Concrete

Cementing a Sustainable Future

Published

2 years ago

January 12, 2024

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Anuj Khandelwal, Business Head, JK Cement, discusses his company’s technological odyssey in environmental stewardship, and how it changed the thought process of India’s cement sector.

In the realm of global construction, the cement industry stands as a vital pillar, albeit one burdened with a significant environmental footprint, contributing to 5-8 per cent of global emissions. JK Cement recognises the imperative role it must play in fostering sustainability, understanding that our long-term growth is intricately linked to advancing the sustainability agenda.

Commitment to Sustainability
JK Cement has undertaken a proactive stance by signing up for Science-Based Targets Initiative (SBTi)-based goals, committing to a robust 21.7 per cent reduction in specific gross CO2 emissions by 2030 compared to the 2020 baseline. These ambitious targets, already validated and approved by SBTi, signify a substantial stride toward a greener future. Remarkably, we have exceeded expectations, achieving a 16.3 per cent reduction in H1FY24 and poised to surpass our FY25 commitments of a 7.2 per cent reduction.

Challenges in the Industry
Understanding the unique challenges of the cement and lime industry is pivotal. Unlike many other industries, the majority of greenhouse gas emissions in cement production emanate not from energy use but from the raw materials themselves. Approximately 60 per cent of CO2 emissions result from limestone processing, necessitating a nuanced approach to sustainability across four dimensions:

Reduce the need for energy-intensive materials
Improve energy intensity
Greenify sources
Prevent release at the source

A Catalyst for Sustainability
Embracing the philosophy that technology is pivotal in the road to sustainability, JK Cement has strategically invested in technological advancements. Our sustainability journey revolves around three key technological pillars:

Technological upgrades for lower energy intensity
Upgrading manufacturing technologies and equipment has been instrumental in achieving lower energy intensity. Notable examples include the upgrade of older plants and kilns, such as Nimbahera L3 and Mangrol L2, with ongoing projects in Mangrol L1 and deployment of state-of-the-art Waste Heat Recovery Systems (WHRS) ensures maximal green power output across all our integrated units.
Technological innovations for enabling usage of greener sources
The substitution of traditional fuels and raw materials with green sources demands technological innovations. JK Cement has taken the lead in deploying a chlorine bypass system at our Muddapur plant to achieve over 35 per cent Thermal Substitution Rate (TSR). Upgrades in feeding systems across kilns facilitate higher TSR levels.
These innovations are integral to our circularity agenda. By harnessing cutting-edge technology, we are redefining our processes, ensuring a more sustainable and environmentally friendly approach to cement production.
Unlocking scale and navigating challenges with technology
Scaling sustainability initiatives requires automation and digital solutions. This is a critical part of our capability build as we move towards the new clean-tech solutions offered.
For instance, real-time power balancing solutions address the variability in green power generation profiles. Digital load and demand balancing solutions have increased the usage of green power, helping us achieve a remarkable 48 per cent+ green power mix for JK Cement in H1FY24.
Similarly addressing challenges associated with quality variance in alternate fuels and impact on stable kiln operations required innovative solutions. NIR sensors for online quality testing enable precise control over the alternative fuel blend. In parallel, automated feedback loops helped ensure stable kiln operations even at higher TSR levels.
Investments in digital quality control systems enable the incorporation of higher alternate raw materials, crucial for maintaining product quality amid the variability of alternate materials.
Our investment in digital solutions not only underscores our commitment to sustainability
but also positions us as industry leaders. By leveraging automation, we not only achieve environmental goals but also enhance operational efficiency and competitiveness. These technological interventions also showcase our dedication to overcoming challenges.
The Road Ahead
Technological innovation remains central to JK Cement’s future sustainability initiatives.
After evaluating the underlying physical and technical limits of available technologies, our
findings are that the three technologies available today can have a material impact on driving
down carbon emissions from cement production by 2030. Therefore, our short-term focus is on the three groups of cost-saving technologies to drive the focus further:
• Substitute Cementitious Materials (SCM), including LC3 Cement
• Biomass and waste alternative fuels
• AI for energy efficiency, predictive maintenance, quality improvement and cement logistic and fleet optimisation
Similarly exploring avenues such as hydrogen (H2) utilisation and electrification, Carbon Capture, Utilisation and Storage (CCUS), carbon-neutral transport, CO2 capture in the built environment, and efficient concrete use will be pivotal in achieving our long-term goals and the basis of technological evolution in these.
As we look to the future, the role of technology in sustainability cannot be overstated. Our commitment to exploring innovative solutions aligns with the ever-evolving landscape of sustainable practices, positioning JK Cement as a beacon of environmental responsibility in the cement industry.

