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Improving Operations using AI

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Tushar Kulkarni, Business Head – Minerals, Cement & Mining, Siemens Large Drivers India, discusses the role of Artificial Intelligence (AI) and premium efficiency standard products in making cement plant operations more sustainable.

By FY27, cement consumption in India is expected to reach 450.78 million tonnes, driven majorly by expanding demand from housing, commercial construction, national infrastructure projects and industrial construction*. To meet the growing demand, many cement companies are planning or are undertaking capacity expansions. Despite market growth, challenges such as fluctuating raw material prices, energy costs, transportation costs, skill shortages and regulatory complexities continue to persist for cement plants.
Cement plants constantly strive to improve productivity and cost efficiency through sustainable manufacturing and operations. It is imperative for them to maintain continuous and reliable machine operations for producing high-quality cement that comply with industry standards, while also adhering to the environmental emission norms and regulations.
Over the last two decades, various technologies for advanced process control (APC) have been developed for the cement industry, viz fuzzy logic, expert systems and rudimentary approaches of artificial intelligence – these being the most widespread form of technology applied to process control. However, with the changes in technology and increasing use of alternate fuel residual (AFR) and alternative raw materials, the current optimisation systems (APC) have limited performance over process control and require excessive retuning.
In this context, adoption of latest technologies viz digitalisation solutions and use of Artificial Intelligence (AI) will significantly help cement plants in their efforts towards innovation, efficiency and sustainability goals through improved process optimization and increased productivity. Our SICEMENT® Operations Digital solutions portfolio (AI based) is well-positioned to support the cement industry in this endeavor.
*Source: IBEF Aug 23

Transforming Data into Insights
Digitalisation involves the integration of digital technologies, automation and data exchange, which creates large volumes of diverse and continuous data. To leverage such a wealth of data, data science is the catalyst that transforms data into actionable intelligence. Data science involves leveraging advanced techniques and technologies to extract meaningful insights, patterns and knowledge from a large volume of data.
Data science being the backbone of digitalisation process, plays a pivotal role to harness the power of data for strategic decision making, efficiency gains and innovation, such as:
Data-driven decision making: Extracting valuable insights from large datasets for insights driven informed decision making.
Predictive analytics: Forecasting future trends and enhancing operational efficiency.
Process optimisation: Identifying areas of optimisation, which can lead to more efficient production and reduced energy consumption.
Smart maintenance: Predictive maintenance models can forecast potential failures, allowing for proactive interventions and minimising downtime.
Integration of AI in data science increases the capabilities of extracting valuable insights, making predictions and automating various tasks. It empowers data scientists to manage complex problems and extract meaningful information from diverse datasets.
To understand more on applying AI in cement production, let us look at an example of the rotary kiln in cement production. It is known that the different parameters of the kiln react differently to changes in the control parameters – some are sensitive, others do not react at all. In addition, some parameters have linear characteristics, while others behave nonlinearly. These significant differences require a differentiated approach to improve the control strategy. AI technology is designed to manage linear and nonlinear behaviour in a complex environment where numerous dependencies determine the engineering process.
The main difference between a data-centric solution and traditional expert systems is the development of a dedicated machine learning-based kiln model that provides more accurate insights into future kiln process trends than traditional approaches. The latter typically provides insights that are based on a generic mathematical toolbox and a simple aggregation of recent historical data. Advanced Process Control (APC) is widely used to improve kiln and mill control. However, in practice, the limitations of the current APC approach are apparent. For instance, a typical fuzzy logic is not able to cover all operating scenarios and is sensitive to operational changes. A typical Model Predictive Control (MPC) uses linear models in most cases and any change in equipment leads to a completely new setting of the model.
In contrast, by incorporating long-term data sets for AI training, the trained AI models can learn from the past and establish correlations between parameters and time and between actions and outcomes. This knowledge, accumulated in the models, forms the basis for better control performance.
The advantage of the AI-based solution over the previously described APC / MPC solutions is the development of a dedicated machine learning based kiln model that leads to more accurate insights into the future trends of the burning process than conventional approaches, which are usually based on a generic mathematical toolbox and a simple aggregation of recent historical data.

Driving Sustainability through Efficient Products
Industry has to adapt to products that have the highest possible efficiency standards. There is a huge drive by regulatory bodies as well as the manufacturers to scale up efficiencies of products used in process. Let us take an example of Low Voltage Motors. Currently the Minimum Efficiency Performance Standard (MEPS) in India is IE2 efficiency. Motors in IE3 and IE4 efficiency class also are available in the market. Due to the very lucrative ROI and also a concern on carbon emission, the penetration of motors with efficiency standard > IE2 is rapidly increasing and as per the estimation, > 30 per cent by kW of LV Motors produced are with efficiency class > IE2. With this encouraging voluntary shift to motors in efficiency class > IE2, industry is expecting the regulatory body to make IE3 as MEPS soon. Sectors such as the cement industries have already started moving towards IE4 in recent years.
The standards allow tolerance in efficiency declared by manufacturers for the purpose of accommodating manufacturing inconsistencies. However, many motors sold to users are by-design, utilising the negative side tolerances meant for manufacturing inconsistencies. Bearing this in mind, IEC has revised the criteria for CE Compliance w.e.f. 1st July 2022 which are stringent and so users are now assured of minimal utilisation of tolerance on the negative side. This will ensure IE3 and IE4 motors with enhanced operational efficiencies. Further, condition monitoring of motors with the help of cloud-based platforms can enhance the operational efficiencies.
Stringent standards, responded positively by manufacturers and aware users will pave a
path of higher level of sustainability in the cement industry.

