Economy & Market

Continuous safety training is rooted in our approach

Published

2 years ago

February 15, 2024

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Sanjay Joshi, Chief – Projects and Manufacturing Officer (North), Nuvoco Vistas Corp, talks about their safety protocols and initiatives as well as the comprehensive approach they take to ensure the well-being of their workforce with the use of advanced technology.

What is the definition of a ‘safe’ plant in your organisation?
At Nuvoco Vistas, a ‘safe’ plant is one that demonstrates Zero Harm, Zero Fatality, Zero Loss Time Injuries (LTI), Zero Medical Incidents (MI), Zero First Aid (FA) and Zero Serious Events (SE) reported. Additionally, a safe plant actively promotes leading indicators, placing a strong emphasis on safety through employee engagement, comprehensive training and prompt reporting of unsafe acts, unsafe conditions, and near misses. The goal is to maintain a workplace with zero tolerance for safety lapses and a commitment to proactive safety measures. This is to ensure that all stakeholders (internal and external) coming inside the plant are safe. Equal importance is also given to ensure zero property damage.

Tell us about the key areas where safety is of paramount importance.
In the realm of cement manufacturing, where the process is intense and operation-oriented, ensuring safety is essential. Here are the key areas where safety is of utmost importance:

Coal shop safety: Ensuring a secure environment in the coal shop is paramount.
Preheater and precalciner safety: Focusing on safety measures in these critical areas of the process including cleaning of cyclone jam.
Working at heights: Implementing safety protocols for tasks that involve working at height across all areas.
Electrical safety and energy isolation: Prioritising safety in electrical operations and implementing effective energy isolation procedures.
Mines safety: Adhering to all safety requirements outlined by DGMS (Directorate General of Mines Safety).
Exposure to respirable crystalline silica and total dust: Managing and minimising the risk of exposure to harmful substances.
Working in confined spaces: Implementing safety measures for tasks conducted in confined spaces.
Conveyor belt safety with machine guarding: Ensuring the safety of personnel in areas involving conveyor belts, with proper machine guarding.
Fire safety: Implementing fire safety measures in all areas containing inflammable materials.
These areas collectively form a comprehensive approach to maintaining a safe working environment in a cement plant, emphasising the well-being of everyone involved in the process. Mock drills are also periodically conducted to confirm readiness in case of any eventuality.

What are the safety equipment used by various personnel in different areas of work?
In different work areas, our personnel use a variety of safety equipment to ensure their well-being. The mandatory Personal Protective Equipment (PPE) in Nuvoco comprises a safety helmet for head protection, safety shoes for safeguarding the legs, a fluorescent jacket (reflective jacket) to enhance visibility and protect the body and safety glasses for eye safety.
Furthermore, for specific job requirements, we provide essential job-specific PPEs, such as full body safety harness for tasks involving fall protection, ear plugs for hearing safety, electrical safety gadgets to prevent electrical hazards, hand gloves for hand protection, welding aprons and other specialised equipment tailored to the unique risks associated with specific tasks performed by our associates. This approach ensures that our personnel have the right safety gear to address the specific hazards they may encounter in their respective work areas, promoting a comprehensive and secure working environment.

Tell us about your organisation’s policies about safety for the workforce.
At Nuvoco Vistas Corp, we prioritise the safety and well-being of all individuals working in our plants. It’s our inherent responsibility to provide a safe and healthy environment for our employees, contract workers, and associates, ensuring compliance with local legal and regulatory requirements. We expect everyone to actively adhere to our health and safety guidelines, with each employee taking personal responsibility for preventing occupational injuries. It’s not just a management concern; it’s a collective effort to conduct day-to-day business with the utmost safety. Visible leadership forms the foundation of our health and safety principles, fostering a work environment where everyone can confidently engage in their tasks.

Does technology play a role in ensuring plant safety? If yes, how?
Certainly, technology plays an important role in ensuring plant safety at Nuvoco Vistas. Our safety management systems strongly influence technology for efficient operations. We utilise the Safety, Tracking, Analysis and Reporting (STAR) software for comprehensive reporting of both leading and lagging indicators, enhancing our ability to monitor and manage safety performance.
In addition, all commuting vehicles are equipped with GPS and VTS (Vehicle Tracking System) for real-time tracking and monitoring, ensuring the safety of transportation activities.
The Lock Out, Tag Out, and Try Out process (LOTOTO) used for the energy isolation system is an advanced electrical safety measure in place, contributing to a secure working environment.
Furthermore, machines are equipped with Visual Cutoff Switches (VCS) for local cutoffs, adding an extra layer of safety to our processes. Across the board, various technologies are implemented in our machineries, collectively creating a technologically advanced and safe working environment throughout our operations.

