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Cement industry should look at real time data and not just data

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2 years ago

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Keyur Shah, Business Manager, SB Engineers, gives a detailed account of how refractories can be made more efficient and sustainable, thereby making the manufacturing process more eco-friendly.

Tell us about the solutions you provide to cement companies to measure and monitor their processes.
We are partners with a company called Thermoteknix Systems Ltd, which is a UK-based company, located in Cambridge that has been providing thermal imaging solutions for the cement industry for over 30 years now. The thermal imaging solutions mainly are kiln shell scanning systems, the function of which is to monitor shell temperature of the rotating kiln.
We also have a burning zone monitoring system or burning zone CCTV and a clinker cooler monitoring system or clinker cooler CCTV.
These are the three major solutions in the thermal imaging area, which we have been providing to the cement industry.

How do your products help cement manufacturers optimise their processes?
Our first product category is the kiln shell scanning system, which very closely monitors the outer shell temperature of the rotating kiln. It gives information about what is the condition of the refractory inside, because there is the material passed through the kiln and the coating inside the kiln that keeps on building and collapsing. So, there is the thickness of the coating as well as thickness of the brick, which indirectly is reflected by the shell temperature of that kiln.
This system monitors the temperature and provides a reading for every single brick of the kiln. The first advantage of using this system is that it informs about the condition of the refractory. If it is too thin it gives you an early alarm to take action which helps avoid any sort of shut down. Shutdowns or any kind of breakdowns are a costly affair. Also, in parallel if there is an abnormality of temperatures along the length of the kiln or across the circumference of the kiln, which is caused by the uneven coating or the failure of the brick, there is an alert that sounds averting unwanted breakdowns, thus, saving cost.
Our second category is a kiln burning zone camera. Conventionally, the burning zone was monitored by installing a CCTV installed on the kiln, which allowed a process person to monitor what is happening in the burning zone, how the flame is doing and how the material is getting processed or condition of the material inside.
Typically for a cement plant approximately 40 to 45 per cent of the fossil fuel (coal) or any other fuel is burnt in this zone. A massive amount of money is being spent in this process of transforming raw material to clinker. The process person can only have an idea of what is happening but not any data.
Thermoteknix has introduced thermal imaging for monitoring the burning zone, as cement companies spend a lot of money in the process and having visual information is not sufficient for modern plants. Therefore, thermal imaging gives information about the temperature and at the same time gives the visual views and helps with the understanding of temperature, flame, temperature of outgoing clinker, temperature of nose ring, temperature of rising material etc. Any person monitoring this system can take appropriate action accordingly.
Data from this system gives better control to the plant and process monitoring. It allows for optimising processes. It helps with any adjustment of the fuel being pumped or to the burning zone, burner air, axil air or any other air, which is being provided to the burner. Available data also helps to make process improvements that helps optimise all critical processes at the cement plants.
Our third category is clinker cooler monitoring. Once the burning process is complete, the materials move out to cool into the clinker cooler to bring down the temperature. Conventionally, the cooler was monitored by a colour CCTV for the purpose of understanding visual aspects of cooling. This slowly became a bottle neck.
Modern cement plants, however, take hot air and feed it into the boiler for regeneration of power. In this case, if the thermal process of the cooler is monitored and the profile of the cooler bed and top are known, the pumping of the air or fan of the cooler can be controlled at the same time. The suction of air taking place from the cooler can be controlled for power generation, which in turn, helps optimise the cooler operations and the AQC boiler or cooler operations as well.

What is the impact of your solutions on the cost efficiency of cement manufacturing?
It is difficult to give a set number, but I will give the cost impact in general.
In the use of kiln shell temperature scanners, there are two aspects: to avoid breakdowns, which cost millions of dollars, and to enhance the service life of the refractory for one or two months, which again means huge money saving for the cement plants. This however, is difficult to quantify but is surely an amount that makes a difference.
Coming to the thermal imaging for burning zone monitoring system, let us say the plant can save only 0.5 per cent of the fuel being pumped or coal being pumped into the burning zone and optimise it by approximately 0.25 percent, that too is a significant amount of money.
Speaking about the cooler, when there is control on the energy given to the cooling fan and suction of air for regeneration of power is controlled, that saves a significant amount of money.

What are the major challenges you face in terms of the cement industry?
A major challenge as of now for us occurs because the cement industry is undergoing transformation from technically automation run plants to data driven running plants. This transformation furthering the adaptability of these new changes by the plant operators or by the plant operations team is a major challenge. But any transformation is painful and this transformation is slowly taking place. The challenge we face is the integration or collaboration of the plant in terms of offering them this solution and making sure it is used for effective purposes.

Are you working on any innovations that the cement industry can look forward to?
In addition to offering thermal imaging we also offer process improvement solutions and these are new and innovative solutions for the cement industry.
The particle sizing system is a measurement of the fineness of the cement by the cement plant. It was traditionally done or is still done by Blaine apparatus as an ISO requirement and is also being done on laboratory basis. We have introduced this as an innovative solution with an in-process particle sizing system, which means that the particle size of the final product is measured instantaneously and live data is available to the plant process team. They use this data for optimising their cement mill or even the raw mill.
It is said that 1 to 4 per cent of the world’s power is consumed for cement grinding. Through the use of automated systems, if this absolute power is improved by even 4 to 5 per cent, it contributes to a huge amount of cost saving for cement plants and allows to deliver consistent product quality. This is one of the most innovative solutions we have successfully introduced into various cement plants globally and in India.
Another most innovative solution we have introduced to the Indian cement industry is the gas flow measurement or the air flow measurement in a cement plant at various locations. Be it at the raw mill, tertiary duct, be it down comer, be it AQC duct, hot and dusty gas flows everywhere, which is laden with a lot of energy. This energy can be used in a modern cement plant for the generation of power.
The venturi system is a mechanical system, which is conventionally used in cement plants to measure dust in the flow of air and gas. It often gets clogged up and the results and readings are not accurate or satisfactory. We have joined hands with Promecon, a German company, and are offering a flow measurement system which works on a triboelectric system that does not involve mechanical devices. It is an electronic flow measurement system which does not require calibration, thus, giving reliable data repeatedly. This has also translated to bringing large cost savings to cement plants.
So, the cement industry should look at real time data and not just data. They used to have periodic data, laboratory data and a manual sample based collection data, and from there they should move to automated real time data, which can be used for process improvement. Going forward, this will become learning for good feeds of raw material, for machine learning and AI. These are likely to become trends in any cement plant.

-Kanika Mathur

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Adani’s Strategic Emergence in India’s Cement Landscape

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5 days ago

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September 16, 2025

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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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1 month ago

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August 16, 2025

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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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1 month ago

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August 16, 2025

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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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