Concrete

Greener energy has a positive impact on manufacturing

Published

2 years ago

October 19, 2023

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Sameer Kumar Pujari, Senior General Manager, JK Cement, elaborates on the role played by technology, alternative raw materials, cost, infrastructure and local regulations in making cement manufacturing process more energy efficient.

Tell us about the role of energy in the manufacturing of cement? What is the volume of your organisation’s energy consumption?
The role of energy in the manufacturing of cement is significant as it is one of the most energy-intensive industries globally. The production of cement involves several energy-intensive processes, from the extraction and crushing of raw materials to production of clinker and finally converting it into cement.
The production of cement consumes large quantities of energy in the form of thermal and electrical. This requires approximately 3.2 GJ to 5.0 GJ of energy per tonne of clinker produced. As an energy intensive industry, thermal energy used in the cement industry accounts for about 20–25 per cent of the production cost. The typical electrical energy consumption of a modern cement plant is about 70 KWh to 80 KWh per tonne of cement. In the manufacturing process, thermal energy is used mainly during the burning process, while maximum share of electrical energy is used for cement grinding.
Our SEC is approximately 61.8KWH/T cement and specific thermal energy is 3.18 GJ/tonne of cement. We are proud to share that our IU at Muddapur Karnataka and GU at Jhajjar, Haryana, are national leaders in energy and have been awarded by renowned organisations like Confederation of Indian Industry (CII). The source of energy in cement manufacturing is fossil fuels (coal, oil and natural gas) and alternative fuels (biomass/waste material/municipal waste etc.).
Other than above, we also use renewable energy solar/wind, WHRS and grid power to produce cement.

What are the various modes of energy sources used by your organisation for its manufacturing needs?
We use fossil fuels as the energy source for manufacturing needs. This includes coal, oil, and natural gas, which are burned in kilns to generate the heat necessary for the production process. We are also utilising alternative fuels to reduce usage of fossil fuels and promote sustainable practices. These alternative fuels can include RDF, biomass, such as rice/mustard husk or agricultural waste as well as waste materials like shredded tires or sewage sludge. By using these alternative fuels, we are not only progressing towards carbon neutrality but also contributing to waste management efforts.
We are using solar, wind and WHRS, too. We are procuring renewable energy through open access. Our capacity in WHRS is 62 MW, solar is 20 MW and we are progressing towards the goal of green cement by 2030. Our Muddapur, Karnataka, plant has achieved 100 per cent renewable energy uses at zero grid consumption through open access.

Which of the said energy sources yields maximum productivity for the plant and which yields the least?
The productivity of different energy sources for cement plants can vary depending on various factors such as technology being used, availability, cost, infrastructure and local regulations. Here are some examples:

Fossil fuels (e.g., coal, oil, and natural gas): Traditionally been the primary energy source for cement production due to their high energy content. However, they contribute significantly to carbon emissions and are considered non-renewable resources.
Biomass: Biomass, such as agricultural residues or dedicated energy crops, can be used as an alternative fuel source in cement production. Its productivity can vary depending on the availability and sustainability of biomass feedstock.
Waste materials: Certain waste materials, such as shredded tires or municipal solid waste, can be used as alternative fuels in cement kilns. The productivity of waste materials as an energy source depends on their calorific value, availability, and proper waste management practices.
Renewable energy sources: Renewable energy sources like solar, wind or geothermal power can be utilised to generate electricity for cement plants. Their productivity depends on factors such as location, resource availability and the ability to integrate them into the plant’s
energy infrastructure.
It is important to note that each cement plant may have unique circumstances and considerations when choosing an energy source. The optimal solution often involves a combination of different energy sources and technologies to achieve maximum productivity while minimising environmental impact.