Tell us about the major challenges faced in terms of ensuring plant safety.
Ensuring safety in cement plants presents significant challenges due to the human-intensive nature of the operations. From mining to clinkerisation, grinding, packing and despatch, each stage involves potential risks to human safety.
Moreover, road safety poses substantial challenges, as global statistics highlight it as one of the most significant safety concerns. The diverse operations and their associated risks make maintaining a safe environment a complex task in our cement plants. Addressing these challenges requires continuous efforts and a comprehensive approach to prioritise and enhance safety measures across all facets of our operations.

Do you conduct safety training and audits for your plant personnel?
Absolutely, our commitment to safety is unwavering, and it begins from the moment any worker steps into the plant. Continuous safety training is rooted in our approach, starting right at the initiation phase, and extending throughout their involvement in plant operations and maintenance. These training sessions serve as the backbone of our safety system, emphasising the importance of safe practices at every step.
In addition to ongoing training, we conduct various safety audits to ensure the effectiveness of our safety measures. This includes cross-functional safety audits, internal safety audits, external safety audits and sectional safety audits throughout the year, maintaining a consistent and thorough evaluation process. We also conduct audits on an as-needed basis, tailoring our assessments to specific plant requirements, such as design safety audits and coal shop safety audits. This holistic approach underscores our dedication to fostering a safe and secure working environment for all personnel.

How do you plan to better the safety of your plant in the years to come?
Ensuring safety is an ongoing journey marked by continuous improvement at every moment of our cement plant operations. Each step is important, considering both human safety and the prevention of property damage.
To enhance safety, we are actively working on minimising road incidents during operations. Additionally, our focus extends to behavioural-based safety improvements among employees, contributing to the overall goal of making our plants safer environments. This commitment to continual improvement underscores our dedication to fostering a secure and protected workplace for everyone involved.

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Economy & Market

Fornnax launches world’s biggest secondary/fine shredder for AFR pre-processing

Published

1 week ago

November 7, 2025

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Fornnax has introduced its latest breakthrough – the R-MAX3300, for handling low-density waste streams, offering a powerful solution for cement AFR plants.

Fornnax Technology has launched its latest breakthrough – the R-MAX3300, the biggest secondary shredder in its class. The unveiling took place on 14th October, 2025 at IFAT India 2025 in Mumbai, one of the most prestigious events for environmental technologies, waste management, and sustainable resource innovation.

The launch ceremony was graced by esteemed industry leaders and dignitaries. The guest list included Md Fahim Sopariwala, CEO, GEPIL India; Sridhar Jagannathan, Vice President, Zigma Global; Priyesh Bhatti, CEO, GEPIL India; Shailendra Singh, Deputy General Manager, Prism Johnson (Cement Division); Ulhas Parlikar, Global Consultant, Waste Management, Circular Economy, Policy Advocacy and Co-processing; Saurabh Palsania, Joint President (Strategic Sourcing), Shree Cement; Rajeev Patel, DGM (Process), Mangalam Cement; and Anumodan Kumar Dubey, Mangalam Cement.

This state-of-the-art equipment represents a significant advancement for India’s recycling and waste processing landscape, offering a powerful solution for cement AFR plants and waste-to-energy facilities.

Building on the proven performance and legacy of the R Series secondary shredder, which has long been trusted for high-density materials like tyres and cables, the newly introduced R-MAX3300 is specifically engineered for handling low-density waste streams. These include Municipal Solid Waste (MSW), Commercial and Industrial (C&I) waste, Bulky waste, Legacy waste, Wood waste, and Construction & Demolition (C&D) waste.

By incorporating advanced shredding technology, the R-MAX3300 enables seamless and highly efficient production of Refuse Derived Fuel (RDF) and Solid Recovered Fuel (SRF) within the ideal particle size range of 30 to 50 mm. Its design prioritises versatility, durability and superior performance, directly supporting industrial operations that demand consistency and scale.

“The R-MAX3300 represents a monumental leap forward in our vision to become a global leader by 2030 in recycling technology through innovation,” said Jignesh Kundaria, Director and CEO, Fornnax Technology. “With the rising challenges of waste management in India and globally, this machine is not just a product; it’s a powerful tool for change. We engineered it to handle the most difficult waste streams with unparalleled efficiency, turning what was once considered unusable waste into a valuable resource. It directly addresses the urgent demand for effective, large-scale shredding technology that can support cement kilns and waste-to-energy facilities in achieving the desired output,” he added.

The launch of the R-MAX3300 arrives at a pivotal moment. India currently generates over 160,000 tons of municipal solid waste daily, while government-led initiatives such as Swachh Bharat Mission and Smart Cities are accelerating the demand for RDF and waste-to-energy solutions. Simultaneously, the global industrial shredder market is expected to grow at a 5–6 per cent CAGR, driven by stricter recycling regulations and increasing waste generation.

