Concrete
Sustainability Strides Ahead
Published
2 years agoon
By
admin
Pankaj Kejriwal, Executive Director, Star Cement, talks about new technologies in modern cement manufacturing and explores elements such as AFR, AI, CCU, WHR, et al.
Sustainable technology is the combination of two complementary ideas. The first is technology that is meant to remedy, improve, or offset carbonisation, environmental setbacks or problems. The second is technology that is produced using green or ecologically responsible materials or processes.
Technology can be developed to create systems that are environmentally sustainable. It will allow us to replace traditional practices with more sustainable ones. Renewable energy, AI and robotics, electric vehicles and automated systems are just some of the many ways technology can contribute to sustainability.
Sustainability continues to make its way higher on business executives list of priorities. Industrial Leaders across the organisations are also treating sustainability as a priority to drive business efficiency and revenue growth.
Digital technologies are critical to help enterprises reach environmental sustainability targets and enable new business models and revenue streams. Digital technologies are already impacting environmental sustainability, and they will continue to play a role in sustainability for the foreseeable future.
Artificial Intelligence (AI) solutions can be used to assess, predict and mitigate climate change and support sustainable waste management. For example, AI techniques can be used to monitor environmental issues like CO2 emission. The data gathered from this is then processed, leveraging machine learning techniques, to predict environmental changes. Adaptive systems and continuous intelligence techniques are used to regularly adjust business and engineering systems to cope with environmental changes and challenges.
When it comes to waste management and accelerating recycling processes, AI techniques have also become common place. Perspective analytics and market knowledge graphs are used to map the movement of waste materials and reduce unnecessary shipping while improving material reuse.
Leverage Internet of Things (IoT) to increase transparency when it comes to energy reduction and smart buildings. For instance, one can run connected assets to focus on energy reduction to benefit the enterprise and society. It is particularly important to run connected assets in industries such as manufacturing. Smart building technologies adapt dynamically to the times people work and types of office environments. Smart buildings can leverage IoT by adjusting lighting and heating, ventilation and air conditioning (HVAC) based on occupancy to reduce energy waste.
Cement manufacturing is an energy-intensive process that has undergone significant technological advancements in recent years. These modern trends and technologies have helped to improve the efficiency and sustainability of their operations. One of the key technologies in modern cement manufacturing is the use of alternative raw materials and alternative fuels.
In the past, cement was primarily produced using limestone, which was abundant and widely available. However, the increasing demand for cement has led to a depletion of limestone reserves and a need to find alternative sources of raw materials. Today, using a variety of alternative materials, including fly ash, slag, and recycled concrete, which not only help to reduce the demand for limestone, but also improve the sustainability of cement production.
Similarly, instead of coal now various alternative fuels such as RDF, bamboo, tyre chips, carbon black, agricultural waste, pharma waste and plastic waste are being used as fuel in cement kiln and captive power plant. Studies are underway to develop the technology to use solar energy for heating kiln thereby drastically reducing the carbon footprints.
Automation and technology contribute towards reduction of dust emission. It is essentially required to put in place the latest technology, management systems and continuous online monetary system that helps to routinely implement the activities that facilitate adherence to the emission norms prescribed under the pollution control legislation. The real-time data of online stack monitoring and ambient air-quality management system (AAQMSI is published on the web for better monitoring and control.
Several environmental impacts riddle the cement production process and, as a result, personal protective measures, such as helmets, goggles, masks earplugs and protective clothing are employed by operatives to address health and safety issues. Drilling limestone beds during mining produces large quantities of dust, for example, but wet drilling, where possible, minimises dust generation.
Other steps are also taken to minimise environmental impact. Rock blasting, which is most commonly conducted in limestone mines, may lead to ground vibration, flying rock, dust generation, and high noise levels. Sequential and controlled blasting helps minimise ground vibration, while blast holes can be optimised to avoid excessive generation of flying rock. Reducing the powder factor (i.e., the quantity of explosive used per tonne of rock broken) helps to minimise dust generation. Similarly, detonators and explosives can be managed so as to avoid high noise levels and control the peak particle velocity of the entire blasting operation. During surface mining, watering limestone can reduce dust generation.
In addition, green cement is a step in this direction. Green cement is an eco-friendly cement that uses a carbon-negative process of manufacturing. The major raw materials used to produce green cement include mostly the discarded waste from the industry. The slag from the blast furnace and fly ash are the chief materials used in the manufacturing of green cement.
A few types of the newly invented green cement are:
1. Ekkomaxx Cement
- Magnesium Oxychloride Cement
- Geopolymer cement
- Ferrocrete
5. Calcium Sulphoaluminate Cement - Sequestrated Carbon Cement
- Cement Produced Using Superheated Steam
Now, technology is being developed where cement will be produced with Reactive Hydrothermal Liquid-phase Densification. This type of cement is produced using the same raw materials as ordinary Portland cement, but at lower temperature and through different chemical reaction that produces less CO2 compared with traditional Portland cement production process.
Concrete with green cement is a form of eco-friendly concrete that is manufactured using waste or residual materials from different industries, and requires less amount of energy for production. Compared to traditional concrete, it produces less carbon dioxide, and is considered environmentally friendly and more durable. Green concrete has a lower shrinkage rate and also becomes stronger
far more quickly than concrete made with traditional cement.
Promising changes in the formulation of cement have begun to emerge. For example, lowering the proportion of limestone in cement can result in fewer process and fuel emissions. Adding CO2 to concrete as it cures can strengthen the solid material, reduce the amount of cement needed, and sequester captured CO2. And improving carbon-capture technology would make it more economical to keep process emissions from entering the atmosphere.
In addition to these, there are also a number of new technologies that are being developed and implemented in modern cement manufacturing. These include advanced materials for cement production, such as nanomaterials and superabsorbent polymers, which can improve the performance and durability of cement. There are also new technologies for producing low-carbon cements, such as carbon capture and utilisation (CCU) technologies, which capture and reuse carbon dioxide emissions from cement plants.
Modern cement manufacturing uses advanced process control systems. These systems use sensors, control algorithms and other technologies to optimise the cement production process, improving efficiency and reducing waste. For example, advanced process control systems can help to optimise the mixing and grinding of raw materials, the burning of fuel, and the clinkering of cement, resulting in significant energy savings and reduced greenhouse gas emissions.
Another important technology in modern cement manufacturing is the use of waste heat recovery systems. These systems capture and reuse the heat generated during the cement production process, which can be used to generate electricity or for other purposes. This not only helps to reduce the energy consumption of cement plants, but also reduces their carbon footprint. Waste heat recovery is one of the most critical parameters to be controlled in cement plants because doing so helps to minimise energy conservation and safeguard the environment.
The modern trends and technologies in cement manufacturing are helping to improve the efficiency, sustainability and performance of this critical industry. As the demand for cement continues to grow, it is likely that these trends and technologies will continue to evolve, further improving the environmental and economic impact of cement production.
ABOUT THE AUTHOR:
Pankal Kejriwal, Executive Director, Star Cement holds over 30 years of experience including a 22-year stint in the cement Industry. He is responsible for conceptualising, engineering, implementation and commissioning of all cement projects to achieve higher outputs, energy conservation, cost optimisation, environmental sustainability, and statutory compliances.

Concrete
Adani’s Strategic Emergence in India’s Cement Landscape
Published
5 days 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
