Concrete

Remote operations are more effective than onsite ones

Published

3 years ago

May 12, 2023

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Manish Chordia, Regional Sales Manager – Cement, South Asia and Africa, ABB, discusses the correlation between digitalisation and efficiency, as the cement sector works towards reduction in carbon emissions.

Tell us about the impact that technology and digitalisation can create on sustainability of cement manufacturing.
The benefits of digitalisation-driven plant operations within the cement industry span not only provides improvement in the process, asset, plant, and enterprise-wide performance but can have an important positive impact on sustainability values. High levels of digitalisation result in higher efficiency gains, reducing energy consumption, while allowing for higher utilisation of alternative fuels and renewable energy sources. Such high levels of digitalisation are best achieved through a unified, cross-functional, and enterprise-wide approach to digital transformation, as those offered by ABB. This approach offers digital process/ asset and enterprise-level optimisation technologies, as well as effective training of plant personnel to be able to use these technologies, to provide targeted business benefits to cement customers.

What are the key pain points in a cement plant that your systems can address and improve?
The cement industry faces a range of challenges in its day-to-day operations around profitability/cost control, quality versus throughput, emissions and environmental sustainability. The cement industry is constantly looking for ways to reduce the cost of operations while maximising yield, improving quality, and reducing emissions all at the same time. ABB systems and solutions help look at old problems with a fresh perspective. It also helps in solving challenges around accuracy and explains the ability of the techniques, so that the machine’s recommendations can be trusted. Data cleansing, anomaly removal, analysing the correlation of parameters and result interpretation are all key elements here.
For instance, ABB’s system anomaly detection app learns your plant and equipment’s ‘normal’ states and uses adaptive setpoints to detect unusual patterns, anomalous behaviours. By triggering alerts, it reduces the effort to identify and rectify energy consumption deviations. Providing no more hassle of setting manual setpoints or alarms or notification overload. The same way the app can learn from your energy usage, production schedules and other factors to deliver accurate forecasts, it can allow for reduced peak demand charges on electricity bills.

How do your systems help achieve energy efficiency in cement plants, thus reducing their energy consumption?
ABB Ability Expert Optimizer is our advanced process control solution for the cement, mining and minerals industries. It takes data from the plant and then uses various technologies – most notably model predictive control – to build a model of whichever part of the plant is the focus. This model allows for the prediction of what is going to happen in the plant or specific areas of the plant based on the real-time data.
This model – effectively a digital twin of the plant or process – can be used to create setpoints that enable the plant to achieve its goals. Initially, this means stabilising the process but will move on to optimising plant performance according to various metrics, such as achieving higher production, lowering energy consumption, or stabilising product quality, depending on what the plant operator has decided and what the initial pain points of the plant are. When the targets have been set, ABB Ability Expert Optimizer is able to take the necessary actions required to meet them without the intervention of the operator.
In the latest releases of ABB Ability Expert Optimizer, ABB has also added the ability to monitor the operation of the plant remotely to ensure that the targets are being met – and to inform the plant whenever there is any variation. It helps to ensure that ABB Ability Expert Optimizer is not switched off by operators and continues to sustain the benefits realised during commissioning.

Tell us about the role of data in achieving optimisation through the manufacturing processes at the plant.
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 – there are 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. Now 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. Based on which, we alert the customer to the probability of failure of a particular part or electronic device. These are already implemented, however, a lot more in asset reliability and process are in the pipeline.
Another proven solution for information management systems, ABB Ability Knowledge Manager provides information consistency across multiple business levels. It can also be used to consolidate and centralise information from
multiple sites into one system, bringing into play a new level of regional and corporate performance indicators and allowing performance comparisons between operations.

What are the best practices that Indian cement manufacturers can adopt to achieve better productivity and efficiency in their operations?
Personally, I feel collaborative operations centre services, which were started a couple of years back, would gain a lot more relevance in the current environment. The customers will prefer to do commissioning remotely with minimal onsite workforce. The troubleshooting being remote, which was always one of our targets. Remote operations are more effective than onsite ones, as all experts are in one place. It saves a lot of time in case of disruptions or even a breakdown.

