Connect with us

Concrete

Lubricant in a machine is like blood in a human body

Published

on

Shares

Gaurav K Mathur, Chief Executive, Global Technical Services, discusses the importance of contamination-free lubrication to keep machinery working at optimum capacities.

What is Total Lubrication Management System.
Cement plants are process plants, with thousands of rotating machines operating 24×7, 365 days. Availability of these machines are critical and plant reliability is vital; operating conditions of cement plants are highly dusty; lubricants can get contaminated before being filled in machines; if not stored according to the well-established system. Therefore, system-oriented approach for contamination-free lubrication is the foremost requirement of the cement industry.
Our Total Lubrication Management (TLM) is implemented at the plants as per Standard Operating Procedures (SOP), for uniform adaptation of best lubrication practices to ensure clean lubricants are fed to machines. Good lubricants storage, handling and dispensing of lubricants is essential for good lubrication programme in any industry.
The important aspects of the SOP are:

  • Roles and responsibilities of all responsible for implementing TLM at every site.
  • Good housekeeping: clean environment in Central Lubrication Cell.
  • Storage of oil and grease barrels: to ensure feed clean lubricants to machines.
  • Colour Coding system: to eliminate contamination.

In-house laboratory and testing procedures:
to establish condition base oil change and oil conservation.

  • Online filtration: to keep oil clean in service at all times
  • Management of spillage and leakages
  • Management of minor and major leakage
  • Regeneration of drained oil and its usage

after lube-testing – a must for oil conservation. Lubricating oil is expensive and needs to be saved.
Some of the largest cement plants in the country have outsourced their lubrication activities on a single window basis to us (GTS), entrusting the responsibility of storage, handling, dispensing, regeneration, and condition monitoring of lubricants for the plants and mines. All resources required for world class lubrication are deployed by GTS including dedicated manpower and a well-equipped oil testing laboratory at each site, beside lubrication equipment, and fifth generation oil filtration systems (they can remove water/moisture besides suspended dust, and wear particles).

How often do you audit or review your implemented systems?
The team of engineers from our Mumbai office visit each site regularly and review our site team work, and discuss with the plant’s mechanical maintenance team for their feedback and further improvement required. Then we make a time bound schedule and implement the same. This is our ongoing process for all sites.
The frequency of reviewing or auditing TLM is a continuous process, quality service requires various yardsticks to identify gaps for continuous improvement. We are pleased to convey that our customers are quite satisfied with our working. We make every effort to achieve world class lubrication management at our sites. We are now in the process of implementing software-based TLM System at some of our sites. Once it is established properly, we will be doing the same at all our sites.
Each cement plant has thousands of lubrication points and each and all points have their lubrication frequency monitoring of lubrication, etc. has been incorporated in the software. Thousands of lubrication points are generating a very large quantum of data and once this software with artificial intelligence (AI) is developed shall a great boon for us and the industry. One of the key challenges today is contamination free lubrication and condition-based oil change system, with the assistance of the site laboratory leading to oil conservation (this shall also be integral part of the AI-based software).
We have developed fifth generation oil filtration system and we have been able to conserve approximately 18 to 20 per cent lubricants at our site, on yearly basis. ‘Oil never dies – it only gets contaminated.’ Once these contaminations are removed, oil is fit for further use. And yes, laboratory test report is important.

How do you maintain quality for the lubricant products provided to the cement manufacturers?
Lubricants are manufactured by well-established oil companies with extensive R&D, high value lubricants are handed over to the industry, however if not stored properly at the industry’s site the high-quality lubricants can get contaminated. Since oil in a machine is like blood in human body, the contaminated lube oil can be damaged the machine. We store the oil very carefully to ensure no dust, dirt or moisture go into the oil barrel and therefore we adopt covered indoor storage and keep the barrels in our Central Lubrication Cell (CLC), which is provided by the site management to us and we develop it to our operating requirements. We do all lubrication activities for the site from CLC. We also establish Oil Test Laboratory at this location (Central Lubrication Cell.)
How do lubricants improve functionality at cement plants?
Cement manufacturing plants work under highly dusty environment. They are located in remote areas away from the major towns. Keeping the oil as clean as possible within the machine is extremely important. This helps improve machine condition, production reliability and ultimately profitability of our customers.

How do you incorporate sustainability in your process and operations?
One of the pillars of TLM regeneration of lubricants. These tested oils are crafted to match the performance of fresh oil, resulting in conservation of lubricants leading to sustainability.

What is the role of automation and technology?
Modern day manufacturing is a lot more demanding, with advancement in technology, data becomes vital and customised software is not developed enough to track assets parameters. There has been a need for software for route planning and execution of lubrication activities – these activities are so many in numbers to monitor them without an AI based software leaves enough room for error.
We are implementing TLM software at plants where TLM is being implemented by us. This software helps micro level operational ease and counter check of activities. All activities data is logged through secured servers. Bringing meaningful, actionable data on the palm top is the key, and all modern technologies are being adopted for the same, including industrial internet of things (IIOT) and autonomous monitoring. We are implementing a mix of technology to have a robust system in the plant, while implementing TLM.

Which innovations are in the pipeline?
It is important that we adopt a system- and AI-based TLM at all the plants. We have established a world class oil testing laboratory at site and a mother oil testing laboratory with modern equipment such as Inductively Coupled Plasma (ICP), covering 5-6 plants and with test results available within 48 hours for oil condition monitoring.
We are developing technologies involving AI, drones, robotics, software and sensors coupled with robust databases, all specifically for machine monitoring, to attain the dream of ‘Machine
for Life’.

Concrete

Adani’s Strategic Emergence in India’s Cement Landscape

Published

on

By

Shares



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.

Continue Reading

Concrete

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

Published

on

By

Shares



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.

Continue Reading

Concrete

Driving Measurable Gains

Published

on

By

Shares



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.

Continue Reading

Trending News

SUBSCRIBE TO THE NEWSLETTER

 

Don't miss out on valuable insights and opportunities to connect with like minded professionals.

 


    This will close in 0 seconds

    This will close in 0 seconds