Conclusion
In conclusion, JK Cement views technology as a catalyst for not only meeting but exceeding sustainability targets. As we navigate the complexities of the cement industry, we remain dedicated to pioneering sustainable solutions that redefine the role of technology in our environmental stewardship. Our endeavours are not just about cement; they are about shaping a sustainable future for generations to come.

ABOUT THE AUTHOR:
Anuj Khandelwal, Business Head, JK Cement, has about 15 years of experience across industry, consulting and strategy roles. He is an MBA from Indian Institute of Management, Lucknow and also has a Chartered Accountancy (CA) degree.

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AFCM Unveils 2035 Regional Decarbonisation Roadmap for Cement Sector

AFCM launches world’s first regional decarbonisation plan for cement at Brunei meet.

Published

3 days ago

December 5, 2025

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The ASEAN Federation of Cement Manufacturers (AFCM) has formally launched the 2035 AFCM Decarbonisation Roadmap, becoming the first regional bloc in the world to introduce a unified decarbonisation strategy for the cement sector. The announcement was made at the 46th AFCM Council Meeting in Brunei Darussalam, chaired by Dr Chana Poomee, and attended by leaders and representatives of cement associations from all eight AFCM member countries. The launch comes as global attention intensifies ahead of COP30 in Brazil, where climate action is expected to be a central priority.

Cement production remains integral to infrastructure and economic development across the ASEAN region, yet it is also a major contributor to CO? emissions. The 2035 AFCM Decarbonisation Roadmap signals a collective regional commitment to accelerating emissions reduction in alignment with national climate policies and global sustainability goals, reinforcing AFCM’s leadership in the transition to low carbon cement production.

Dr Chana Poomee, AFCM President and Chairman of the Thai Cement Manufacturers Association (TCMA), described the roadmap as a landmark achievement for the region’s cement industry. He noted that the shared framework would support systematic CO? reduction, strengthen regional competitiveness and enhance ASEAN’s contribution to global climate objectives.

Developed with strong support from the Global Cement and Concrete Association (GCCA), the 2035 Roadmap sets out a comprehensive transition pathway anchored around four strategic pillars:

• Expansion of low carbon cement enabled by performance-based standards;

• Transition to clean and renewable energy across production processes, alongside improved thermal and electrical efficiency;

• Deployment of advanced decarbonisation technologies, including Carbon Capture, Utilisation and Storage (CCUS); and

• Development of new supplementary cementitious materials to support next-generation low carbon cement products.

Dr Chana urged all AFCM members to treat the roadmap as a coordinated regional strategy for sustainable growth. At the ASEAN level, the measures outlined have the potential to reduce up to 38 million tonnes of CO2 by 2035. While the roadmap sets a collective vision, it acknowledges the diversity of national conditions, recognising that each member country will set its own targets based on regulatory frameworks, industrial maturity and technological capacity. One key early-action priority is the reduction and phasedown of Ordinary Portland Cement (OPC), providing an immediate opportunity for substantial emissions cuts.

Cement associations from Brunei Darussalam, Cambodia, Indonesia, Malaysia, the Philippines, Singapore, Thailand and Vietnam expressed strong support for the roadmap and reaffirmed their commitment to advancing decarbonisation within their national contexts. Members emphasised the need for supportive policies, expanded use of alternative fuels, improved energy efficiency, accelerated adoption of advanced technologies and greater promotion of low carbon cement and concrete solutions. They also recognised that specific decarbonisation pathways will vary based on each country’s energy mix, material availability, policy environment and market readiness.

“The 2035 AFCM Decarbonisation Roadmap presents a significant opportunity to enhance regional competitiveness, drive sustainable development and unlock substantial economic benefits. Government support, including policy adaptation, will be essential for effective implementation. Through collaboration, innovation and collective action, AFCM can accelerate the adoption of low carbon technologies, attract green investment, create new economic opportunities and build a resilient, future-ready cement industry that contributes meaningfully to global decarbonisation,” Dr Chana concluded.

The issuer is solely responsible for the content of this announcement.

Concrete

Cement Makers Positive on H2 Demand Outlook

Major producers expect stronger sales in the second half of FY26.