How have you contributed to the Net Zero mission for the Indian cement industry and how do you plan to do so in the future?
Our system can play a vital role in reaching environmental sustainability targets, and not just around reducing emissions, but also energy optimisation and management. This creates
immediate benefits for operating costs and margins, also enabling new business models for high-tech low-CO2 cements.

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Concrete

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

Published

7 days ago

February 5, 2026

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FORNNAX TECHNOLOGY has appointed industry veteran Dieter Jerschl as its new sales partner in Germany to strengthen its presence across Central Europe. The partnership aims to accelerate the adoption of FORNNAX’s high-capacity, sustainable recycling solutions while building long-term regional capabilities.

FORNNAX TECHNOLOGY, one of the leading advanced recycling equipment manufacturers, has announced the appointment of a new sales partner in Germany as part of its strategic expansion into Central Europe. The company has entered into a collaborative agreement with Mr. Dieter Jerschl, a seasoned industry professional with over 20 years of experience in the shredding and recycling sector, to represent and promote FORNNAX’s solutions across key European markets.

Mr. Jerschl brings extensive expertise from his work with renowned companies such as BHS, Eldan, Vecoplan, and others. Over the course of his career, he has successfully led the deployment of both single machines and complete turnkey installations for a wide range of applications, including tyre recycling, cable recycling, municipal solid waste, e-waste, and industrial waste processing.

Speaking about the partnership, Mr. Jerschl said,
“I’ve known FORNNAX for over a decade and have followed their growth closely. What attracted me to this collaboration is their state-of-the-art & high-capacity technology, it is powerful, sustainable, and economically viable. There is great potential to introduce FORNNAX’s innovative systems to more markets across Europe, and I am excited to be part of that journey.”

The partnership will primarily focus on Central Europe, including Germany, Austria, and neighbouring countries, with the flexibility to extend the geographical scope based on project requirements and mutual agreement. The collaboration is structured to evolve over time, with performance-driven expansion and ongoing strategic discussions with FORNNAX’s management. The immediate priority is to build a strong project pipeline and enhance FORNNAX’s brand presence across the region.

FORNNAX’s portfolio of high-performance shredding and pre-processing solutions is well aligned with Europe’s growing demand for sustainable and efficient waste treatment technologies. By partnering with Mr. Jerschl—who brings deep market insight and established industry relationships—FORNNAX aims to accelerate adoption of its solutions and participate in upcoming recycling projects across the region.

As part of the partnership, Mr. Jerschl will also deliver value-added services, including equipment installation, maintenance, and spare parts support through a dedicated technical team. This local service capability is expected to ensure faster project execution, minimise downtime, and enhance overall customer experience.

Commenting on the long-term vision, Mr. Jerschl added,
“We are committed to increasing market awareness and establishing new reference projects across the region. My goal is not only to generate business but to lay the foundation for long-term growth. Ideally, we aim to establish a dedicated FORNNAX legal entity or operational site in Germany over the next five to ten years.”

For FORNNAX, this partnership aligns closely with its global strategy of expanding into key markets through strong regional representation. The company believes that local partnerships are critical for navigating complex market dynamics and delivering solutions tailored to region-specific waste management challenges.

“We see tremendous potential in the Central European market,” said Mr. Jignesh Kundaria, Director and CEO of FORNNAX.
“Partnering with someone as experienced and well-established as Mr. Jerschl gives us a strong foothold and allows us to better serve our customers. This marks a major milestone in our efforts to promote reliable, efficient and future-ready recycling solutions globally,” he added.

This collaboration further strengthens FORNNAX’s commitment to environmental stewardship, innovation, and sustainable waste management, supporting the transition toward a greener and more circular future.

Concrete

Budget 2026–27 infra thrust and CCUS outlay to lift cement sector outlook

Published

1 week ago

February 2, 2026

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Higher capex, city-led growth and CCUS funding improve demand visibility and decarbonisation prospects for cement

Mumbai

Cement manufacturers have welcomed the Union Budget 2026–27’s strong infrastructure thrust, with public capital expenditure increased to Rs 12.2 trillion, saying it reinforces infrastructure as the central engine of economic growth and strengthens medium-term prospects for the cement sector. In a statement, the Cement Manufacturers’ Association (CMA) has welcomed the Union budget 2026-27 for reinforcing the ambitions for the nation’s growth balancing the aspirations of the people through inclusivity inspired by the vision of Narendra Modi, Prime Minister of India, for a Viksit Bharat by 2047 and Atmanirbharta.