What are the alternative energy sources that are being adapted by the cement industry and your organisation?
Generally fossil fuels such as coal, petroleum coke and natural gas provide the thermal energy required for the cement industry. With increasing economic benefits in usage of alternative fuel (AF) over conventional fuels gives high thrust on usage of AF. Other factors, which give a push to usage of AF, are limited resources of fossil fuel and environmental concerns. AF covers all non-fossil fuels and waste from other industries including tire-derived fuels, biomass residues, sewage sludge and different commercial wastes. The kiln used in cement manufacturing is able to burn a wide range of materials due to the long exposure time at high temperatures (up to 1400oC), intrinsic ability of clinker to absorb and lock contaminants into the clinker and the alkalinity of the kiln environment. Materials like waste oils, plastics, waste tires and sewage sludge are being adopted as alternative fuels by the cement industries. Biomass waste and spent pot linings produced in aluminium smelters are also identified as potential alternative fuels for the cement industry.
Our organisation uses almost all kinds of plastic wastes, non-hazardous and hazardous waste, and biomass. We have a dedicated AFR feeding system in our plants. We initially focused on using plastic waste, shredded RDF. Slowly and gradually, we increased our capacity and started using hazardous materials also. For the processing of hazardous waste, we needed impregnation material like biomass such as rice husk, saw dust, wood chips, etc. So, we started utilising them in smaller proportions. And with the experience so far, now we are consuming around 20 per cent to 25 per cent of hazardous solid waste, 40 per cent to 50 per cent MSW/RDF waste, and up to 25 per cent non-hazardous solid wastes.

What is the impact of greener energy sources on the productivity and cost of cement manufacturing?
Greener energy has a positive impact on manufacturing, including commercial and technical aspects. Here are some potential impacts:
• Productivity: Greener energy sources have a positive impact on the productivity of cement manufacturing. For example, using alternative fuels like biomass or waste materials can
provide a reliable and consistent source of heat for kilns, ensuring a stable production process. This can help reduce downtime and improve overall productivity.
• Cost: The cost implications of using greener energy sources in cement manufacturing can also vary. In some cases, alternative energy sources may be more cost-effective compared to traditional fossil fuels as AF gives additional revenue to consumers of AF. Additionally, utilising waste materials as alternative fuels can reduce waste disposal costs for cement plants.
• Energy efficiency: Greener energy sources often promote energy efficiency in cement manufacturing. For example, using renewable energy sources like solar or wind power can reduce reliance on fossil fuels and decrease energy consumption. This can result in cost savings and improved overall efficiency.
• Environmental impact: One of the key benefits of greener energy sources in cement manufacturing is the reduction in environmental impact. By transitioning to alternative fuels or renewable energy sources, cement plants can significantly reduce greenhouse gas emissions and air pollution associated with traditional fossil fuel combustion. This can contribute to environmental sustainability goals and help meet regulatory requirements.
It is important to note that the specific impact on productivity and cost will depend on the individual circumstances of each cement organisation, including factors such as location, availability of resources, technological capabilities and government policies or incentives.

How does automation and technology help in optimising the use of energy in cement plants?
Automation and technology play a pivotal role in optimising the use of energy in cement plants. We are using VFD, Smart MCC, Sensors, Integrated Load Management System, Energy Monitoring System and Smart Lighting System for effectively optimising the use of energy in our organisation.
Here are some ways which helps to reduce the energy:
• Energy monitoring and control: Automation systems can continuously monitor energy consumption in various parts of the cement plant, such as kilns, mills, and crushers. This real-time data allows operators to identify pilferage processes or equipment and optimise energy usage.
• Process optimisation: Advanced control systems and predictive analytics can optimise the cement manufacturing process to minimise energy consumption. By analysing data from various sensors and instruments, these technologies can identify opportunities for energy savings and automatically adjust parameters to achieve optimal efficiency.
• Energy management systems: Automation systems can integrate with energy management systems to provide a holistic view of energy usage across the entire plant. This allows operators to track energy performance and accordingly set targets, and implement energy-saving measures effectively.
• Load management: Automation systems can optimise the scheduling and sequencing of equipment to ensure a balanced load distribution, reducing peak demand and improving overall energy efficiency. For example, by coordinating the operation of kilns, mills, and other machinery, the system can minimise energy wastage during periods of low demand.
• Energy recovery: Automation technology can facilitate the implementation of energy recovery systems in cement plants. For instance, waste heat from kilns can be captured and used to generate electricity or provide heat for other processes, reducing the reliance on external energy sources.
• Equipment optimisation: Automation systems can monitor the performance of individual equipment and identify inefficiencies or malfunctions that may contribute to excessive energy consumption. By providing real-time alerts and diagnostics, operators can take corrective actions promptly, ensuring optimal equipment performance and energy usage.
Overall, automation and technology enable cement plants to have better visibility, control and optimisation of energy usage. This leads to improved energy efficiency, cost savings and reduced environmental impact.