Published

5 days ago

December 3, 2025

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The leading cement producers have posted high single-digit volume growth and better sales realisation in the July–September quarter, setting a positive tone for the second half of FY26. Companies are upbeat on demand prospects, supported by a strong housing sector and continued government spending on major infrastructure projects.

UltraTech, Ambuja Cement, Shree Cement, Dalmia Bharat and Nuvoco Vistas recorded revenue growth of up to 18 per cent in the September quarter. The rise was driven by firm realisations, softer input costs and an increased share of premium products.

With coal prices easing and diesel rates remaining stable year-on-year, companies expect margins to improve further in the coming months despite a rise in petcoke costs. In recent earnings calls, cement makers highlighted that the individual home builders segment across rural and urban markets is likely to drive demand, aided by favourable monsoon conditions, recent tax benefits and GST reforms.

Concrete

Fornnax Unveils the World’s Largest NPD and Demo Centre to Accelerate Global Recycling Innovation

Published

5 days ago

December 3, 2025

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A 12-acre innovation campus enables Fornnax to design, test and validate high-performance recycling solutions at global standards in record time.

Fornnax has launched one of the world’s largest New Product Development (NPD) centres and demo plants, spanning more than 12 acres, marking a major step toward its vision of becoming a global recycling technology leader by 2030. Designed to accelerate real-world innovation, the facility will enable faster product design cycles, large-scale performance validation, and more reliable equipment for high-demand recycling applications.

At the core of the new campus is a live demo plant engineered to support application-specific testing. Fornnax will use this facility to upgrade its entire line of shredders and granulators—enhancing capacity, improving energy efficiency, and reducing downtime. With controlled test environments, machines can be validated for 3,000 to 15,000 hours of operation, ensuring real-world durability and high availability of 18–20 hours per day. This approach gives customers proven performance data before deployment.

“Innovation in product development is the key to becoming a global leader,” said Jignesh Kundariya, Director and CEO of Fornnax. “With this facility, we can design, test and validate new technologies in 6–8 months, compared to 4–5 years in a customer’s plant. Every machine will undergo rigorous Engineering Build (EB) and Manufacturing Build (MB) testing in line with international standards.”

Engineering Excellence Powered by Gate Review Methodology

Fornnax’s NPD framework follows a structured Gate Review Process, ensuring precision and discipline at every step. Projects begin with market research and ideation led by Sales and Marketing, followed by strategic review from the Leadership Team. Detailed engineering is then developed by the Design Team and evaluated by Manufacturing, Service and Safety before approval. A functional prototype is built and tested for 6–8 months, after which the design is optimised for mass production and commercial rollout.

Open-Door Customer Demonstration and Material Testing

The facility features an open-door demonstration model, allowing customers to bring their actual materials and test multiple machines under varied operating conditions. Clients can evaluate performance parameters, compare configurations and make informed purchasing decisions without operational risk.

The centre will also advance research into emerging sectors including E-waste, cables, lithium-ion batteries and niche heterogeneous waste streams. Highly qualified engineering and R&D teams will conduct feasibility studies and performance analysis to develop customised solutions for unfamiliar or challenging materials. This capability reinforces Fornnax’s reputation as a solution-oriented technology provider capable of solving real recycling problems.

Developing Global Recycling Talent

Beyond technology, the facility also houses a comprehensive OEM training centre. It will prepare operators and maintenance technicians for real-world plant conditions. Trainees will gain hands-on experience in assembly, disassembly and grinding operations before deployment at customer sites. Post-training, they will serve as skilled support professionals for Fornnax installations. The company will also deliver corporate training programs for international and domestic clients to enable optimal operation, swift troubleshooting and high-availability performance.

A Roadmap to Capture Global Demand

Fornnax plans to scale its offerings in response to high-growth verticals including Tyre recycling, Municipal Solid Waste (MSW), E-waste, Cable and Aluminium recycling. The company is also preparing solutions for new opportunities such as Auto Shredder Residue (ASR) and Lithium-Ion Battery recovery. With research, training, validation and customer engagement housed under one roof, Fornnax is laying the foundation for the next generation of recycling technologies.

“Our goal is to empower customers with clarity and confidence before they invest,” added Kundariya. “This facility allows them to test their own materials, compare equipment and see real performance. It’s not just about selling machines—it’s about building trust through transparency and delivering solutions that work.”

With this milestone, Fornnax reinforces its long-term commitment to enabling industries worldwide with proven, future-ready recycling solutions rooted in innovation, engineering discipline and customer collaboration.