Concrete
Automation systems minimise material and energy use
Published
2 years agoon
By
admin
Manish Chordia, Regional Sales Manager-Cement (South Asia and Africa), ABB India Limited, discusses the importance of automation in cement plants to achieve efficient production with minimal environmental impact.
How do your solutions help cement plants to adjust to changing fuels and raw materials?
Delivering high quality products, while keeping production costs low and plant efficiency high, is an ongoing challenge for all process industries. Cement manufacturers face these challenges daily and the drive for improved efficiency cannot undercut the stability of production processes. ABB AbilityTM Expert Optimiser (EO) helps in alternative fuel management and raw material handling. EO can control, mix and monitor rates of alternative fuels to ensure consistent burning, while also ensuring that the kiln does not become unstable due to changes in fuel calorific value.
Stable and correctly proportioned raw material is essential for energy-efficient clinker production. Cement blended at the right proportions is essential to ensure that specifications are met and a quality product is delivered to end-customers. Implementing EO can positively impact both raw material and the cement blending processes. Incorporating optimisation and analytics technologies, the software enables a plant to automatically make the best operational decisions accurately and consistently. ABB AbilityTM EO standardises the optimisation strategy to minimise both shift-to-shift variations and human workload. This frees up operators to focus on more pressing tasks. EO for cement combines Advanced Process Control (APC) technologies with ABB’s extensive industry expertise, stabilising the process and maximising profitability to manage critical plant components, including kiln, alternative fuels, mills, and blending. It constantly pushes the boundaries of what is possible in a plant to maximise yield and throughput whilst minimising operating costs such as fuel and electricity.
Tell us more about your Advanced Process Control (APC) solution and its functionality.
ABB’s APC technology helps to improve fuel management, mill optimisation and material blending in cement manufacturing. The suite comprises a set of tools, both online and offline, that allow the deployment of advanced controllers and analytic models. This provides monitoring, predictive analytics, and closed loop control capabilities at the device, edge, and cloud to ensure real-time operational efficiencies. It also helps process and energy industries to optimise operations by using emergent technologies – such as the cloud, data analytics, visualisation, and advanced modelling algorithms, as part of the disruptive change offered by the Internet of Things (IoT). It extracts knowledge from existing data in the plant and uses that for detailed analysis to arrive at the best course of action to improve
specific processes.
How does automation help cement plants achieve accuracy and efficiency in production?
Efforts to reduce energy demands, by using higher efficiency equipment and substituting fuels and raw materials, are important to lower production costs. These changes introduce constraints that must be managed to secure the required quality and productivity of the plant. The ABB plant-wide automation strategy searches for the optimal operation point while maximising product quality and productivity, at the lowest energy consumption and least environmental impact. This is achieved through a combination of variable speed drives (VSD), advanced process control, energy monitoring and reporting.
Electrical energy savings of up to 70 per cent can be achieved by using VSD over a fixed-speed motor and damper. The multi-drive solution provides the optimised drive solution for the grate cooler. The control and optimisation of the kiln will reduce thermal fuel consumption by up to 8 per cent. When this is combined with the automated collection, organisation and distribution of production, quality and energy reports, fast decisions and interaction to reach the goals of energy management are achieved.
There can be no flaws or failures in cement composition or entire structures could disintegrate. Advanced measuring, information and optimisation systems are needed as never before to monitor and correct any deviations in quality standards – from quarry to dispatch. ABB’s tailored products, digital applications and services improve processes and help you achieve optimum production standards. Automation systems minimise material and energy use in complex processes.
Instead of controlling independent equipment and systems supplied by different suppliers over separate control systems, it is a great advantage to integrate and control automation islands centrally. ABB integrates these processes and adds value to the companies they work with. The processes covered in the scope of the ABB AbilityTM platform are considered to be a fully compatible integration with energy efficiency, production increase and optimisation, reduced downtime, business and asset management, ERP systems in factories by utilisation of Level 3 software. ABB produces its software unique for the sector by utilising the Minerals Library, which ABB has developed specifically for the cement sector. This library is composed of object-based software control and energy management applications productively and in an entirely parameterised manner at the same time. Thus, customers have the opportunity to operate and continue their production process and asset management in the most efficient way.
What is the data support provided by your solutions to the cement manufacturers?
In recent years, rapid advancements in big data and digital technologies have begun a revolution in industrial processes, commonly known as Industry 4.0. This revolution is defined by the application of disruptive technologies such as the IoT, augmented reality (AR) and artificial intelligence (AI) to industrial settings to optimise process performance, reduce operating costs, and enable safer and more secure production. One of the key elements for cement customers is to have an information management system that allows transparency across operations. ABB Ability™ Knowledge Manager information management system provides analytical insight to identify best practice and improve overall operations at plant and corporate level. Enhancing transparency across a plant or fleet of plants, Knowledge Manager is also available via a mobile app for smartphones or tablets, enabling plant and company managers to view operational performance at any time and from anywhere. Knowledge Manager software ensures executives can access instantly to the key performance indicators (KPI) of many cement factories. By utilisation of this software, they may see how much energy their factory transiently consumes, how much transient production they accomplish, which alternative fuels or minerals they use, and their profitability at any instant.
What are the major challenges in executing your solutions?
As ABB, we can provide solutions from quarry to dispatch to the cement industry which means automation, instrumentation, electrification, digitalisation, project management and engineering, infrastructure, and service. Additionally, ABB can also support cement manufacturers in the journey of decarbonisation with the help of co-operations with the likes of Coolbrook and Captimise. ABB’s experienced engineering team can react to changes in projects, offering expertise and take action quickly to produce solutions. In addition, despite the fact that electrification and automation systems are the final point during commissioning works, ABB can provide added value to the customers by trying to go one step ahead of the construction and mechanical works.
Other main challenges are the readiness of the companies for the decarbonisation journey considering both technical and financial ways. As ABB, we are ready to support them beginning with pre-feasibility studies.
Tell us about the innovations by your organisation that the cement industry can look forward to?
The most important feature differentiating ABB is customer satisfaction for its products and systems, ABB’s steadfast devotion in adherence to quality and global ethical principles, engineering strength and know-how, and powerful supply chain. By providing service and support for the projects and systems designed by ABB even after many years, we differentiate ourselves from other companies. We are investing in new technologies that reduce the use of fossil fuel consumption and reduce unscheduled stoppages as well as collaborative partnerships to reduce emissions in the cement industry. Collaboration with Coolbrook’s RotoDynamic technology, which replaces fossil fuels with renewable electricity, with Captimise to join forces to support the cement industry in planning CCS projects by providing technology agnostic FEED studies and a small sized trail facility to allow testing of the selected Carbon Capture technology will help the cement customers during their journey to achieve Net Zero target.
- –Kanika Mathur
Concrete
Adani’s Strategic Emergence in India’s Cement Landscape
Published
2 weeks agoon
September 16, 2025By
admin
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.
Concrete
Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series
Published
1 month agoon
August 16, 2025By
admin
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.

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.

Adani’s Strategic Emergence in India’s Cement Landscape

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

Driving Measurable Gains

Reshaping the Competitive Landscape

CCU testbeds in Tamil Nadu

Adani’s Strategic Emergence in India’s Cement Landscape

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

Driving Measurable Gains

Reshaping the Competitive Landscape
