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The cement industry has been emphasising on digitalisation

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Anoop Anand, Motion System Drives Division President, ABB India, discusses how innovative technologies and solutions help cement plants overcome the challenges related to efficiency.

Tell us about the role of drives in a cement plant machinery.
As an industry, if we evaluate the cost components for making cement, energy cost becomes one of the largest contributors. Due to this, every cement plant closely monitors its energy consumption per tonne of cement production. The quantity of energy consumption is a key deciding factor on whether the manufacturer can be more profitable or competitive in a specific market.
Variable Frequency Drives (VFDs) are commonly used in the cement industry for various applications due to their ability to precisely control the speed of electric motors, thereby optimise the energy consumption in most of the production processes. By adjusting the motor speed to match the required load, VFDs can significantly reduce wastage and improve overall energy efficiency. Like most of the process industries, Cement plants also have various motor-driven equipment, such as crushers, mills, kilns, conveyors, fans and pumps. VFDs provide accurate control of motor speed and torque, enabling efficient operation and better process conditions and process control, and thereby better quality of the product produced. They also allow gradual controlled acceleration and deceleration of motors, reducing mechanical stress and extending equipment lifespan.
Additionally, cement manufacturing processes often involve large motors with high starting currents. VFDs offer soft start capabilities, gradually ramping up the motor speed and reducing the impact of inrush current. This feature not only minimises mechanical and electrical stress on the equipment but also prevents voltage drops in the electrical system during large motor starting.
Conveyors are extensively used in cement plants for transporting materials such as limestone, clay and gypsum. VFDs allow precise control of conveyor speed, enabling optimised material flow and reducing the risk of jams or blockages. When applied to any Fans and Pumps, this enables better control of airflows and fluid flows. VFDs also offer diagnostic features that provide information about motor and system performance, enabling predictive and preventive maintenance practices. They can monitor motor parameters such as temperature, current and vibration, helping identify potential issues before they lead to failures. Overall, VFDs provide significant benefits in terms of energy savings, process control, equipment protection and maintenance in the cement industry. They contribute to improved operational efficiency, reduced downtime and cost saving.

Tell us about the portfolio of drives and motors that you offer to the cement industry.
ABB’s portfolio includes a wide range of low voltage drives, medium voltage drives, DC drives, scalable PLCs, low voltage and medium voltage motors, both Sq Cage and Slip ring and Plant Automation Systems with various process optimisation packages. With our extensive knowledge within cement processing and application, we can offer the right solutions to enhance productivity and energy savings.
With sustainability and enabling a low carbon society now being part of almost all cement manufacturers long term vision, ABB also plays a very positive role in this journey. ABB has targeted to achieve carbon neutrality in our operations by 2030. We also introduced the ‘Energy Efficiency Movement’ globally and many of our customers and even peers in the market are becoming a part of this initiative. In India itself we have about 130+ customers signed up to walk along with us on this journey. We look at sustainability initiatives with a two-pronged approach. One is to support our customers through our products and solutions. Most customers have now moved to High Efficiency motors (IE4) and have also started introducing Ultra Low Harmonic Drives for all their applications. Customers have also been evaluating the long-term benefits of having water cooled solutions for drives and motors as they provide a large potential for energy saving.
The second part of our sustainability journey is implementing actions within our operations which we preach to our customers. I am happy to share with you that when our customers receive our motors and drives, they can be rest assured that they are coming from factories which have most sustainability measures implemented. Our factories are RE100 (renewable energy), water positive, platinum certified green buildings and also working towards zero waste to landfill and single use plastic free operations.