Kundaria further emphasised, “Our commitment goes beyond just selling machinery; it’s about empowering our customers to achieve lasting efficiency, sustainability, and growth. We see ourselves as a trusted partner who stands beside them at every step – from technology deployment to ongoing support, ensuring they can rely on Fornnax not only for performance but also for consistency, dependability, and long-term value.”

The R-MAX3300 is equipped to handle high-throughput processing of pre-shredded or coarse materials, making it ideal for SRF/RDF production, composting pre-treatment, and volume reduction for logistics optimisation. It is expected to play a crucial role in Integrated Waste Management Projects (IWMP) and bio-mining operations both within India and globally.

With this grand launch, Fornnax continues to set global benchmark and move decisively towards the vision of becoming global leader in recycling technology by 2030 that is state-of-the-art, innovative, economical, efficient reliable and eco-friendly.

Concrete

Fornnax wins Top Domestic Sales Award 2024-25 by AIRIA

Published

1 week ago

November 7, 2025

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Fornnax bags the Excellence in Top Domestic Sales Award 2024–25 by the All India Rubber Industries Association (AIRIA).

The company has been honoured with the Excellence in Top Domestic Sales Award 2024–25 by the All India Rubber Industries Association (AIRIA) under the Rubber Machineries and Equipment category. The award recognises Fornnax’s exceptional market leadership, strong sales performance and continued commitment to sustainable innovation.

With over a decade of specialised expertise, Fornnax has emerged as a transformative force in India’s tyre recycling sector, commanding nearly 90 per cent of the domestic market while steadily expanding across Europe, Australia, the GCC, and other global regions.

Fornnax’s advanced recycling systems—comprising the SR-Series Primary Shredders, R-Series Secondary Shredders, and TR-Series Granulators—are engineered for durability, efficiency, and high-output performance. These technologies are widely deployed in end-of-life tyre (ELT) processing and other waste management applications, reinforcing Fornnax’s reputation as a trusted industry partner.

Expressing his gratitude, Jignesh Kundaria, Director & CEO, Fornnax, said, “We are incredibly proud to receive this recognition from AIRIA. This award validates the trust that our customers and partners have placed in us over the years. I would like to extend my heartfelt gratitude to all our clients and partners who have been an integral part of this journey and our continued success. At Fornnax, our goal has always been to empower the recycling industry with innovative, high-performance solutions that make sustainability both achievable and profitable.”

The award also underscores Fornnax’s pivotal role in promoting circular economy practices by enabling the conversion of end-of-life tyres and rubber waste into reusable raw materials. Through ongoing R&D, new product innovation, and a solutions-driven approach, the company continues to help industries worldwide adopt eco-conscious, scalable recycling models.

As India’s recycling landscape evolves to meet global sustainability benchmarks, Fornnax stands at the forefront with internationally certified technology, a proven track record, and a clear vision for environmentally responsible growth.

Concrete

Pacific Avenue Completes Acquisition of FLSmidth Cement; Rebrands as Fuller Technologies

Published

2 weeks ago

November 4, 2025

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The acquisition of FLSmidth Cement by Pacific Avenue Capital Partners marks a new phase of focused growth and innovation.
Rebranded as Fuller® Technologies, the company will continue delivering world-class solutions with renewed investment and direction.

Pacific Avenue Capital Partners (“Pacific Avenue”), a global private equity firm, has completed its acquisition of FLSmidth Cement following the fulfillment of all customary closing conditions and regulatory approvals. The transaction includes all of FLSmidth Cement’s intellectual property, technology, employees, manufacturing facilities, and global sales and service organizations.

As Fuller Technologies, the company will continue to seamlessly support its customers while advancing its robust portfolio of capital equipment, digital solutions, and service offerings. With a sharpened focus on Pyro and Grinding technologies, alongside core brands such as PFISTER®, Ventomatic®, Pneumatic Conveying, and Automation, Fuller Technologies aims to deliver enhanced value and reliability across the cement and industrial sectors.

Under Pacific Avenue’s ownership, Fuller Technologies will benefit from increased investment in people, products, and innovation. The dedicated management team will work to optimize operations and strengthen customer relationships, ensuring continuity and excellence during this exciting transition.

“We are proud to be the new owner of FLSmidth Cement, now Fuller Technologies, a global leader with a rich history of providing mission-critical equipment and aftermarket solutions in the cement and industrial sectors. We will continue to build upon the Company’s legacy of being at the forefront of technological innovation, service delivery, and product quality as we support our customers’ operations,” says Chris Sznewajs, Managing Partner and Founder of Pacific Avenue Capital Partners.

Pacific Avenue’s deep experience in executing complex industrial carve-outs and guiding standalone businesses into their next growth phase will be instrumental in shaping Fuller Technologies’ future. With a proven track record in building products and capital equipment industries, Pacific Avenue is poised to help Fuller Technologies optimize performance, accelerate growth, and create long-term value for its customers and stakeholders worldwide.