The budget underscores India’s steady economic trajectory over the past 12 years, marked by fiscal discipline, sustained growth and moderate inflation, and offers strong demand visibility for infrastructure linked sectors such as cement.

The Budget’s strong infrastructure push, with public capital expenditure rising from Rs 11.2 trillion in fiscal year 2025–26 to Rs 12.2 trillion in fiscal year 2026–27, recognises infrastructure as the primary anchor for economic growth creating positive prospects for the Indian cement industry and improving long term visibility for the cement sector. The emphasis on Tier 2 and Tier 3 cities with populations above 5 lakh and the creation of City Economic Regions (CERs) with an allocation of Rs 50 billion per CER over five years, should accelerate construction activity across housing, transport and urban services, supporting broad based cement consumption.

Logistics and connectivity measures announced in the budget are particularly significant for the cement industry. The announcement of new dedicated freight corridors, the operationalisation of 20 additional National Waterways over the next five years, the launch of the Coastal Cargo Promotion Scheme to raise the modal share of waterways and coastal shipping from 6 per cent to 12 per cent by 2047, and the development of ship repair ecosystems should enhance multimodal freight efficiency, reduce logistics costs and improve the sector’s carbon footprint. The announcement of seven high speed rail corridors as growth corridors can be expected to further stimulate regional development and construction demand.

Commenting on the budget, Parth Jindal, President, Cement Manufacturers’ Association (CMA), said, “As India advances towards a Viksit Bharat, the three kartavya articulated in the Union Budget provide a clear context for the Nation’s growth and aspirations, combining economic momentum with capacity building and inclusive progress. The Cement Manufacturers’ Association (CMA) appreciates the Union Budget 2026-27 for the continued emphasis on manufacturing competitiveness, urban development and infrastructure modernisation, supported by over 350 reforms spanning GST simplification, labour codes, quality control rationalisation and coordinated deregulation with States. These reforms, alongside the Budget’s focus on Youth Power and domestic manufacturing capacity under Atmanirbharta, stand to strengthen the investment environment for capital intensive sectors such as Cement. The Union Budget 2026-27 reflects the Government’s focus on infrastructure led development emerging as a structural pillar of India’s growth strategy.”

He added, “The Rs 200 billion CCUS outlay for various sectors, including Cement, fundamentally alters the decarbonisation landscape for India’s emissions intensive industries. CCUS is a significant enabler for large scale decarbonisation of industries such as Cement and this intervention directly addresses the technology and cost requirements of the Cement sector in context. The Cement Industry, fully aligned with the Government of India’s Net Zero commitment by 2070, views this support as critical to enabling the adoption and scale up of CCUS technologies while continuing to meet the Country’s long term infrastructure needs.”

Dr Raghavpat Singhania, Vice President, CMA, said, “The government’s sustained infrastructure push supports employment, regional development and stronger local supply chains. Cement manufacturing clusters act as economic anchors across regions, generating livelihoods in construction, logistics and allied sectors. The budget’s focus on inclusive growth, execution and system level enablers creates a supportive environment for responsible and efficient expansion offering opportunities for economic growth and lending momentum to the cement sector. The increase in public capex to Rs 12.2 trillion, the focus on Tier 2 and Tier 3 cities, and the creation of City Economic Regions stand to strengthen the growth of the cement sector. We welcome the budget’s emphasis on tourism, cultural and social infrastructure, which should broaden construction activity across regions. Investments in tourism facilities, heritage and Buddhist circuits, regional connectivity in Purvodaya and North Eastern States, and the strengthening of emergency and trauma care infrastructure in district hospitals reinforce the cement sector’s role in enabling inclusive growth.”

CMA also noted the Government’s continued commitment to fiscal discipline, with the fiscal deficit estimated at 4.3 per cent of GDP in FY27, reinforcing macroeconomic stability and investor confidence.

Concrete

Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

Published

2 weeks ago

January 31, 2026

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Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

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