What are the major challenges your organisation faces in managing the energy needs?
We are facing challenges of imposition of power curtailment from grid mostly at our Rajasthan-based plants:
• Grid disturbances and power outages
• There is high volatile market and heavy fluctuations in fuel sourcing
• Energy cost volatility: Cement production is highly energy-intensive, and the cost of energy can fluctuate significantly. This makes it challenging to plan and budget for energy needs effectively an increase in the prices of fossil fuel
would adversely impact the industry, leading to an increase in production costs, however we focused on driving optimisation of fuel mix, energy efficiency and use of alternative fuel to mitigate this
• Ageing infrastructure: To upgrade or replace the ageing infrastructure/ systems can be expensive and may require significant downtime. However, we have completed the brownfield modernisation of our Nimbahera Line-3, with the kiln now capable of producing 6,500 TPD, against the earlier capacity of 5,000 TPD. The brownfield projects that have been undertaken over the past few years have been delivering greater efficiencies in the form of reduced power and fuel consumption and increased WHR.

Tell us about the compliance and standards followed by you to maintain energy use and efficiency in the organisation.
Some of the key regulations and standards include:
• ISO 50001: This international standard provides a framework for organisations to establish, implement, maintain, and improve an energy management system. We are ISO 50001 certified company and regularly enhance our energy performance, identify energy-saving opportunities and comply with energy management requirements.
• PAT Compliance: PAT is a mechanism for improvements in energy efficiency of energy intensive industries. Specific high energy intensive industries are identified as Designated Consumers (DC) within certain key sectors, who are required to appoint an energy manager, file energy consumption returns every year and conduct mandatory energy audits regularly. The key tasks in the PAT mechanism is to set the methodology for deciding the Specific Energy Consumption (SEC) norms for each designated consumers in the baseline year and in the target years, devise verification process for SEC, finding ways of issuing the Energy Savings Certificates, operationalisation of the trading process for ESCert in addition to the compliance and reconciliation process for ESCert.
To ensure compliance with these regulations and standards, JK Cement regularly monitors our energy consumption, implements energy management systems, conducts energy audits, invests in energy-efficient technologies, and reports the emissions and energy performance to relevant authorities. Additionally, we collaborate with industry associations, research institutions and government agencies to stay
updated on evolving regulations and best practices in energy management.

How often are audits done to ensure optimum use of energy? What is the suggested duration for the same?
• We conduct energy audits every year as a part of energy management practices. This allows us to assess the energy performance, identify
areas for improvement and implement energy-saving measures.
• We have formed internal management teams across our plants where we closely monitor
our energy consumption on a daily basis. We fix our best targets across the locations
and further compare and revise our targets to further optimisation.

What kind of innovations in the area of energy consumption do you wish to see in the cement industry?
Some potential innovations in the area of energy consumption that we may wish to see in the cement industry:
• Alternative fuel sources: Increased utilisation of alternative fuels, such as biomass, waste materials, or renewable energy sources, can reduce reliance on fossil fuels and lower carbon emissions.
• Energy-efficient technologies: The adoption of advanced technologies, such as more efficient kilns, improved heat recovery systems, and optimised grinding processes, can help reduce energy consumption in cement production.
• Carbon capture and utilisation: Implementing carbon capture, storage, and utilisation (CCUS) technologies can help capture and store carbon dioxide emissions from cement plants or utilise them in other industrial processes.
• Process optimisation through AI: Continuous process optimisation through AI data analytics, machine learning, and automation can identify areas of inefficiency and enable real-time adjustments to optimise energy consumption.
• Circular economy practises: Adopting circular economy principles, such as recycling and reusing waste materials or by-products from cement production, can reduce resource consumption and minimise environmental impact.
• Collaborative research and development: Encouraging collaboration between industry stakeholders, researchers and governments can drive innovation in energy-efficient cement production technologies and practices.
• We want to innovate to produce entirely green cement with sustainability and to achieve our net zero target by 2030.
• Cement manufacturing with an alternative of fly ash and lesser water curing requirements also plants with less heat consumption during clinker production such as in LC3 cement.

-Kanika Mathur

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Concrete

Cement Demand Revives As Prices Decline In Q3 FY26

Nuvama reports improved volume growth after price correction

Published

1 day ago

February 24, 2026

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A report by Nuvama Financial Services (Nuvama) said cement sector demand revived in the third quarter of fiscal year twenty twenty six as prices declined, supporting volume growth across regions. The note indicated that sequential price correction helped replenish demand that had been subdued by elevated pricing earlier in the year. Nuvama quantified the price decline as a sequential correction that varied across states and segments, facilitating restocking by merchants and traders.

