process models, digital twins enable engineers to simulate process variations and run ‘what-if’
scenarios without disrupting actual production. These simulations support decisions on variables such as grinding media charge, mill speed and classifier settings, allowing optimisation of energy use and product fineness.
Digital twins have been used to optimise kilns and grinding circuits in plants worldwide, reducing unplanned downtime and allowing predictive maintenance to extend the life of expensive grinding assets.

Grinding media and grinding aids in a digital era
While digital technologies improve control and prediction, materials science innovations in grinding media and grinding aids have become equally crucial for achieving performance gains.
Grinding media, which comprise the balls or cylinders inside mills, directly influence the efficiency of clinker comminution. Traditionally composed of high-chrome cast iron or forged steel, grinding media account for nearly a quarter of global grinding media consumption by application, with efficiency improvements translating directly to lower energy intensity.
Recent advancements include ceramic and hybrid media that combine hardness and toughness to reduce wear and energy losses. For example, manufacturers such as Sanxin New Materials in China and Tosoh Corporation in Japan have developed sub-nano and zirconia media with exceptional wear resistance. Other innovations include smart media embedded with sensors to monitor wear, temperature, and impact forces in real time, enabling predictive maintenance and optimal media replacement scheduling. These digitally-enabled media solutions can increase grinding efficiency by as much as 15 per cent.
Complementing grinding media are grinding aids, which are chemical additives that improve mill throughput and reduce energy consumption by altering the surface properties of particles, trapping air, and preventing re-agglomeration. Technology leaders like SIKA AG and GCP Applied Technologies have invested in tailored grinding aids compatible with AI-driven dosing platforms that automatically adjust additive concentrations based on real-time mill conditions. Trials in South America reported throughput improvements nearing 19 per cent when integrating such digital assistive dosing with process control systems.
The integration of grinding media data and digital dosing of grinding aids moves the mill closer to a self-optimising system, where AI not only predicts media wear or energy losses but prescribes optimal interventions through automated dosing and operational adjustments.

Global case studies in digital adoption
Several cement companies around the world exemplify digital transformation in practice.
Heidelberg Materials has deployed digital twin technologies across global plants, achieving up to 15 per cent increases in production efficiency and 20 per cent reductions in energy consumption by leveraging real-time analytics and predictive algorithms.
Holcim’s Siggenthal plant in Switzerland piloted AI controllers that autonomously adjusted kiln operations, boosting throughput while reducing specific energy consumption and emissions.
Cemex, through its AI and predictive maintenance initiatives, improved kiln availability and reduced maintenance costs by predicting failures before they occurred. Global efforts also include AI process optimisation initiatives to reduce energy consumption and environmental impact.

Challenges and the road ahead
Despite these advances, digitalisation in cement grinding faces challenges. Legacy equipment may lack sensor readiness, requiring retrofits and edge-cloud connectivity upgrades. Data governance and integration across plants and systems remains a barrier for many mid-tier producers. Yet, digital transformation statistics show momentum: more than half of cement companies have implemented IoT sensors for equipment monitoring, and digital twin adoption is growing rapidly as part of broader Industry 4.0 strategies.
Furthermore, as digital systems mature, they increasingly support sustainability goals: reduced energy use, optimised media consumption and lower greenhouse gas emissions. By embedding intelligence into grinding circuits and material inputs like grinding aids, cement manufacturers can strike a balance between efficiency and environmental stewardship.
Conclusion
Digitalisation is not merely an add-on to cement manufacturing. It is reshaping the competitive and sustainability landscape of an industry often perceived as inertia-bound. With grinding representing a nexus of energy intensity and cost, digital technologies from sensor networks and predictive analytics to digital twins offer new levers of control. When paired with innovations in grinding media and grinding aids, particularly those with embedded digital capabilities, plants can achieve unprecedented gains in efficiency, predictability and performance.
For global cement producers aiming to reduce costs and carbon footprints simultaneously, the future belongs to those who harness digital intelligence not just to monitor operations, but to optimise and evolve them continuously.

About the author:
Professor Procyon Mukherjee, ex-CPO Lafarge-Holcim India, ex-President Hindalco, ex-VP Supply Chain Novelis Europe, has been an industry leader in logistics, procurement, operations and supply chain management. His career spans 38 years starting from Philips, Alcan Inc (Indian Aluminum Company), Hindalco, Novelis and Holcim. He authored the book, ‘The Search for Value in Supply Chains’. He serves now as Visiting Professor in SP Jain Global, SIOM and as the Adjunct Professor at SBUP. He advises leading Global Firms including Consulting firms on SCM and Industrial Leadership and is a subject matter expert in aluminum and cement. An Alumnus of IIM Calcutta and Jadavpur University, he has completed the LH Senior Leadership Programme at IVEY Academy at Western University, Canada.