As machinery in cement plants is advancing with time, how do you accommodate the change in drives for the betterment of functionality in cement plants?
ABB Drives have been known for their user friendliness and we also now have all drives covered under the ‘All Compatible’ umbrella where the user conversant with LV Drives from ABB will also have the same look and feel and even operational experience with the interfaces in MV Drives.
The cement industry has been emphasising on digitalisation and ABB is a front runner in developing ways and means to do things better. We now have the option of getting every drive functioning in an industry connected remotely to our remote monitoring centres, which enable 24×7 watch on the critical performance parameters of the drives and proactively advise the plant engineers for taking preventive actions if any negative trend is shown on any critical parameters.
The challenge has always been that it was not economically viable to extend monitoring to a much greater scope of equipment across a plant. That has now changed with the introduction of a new generation of wireless smart sensors for motors. The availability of cloud computing, data analytics, and mobile data transmission, has paved the way for the arrival of low-cost, IoT-based wireless sensors. With no hard wiring requirements, they allow for permanent monitoring at a fraction of the cost of traditional condition monitoring systems.
Tell us about the upcoming innovations from your organisation that would be beneficial for cement plants?
ABB offers a range of innovative solutions that can significantly benefit the cement industry. ABB’s advanced process control systems and optimisation solutions can enhance the efficiency and productivity of cement manufacturing. By leveraging real-time data and advanced algorithms, these systems optimise key process parameters such as kiln operation,
fuel consumption and raw material blending, leading to improved energy efficiency and reduced production costs.
ABB provides robotic solutions for various applications in the cement industry, including material handling, packaging and palletising. These robots can perform repetitive tasks with precision, speed and consistency, reducing manual labour requirements and improving safety in hazardous environments.
Our digital solutions enable the collection, integration, and analysis of data from various sources within the cement plant. By applying artificial intelligence (AI) and machine learning algorithms, these solutions can identify patterns, optimise maintenance schedules, predict equipment failures and improve overall plant performance. Real-time monitoring and remote operation capabilities facilitate proactive decision-making and reduce downtime.
ABB also offers modular and scalable drive solutions that can be customised to meet specific application requirements. This flexibility allows cement manufacturers to adapt their systems to changing needs, expand capacity, and integrate new technologies easily. Our ultra-low harmonic drives help mitigate harmonics and related power quality issues, which in turn also helps in optimising the various equipment in the value chain and save significant energy.
In low voltage motors, we have introduced IE5 efficiency motors using synchronous reluctance technology without the use of permanent magnets. Our innovative designs in HV motors offer high efficiency with high reliability. For example, they have set the world record for HV synchronous motors with 99.05 per cent efficiency.
Our innovation in digitalisation for condition monitoring of LV motors with our smart sensors apart from monitoring critical health parameters also can support in energy appraisal, HV motors monitoring through Machsense-R and remote monitoring of drives helping to predict impending failures and monitor performance.
By leveraging ABB’s innovative technologies, the cement industry can achieve higher levels of operational efficiency, reduce energy consumption, minimise environmental impact, and enhance safety standards. These advancements contribute to the industry’s overall sustainability and competitiveness in an evolving global market.

Which machinery at a cement plant is the most challenging and how do you overcome the challenge?
Among the various machinery in a cement plant, the kiln is often considered one of the most challenging and critical components. The kiln is responsible for the production of clinker, the primary ingredient in cement, through a complex process involving high temperatures and chemical reactions. We have developed innovative solutions to overcome the challenges associated with kiln operations.
ABB’s advanced process control (APC) systems utilise sophisticated algorithms to optimise kiln operations. These systems continuously monitor and adjust critical parameters such as fuel combustion, raw material feed, and air flow to ensure optimal clinker production and energy efficiency. By providing real-time control and optimisation, APC systems enable stable and efficient kiln performance.
ABB’s kiln monitoring solutions incorporate advanced sensors and data analytics to provide real-time insights into the kiln’s condition and performance. Temperature, pressure, and gas composition sensors are deployed to monitor critical areas within the kiln, enabling early detection of anomalies and potential issues. The data collected is analysed using machine learning algorithms to predict and prevent kiln disruptions, optimising maintenance strategies and minimising downtime.
We offers flame monitoring systems that use high-speed cameras and image processing techniques to monitor and optimise the kiln’s combustion process. These systems enable precise control of the flame shape, size, and position, ensuring efficient fuel utilisation and reducing emissions. By continuously analysing the flame characteristics, ABB’s solutions can automatically adjust burner settings to maintain optimal combustion conditions.
Our variable speed drives (VSDs) provide accurate and reliable control of kiln motors, such as those driving the rotating kiln shell and the main drive. VSDs offer precise speed and torque control, enabling smooth and efficient operation, while also reducing mechanical stress on the equipment. ABB’s VSDs also contribute to energy savings by optimising motor performance and reducing power consumption.
ABB’s safety solutions play a crucial role in protecting the kiln and its surrounding infrastructure. Integrated safety systems, including fire and gas detection, emergency shutdown systems, and perimeter monitoring, help prevent accidents and mitigate potential hazards.
By combining these innovative technologies and solutions, ABB helps cement plants overcome the challenges associated with kiln operations. These advancements enable efficient and reliable production of clinker, optimise energy consumption, ensure safety and extend the lifespan of critical kiln components, contributing to the overall performance and profitability of the cement plant.

Concrete

Adani’s Strategic Emergence in India’s Cement Landscape

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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.

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Concrete

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

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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.

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Concrete

Driving Measurable Gains

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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.

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