The report suggested that improved affordability after the price correction encouraged housing and infrastructure activity, with developers and contractors adjusting procurement plans. It added that regional dynamics varied, with some markets showing faster recovery while others remained reliant on seasonal construction cycles. Housing demand was driven by both affordable and mid segment projects, while infrastructure segment recovery was contingent on timely execution of public works.

Analysts at Nuvama assessed that the price moderation eased inventory pressures for manufacturers and distributors and supported margin stabilisation at several producers. Demand improvement was visible in both urban and rural segments, although the pace of recovery differed by state and trade channel. Producers were seen balancing price realisations with volume targets and managing input cost volatility through operational efficiencies.

The report recommended that investors monitor volumes and realisations closely as market equilibrium emerges in the coming quarters, noting that sustainability of recovery would depend on monsoon patterns and government infrastructure outlays. Overall, the assessment pointed to a cautiously optimistic outlook for the cement industry as price correction translated into tangible volume gains. Market participants were advised to track early signs of demand broadening beyond core construction hubs to assess the depth of the rebound.

Concrete

Refractory demands in our kiln have changed

Published

6 days ago

February 20, 2026

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Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, points out why performance, predictability and life-cycle value now matter more than routine replacement in cement kilns.

As Indian cement plants push for higher throughput, increased alternative fuel usage and tighter shutdown cycles, refractory performance in kilns and pyro-processing systems is under growing pressure. In this interview, Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, shares how refractory demands have evolved on the ground and how smarter digital monitoring is improving kiln stability, uptime and clinker quality.

How have refractory demands changed in your kiln and pyro-processing line over the last five years?
Over the last five years, refractory demands in our kiln and pyro line have changed. Earlier, the focus was mostly on standard grades and routine shutdown-based replacement. But now, because of higher production loads, more alternative fuels and raw materials (AFR) usage and greater temperature variation, the expectation from refractory has increased.
In our own case, the current kiln refractory has already completed around 1.5 years, which itself shows how much more we now rely on materials that can handle thermal shock, alkali attack and coating fluctuations. We have moved towards more stable, high-performance linings so that we don’t have to enter the kiln frequently for repairs.
Overall, the shift has been from just ‘installation and run’ to selecting refractories that give longer life, better coating behaviour and more predictable performance under tougher operating conditions.

What are the biggest refractory challenges in the preheater, calciner and cooler zones?
• Preheater: Coating instability, chloride/sulphur cycles and brick erosion.
• Calciner: AFR firing, thermal shock and alkali infiltration.
• Cooler: Severe abrasion, red-river formation and mechanical stress on linings.
Overall, the biggest challenge is maintaining lining stability under highly variable operating conditions.

How do you evaluate and select refractory partners for long-term performance?
In real plant conditions, we don’t select a refractory partner just by looking at price. First, we see their past performance in similar kilns and whether their material has actually survived our operating conditions. We also check how strong their technical support is during shutdowns, because installation quality matters as much as the material itself.
Another key point is how quickly they respond during breakdowns or hot spots. A good partner should be available on short notice. We also look at their failure analysis capability, whether they can explain why a lining failed and suggest improvements.
On top of this, we review the life they delivered in the last few campaigns, their supply reliability and their willingness to offer plant-specific custom solutions instead of generic grades. Only a partner who supports us throughout the life cycle, which includes selection, installation, monitoring and post-failure analysis, fits our long-term requirement.

Can you share a recent example where better refractory selection improved uptime or clinker quality?
Recently, we upgraded to a high-abrasion basic brick at the kiln outlet. Earlier we had frequent chipping and coating loss. With the new lining, thermal stability improved and the coating became much more stable. As a result, our shutdown interval increased and clinker quality remained more consistent. It had a direct impact on our uptime.

How is increased AFR use affecting refractory behaviour?
Increased AFR use is definitely putting more stress on the refractory. The biggest issue we see daily is the rise in chlorine, alkalis and volatiles, which directly attack the lining, especially in the calciner and kiln inlet. AFR firing is also not as stable as conventional fuel, so we face frequent temperature fluctuations, which cause more thermal shock and small cracks in the lining.
Another real problem is coating instability. Some days the coating builds too fast, other days it suddenly drops, and both conditions impact refractory life. We also notice more dust circulation and buildup inside the calciner whenever the AFR mix changes, which again increases erosion.
Because of these practical issues, we have started relying more on alkali-resistant, low-porosity and better thermal shock–resistant materials to handle the additional stress coming from AFR.