ABOUT THE AUTHOR:
Tushar Kulkarni, Business Head – Minerals, Cement & Mining, Siemens Large Drivers India,
leads the business verticals of Minerals – Cement & Mining within Innomotics India Pvt Ltd. With over 20 years of experience, he has held positions across business development, customer relationship management and project management amongst others.

Case Study: Retrofitting of lower efficient DC Motor by compact and highly efficient SIMOTICS H-Compact AC motor for Kiln Main Drive at one of India’s largest cement manufacturers. An Innomotics engineer was invited by a customer with an existing motor based on Direct Current Technology and was installed approx. 30 years ago. Based on the customer’s request, the Innomotics engineer visited the site to replace this old motor with a high efficiency AC Motor for Kiln Main Drive application. The customer’s priority was to have a tailor-made solution without disturbing existing mechanical and foundation set-up. After a detailed study during the site visit, the solution was a H-Compact 1PQ4 motor with high efficiency (97.7 per cent @ 75 per cent load) which enabled a reduction in annual energy consumption by 682,000 kWh. This helped in CO2 emission reduction by 440 Tons per annum which approximately would require 17,600 full grown trees to offset. Rating: 1000kW/6P/690V/50Hz/60°C, Application: Kiln Main Drive; Frame: H-Compact, 1PQ4 500 frame.

Concrete

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

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FORNNAX TECHNOLOGY has appointed industry veteran Dieter Jerschl as its new sales partner in Germany to strengthen its presence across Central Europe. The partnership aims to accelerate the adoption of FORNNAX’s high-capacity, sustainable recycling solutions while building long-term regional capabilities.

FORNNAX TECHNOLOGY, one of the leading advanced recycling equipment manufacturers, has announced the appointment of a new sales partner in Germany as part of its strategic expansion into Central Europe. The company has entered into a collaborative agreement with Mr. Dieter Jerschl, a seasoned industry professional with over 20 years of experience in the shredding and recycling sector, to represent and promote FORNNAX’s solutions across key European markets.

Mr. Jerschl brings extensive expertise from his work with renowned companies such as BHS, Eldan, Vecoplan, and others. Over the course of his career, he has successfully led the deployment of both single machines and complete turnkey installations for a wide range of applications, including tyre recycling, cable recycling, municipal solid waste, e-waste, and industrial waste processing.

Speaking about the partnership, Mr. Jerschl said,
“I’ve known FORNNAX for over a decade and have followed their growth closely. What attracted me to this collaboration is their state-of-the-art & high-capacity technology, it is powerful, sustainable, and economically viable. There is great potential to introduce FORNNAX’s innovative systems to more markets across Europe, and I am excited to be part of that journey.”

The partnership will primarily focus on Central Europe, including Germany, Austria, and neighbouring countries, with the flexibility to extend the geographical scope based on project requirements and mutual agreement. The collaboration is structured to evolve over time, with performance-driven expansion and ongoing strategic discussions with FORNNAX’s management. The immediate priority is to build a strong project pipeline and enhance FORNNAX’s brand presence across the region.

FORNNAX’s portfolio of high-performance shredding and pre-processing solutions is well aligned with Europe’s growing demand for sustainable and efficient waste treatment technologies. By partnering with Mr. Jerschl—who brings deep market insight and established industry relationships—FORNNAX aims to accelerate adoption of its solutions and participate in upcoming recycling projects across the region.

As part of the partnership, Mr. Jerschl will also deliver value-added services, including equipment installation, maintenance, and spare parts support through a dedicated technical team. This local service capability is expected to ensure faster project execution, minimise downtime, and enhance overall customer experience.

Commenting on the long-term vision, Mr. Jerschl added,
“We are committed to increasing market awareness and establishing new reference projects across the region. My goal is not only to generate business but to lay the foundation for long-term growth. Ideally, we aim to establish a dedicated FORNNAX legal entity or operational site in Germany over the next five to ten years.”

For FORNNAX, this partnership aligns closely with its global strategy of expanding into key markets through strong regional representation. The company believes that local partnerships are critical for navigating complex market dynamics and delivering solutions tailored to region-specific waste management challenges.

“We see tremendous potential in the Central European market,” said Mr. Jignesh Kundaria, Director and CEO of FORNNAX.
“Partnering with someone as experienced and well-established as Mr. Jerschl gives us a strong foothold and allows us to better serve our customers. This marks a major milestone in our efforts to promote reliable, efficient and future-ready recycling solutions globally,” he added.

