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

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

6 days ago

June 5, 2026

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

Concrete

Building a Greener Future Together

Published

7 days ago

June 4, 2026

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

Published

1 week ago

June 1, 2026

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.