What role does digital monitoring or thermal profiling play in your refractory strategy?
Digital tools like kiln shell scanners, IR imaging and thermal profiling help us detect weakening areas much earlier. This reduces unplanned shutdowns, helps identify hotspots accurately and allows us to replace only the critical sections. Overall, our maintenance has shifted from reactive to predictive, improving lining life significantly.

How do you balance cost, durability and installation speed during refractory shutdowns?
We focus on three points:
• Material quality that suits our thermal profile and chemistry.
• Installation speed, in fast turnarounds, we prefer monolithic.
• Life-cycle cost—the cheapest material is not the most economical. We look at durability, future downtime and total cost of ownership.
This balance ensures reliable performance without unnecessary expenditure.

What refractory or pyro-processing innovations could transform Indian cement operations?
Some promising developments include:
• High-performance, low-porosity and nano-bonded refractories
• Precast modular linings to drastically reduce shutdown time
• AI-driven kiln thermal analytics
• Advanced coating management solutions
• More AFR-compatible refractory mixes

These innovations can significantly improve kiln stability, efficiency and maintenance planning across the industry.

Concrete

Digital supply chain visibility is critical

Published

6 days ago

February 20, 2026

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MSR Kali Prasad, Chief Digital and Information Officer, Shree Cement, discusses how data, discipline and scale are turning Industry 4.0 into everyday business reality.

Over the past five years, digitalisation in Indian cement manufacturing has moved decisively beyond experimentation. Today, it is a strategic lever for cost control, operational resilience and sustainability. In this interview, MSR Kali Prasad, Chief Digital and Information Officer, Shree Cement, explains how integrated digital foundations, advanced analytics and real-time visibility are helping deliver measurable business outcomes.

How has digitalisation moved from pilot projects to core strategy in Indian cement manufacturing over the past five years?
Digitalisation in Indian cement has evolved from isolated pilot initiatives into a core business strategy because outcomes are now measurable, repeatable and scalable. The key shift has been the move away from standalone solutions toward an integrated digital foundation built on standardised processes, governed data and enterprise platforms that can be deployed consistently across plants and functions.
At Shree Cement, this transition has been very pragmatic. The early phase focused on visibility through dashboards, reporting, and digitisation of critical workflows. Over time, this has progressed into enterprise-level analytics and decision support across manufacturing and the supply chain,
with clear outcomes in cost optimisation, margin protection and revenue improvement through enhanced customer experience.
Equally important, digital is no longer the responsibility of a single function. It is embedded into day-to-day operations across planning, production, maintenance, despatch and customer servicing, supported by enterprise systems, Industrial Internet of Things (IIoT) data platforms, and a structured approach to change management.

Which digital interventions are delivering the highest ROI across mining, production and logistics today?
In a capital- and cost-intensive sector like cement, the highest returns come from digital interventions that directly reduce unit costs or unlock latent capacity without significant capex.
Supply chain and planning (advanced analytics): Tools for demand forecasting, S&OP, network optimisation and scheduling deliver strong returns by lowering logistics costs, improving service levels, and aligning production with demand in a fragmented and regionally diverse market.
Mining (fleet and productivity analytics): Data-led mine planning, fleet analytics, despatch discipline, and idle-time reduction improve fuel efficiency and equipment utilisation, generating meaningful savings in a cost-heavy operation.
Manufacturing (APC and process analytics): Advanced Process Control, mill optimisation, and variability reduction improve thermal and electrical efficiency, stabilise quality and reduce rework and unplanned stoppages.
Customer experience and revenue enablement (digital platforms): Dealer and retailer apps, order visibility and digitally enabled technical services improve ease of doing business and responsiveness. We are also empowering channel partners with transparent, real-time information on schemes, including eligibility, utilisation status and actionable recommendations, which improves channel satisfaction and market execution while supporting revenue growth.
Overall, while Artificial Intelligence (AI) and IIoT are powerful enablers, it is advanced analytics anchored in strong processes that typically delivers the fastest and most reliable ROI.