This collaboration further strengthens FORNNAX’s commitment to environmental stewardship, innovation, and sustainable waste management, supporting the transition toward a greener and more circular future.

 

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Budget 2026–27 infra thrust and CCUS outlay to lift cement sector outlook

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Higher capex, city-led growth and CCUS funding improve demand visibility and decarbonisation prospects for cement

Mumbai

Cement manufacturers have welcomed the Union Budget 2026–27’s strong infrastructure thrust, with public capital expenditure increased to Rs 12.2 trillion, saying it reinforces infrastructure as the central engine of economic growth and strengthens medium-term prospects for the cement sector. In a statement, the Cement Manufacturers’ Association (CMA) has welcomed the Union budget 2026-27 for reinforcing the ambitions for the nation’s growth balancing the aspirations of the people through inclusivity inspired by the vision of Narendra Modi, Prime Minister of India, for a Viksit Bharat by 2047 and Atmanirbharta.

The budget underscores India’s steady economic trajectory over the past 12 years, marked by fiscal discipline, sustained growth and moderate inflation, and offers strong demand visibility for infrastructure linked sectors such as cement.

The Budget’s strong infrastructure push, with public capital expenditure rising from Rs 11.2 trillion in fiscal year 2025–26 to Rs 12.2 trillion in fiscal year 2026–27, recognises infrastructure as the primary anchor for economic growth creating positive prospects for the Indian cement industry and improving long term visibility for the cement sector. The emphasis on Tier 2 and Tier 3 cities with populations above 5 lakh and the creation of City Economic Regions (CERs) with an allocation of Rs 50 billion per CER over five years, should accelerate construction activity across housing, transport and urban services, supporting broad based cement consumption.

Logistics and connectivity measures announced in the budget are particularly significant for the cement industry. The announcement of new dedicated freight corridors, the operationalisation of 20 additional National Waterways over the next five years, the launch of the Coastal Cargo Promotion Scheme to raise the modal share of waterways and coastal shipping from 6 per cent to 12 per cent by 2047, and the development of ship repair ecosystems should enhance multimodal freight efficiency, reduce logistics costs and improve the sector’s carbon footprint. The announcement of seven high speed rail corridors as growth corridors can be expected to further stimulate regional development and construction demand.

Commenting on the budget, Parth Jindal, President, Cement Manufacturers’ Association (CMA), said, “As India advances towards a Viksit Bharat, the three kartavya articulated in the Union Budget provide a clear context for the Nation’s growth and aspirations, combining economic momentum with capacity building and inclusive progress. The Cement Manufacturers’ Association (CMA) appreciates the Union Budget 2026-27 for the continued emphasis on manufacturing competitiveness, urban development and infrastructure modernisation, supported by over 350 reforms spanning GST simplification, labour codes, quality control rationalisation and coordinated deregulation with States. These reforms, alongside the Budget’s focus on Youth Power and domestic manufacturing capacity under Atmanirbharta, stand to strengthen the investment environment for capital intensive sectors such as Cement. The Union Budget 2026-27 reflects the Government’s focus on infrastructure led development emerging as a structural pillar of India’s growth strategy.”

He added, “The Rs 200 billion CCUS outlay for various sectors, including Cement, fundamentally alters the decarbonisation landscape for India’s emissions intensive industries. CCUS is a significant enabler for large scale decarbonisation of industries such as Cement and this intervention directly addresses the technology and cost requirements of the Cement sector in context. The Cement Industry, fully aligned with the Government of India’s Net Zero commitment by 2070, views this support as critical to enabling the adoption and scale up of CCUS technologies while continuing to meet the Country’s long term infrastructure needs.”

Dr Raghavpat Singhania, Vice President, CMA, said, “The government’s sustained infrastructure push supports employment, regional development and stronger local supply chains. Cement manufacturing clusters act as economic anchors across regions, generating livelihoods in construction, logistics and allied sectors. The budget’s focus on inclusive growth, execution and system level enablers creates a supportive environment for responsible and efficient expansion offering opportunities for economic growth and lending momentum to the cement sector. The increase in public capex to Rs 12.2 trillion, the focus on Tier 2 and Tier 3 cities, and the creation of City Economic Regions stand to strengthen the growth of the cement sector. We welcome the budget’s emphasis on tourism, cultural and social infrastructure, which should broaden construction activity across regions. Investments in tourism facilities, heritage and Buddhist circuits, regional connectivity in Purvodaya and North Eastern States, and the strengthening of emergency and trauma care infrastructure in district hospitals reinforce the cement sector’s role in enabling inclusive growth.”

CMA also noted the Government’s continued commitment to fiscal discipline, with the fiscal deficit estimated at 4.3 per cent of GDP in FY27, reinforcing macroeconomic stability and investor confidence.

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Concrete

Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

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Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

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