How is real-time data helping plants shift from reactive maintenance to predictive and prescriptive operations?
Real-time and near real-time data is driving a more proactive and disciplined maintenance culture, beginning with visibility and progressively moving toward prediction and prescription.
At Shree Cement, we have implemented a robust SAP Plant Maintenance framework to standardise maintenance workflows. This is complemented by IIoT-driven condition monitoring, ensuring consistent capture of equipment health indicators such as vibration, temperature, load, operating patterns and alarms.
Real-time visibility enables early detection of abnormal conditions, allowing teams to intervene before failures occur. As data quality improves and failure histories become structured, predictive models can anticipate likely failure modes and recommend timely interventions, improving MTBF and reducing downtime. Over time, these insights will evolve into prescriptive actions, including spares readiness, maintenance scheduling, and operating parameter adjustments, enabling reliability optimisation with minimal disruption.
A critical success factor is adoption. Predictive insights deliver value only when they are embedded into daily workflows, roles and accountability structures. Without this, they remain insights without action.

In a cost-sensitive market like India, how do cement companies balance digital investment with price competitiveness?
In India’s intensely competitive cement market, digital investments must be tightly linked to tangible business outcomes, particularly cost reduction, service improvement, and faster decision-making.
This balance is achieved by prioritising high-impact use cases such as planning efficiency, logistics optimisation, asset reliability, and process stability, all of which typically deliver quick payback. Equally important is building scalable and governed digital foundations that reduce the marginal cost of rolling out new use cases across plants.
Digitally enabled order management, live despatch visibility, and channel partner platforms also improve customer centricity while controlling cost-to-serve, allowing service levels to improve without proportionate increases in headcount or overheads.
In essence, the most effective digital investments do not add cost. They protect margins by reducing variability, improving planning accuracy, and strengthening execution discipline.

How is digitalisation enabling measurable reductions in energy consumption, emissions, and overall carbon footprint?
Digitalisation plays a pivotal role in improving energy efficiency, reducing emissions and lowering overall carbon intensity.
Real-time monitoring and analytics enable near real-time tracking of energy consumption and critical operating parameters, allowing inefficiencies to be identified quickly and corrective actions to be implemented. Centralised data consolidation across plants enables benchmarking, accelerates best-practice adoption, and drives consistent improvements in energy performance.
Improved asset reliability through predictive maintenance reduces unplanned downtime and process instability, directly lowering energy losses. Digital platforms also support more effective planning and control of renewable energy sources and waste heat recovery systems, reducing dependence on fossil fuels.
Most importantly, digitalisation enables sustainability progress to be tracked with greater accuracy and consistency, supporting long-term ESG commitments.

What role does digital supply chain visibility play in managing demand volatility and regional market dynamics in India?
Digital supply chain visibility is critical in India, where demand is highly regional, seasonality is pronounced, and logistics constraints can shift rapidly.
At Shree Cement, planning operates across multiple horizons. Annual planning focuses on capacity, network footprint and medium-term demand. Monthly S&OP aligns demand, production and logistics, while daily scheduling drives execution-level decisions on despatch, sourcing and prioritisation.
As digital maturity increases, this structure is being augmented by central command-and-control capabilities that manage exceptions such as plant constraints, demand spikes, route disruptions and order prioritisation. Planning is also shifting from aggregated averages to granular, cost-to-serve and exception-based decision-making, improving responsiveness, lowering logistics costs and strengthening service reliability.

How prepared is the current workforce for Industry 4.0, and what reskilling strategies are proving most effective?
Workforce preparedness for Industry 4.0 is improving, though the primary challenge lies in scaling capabilities consistently across diverse roles.
The most effective approach is to define capability requirements by role and tailor enablement accordingly. Senior leadership focuses on digital literacy for governance, investment prioritisation, and value tracking. Middle management is enabled to use analytics for execution discipline and adoption. Frontline sales and service teams benefit from
mobile-first tools and KPI-driven workflows, while shop-floor and plant teams focus on data-driven operations, APC usage, maintenance discipline, safety and quality routines.
Personalised, role-based learning paths, supported by on-ground champions and a clear articulation of practical benefits, drive adoption far more effectively than generic training programmes.

Which emerging digital technologies will fundamentally reshape cement manufacturing in the next decade?
AI and GenAI are expected to have the most significant impact, particularly when combined with connected operations and disciplined processes.
Key technologies likely to reshape the sector include GenAI and agentic AI for faster root-cause analysis, knowledge access, and standardisation of best practices; industrial foundation models that learn patterns across large sensor datasets; digital twins that allow simulation of process changes before implementation; and increasingly autonomous control systems that integrate sensors, AI, and APC to maintain stability with minimal manual intervention.
Over time, this will enable more centralised monitoring and management of plant operations, supported by strong processes, training and capability-building.