Concrete

Proactive Maintenance

Published

2 years ago

March 19, 2024

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Gaurav Mathur, Director and Chief Executive, Global Technical Services, discusses the importance of an on-site oil testing laboratory within industrial plants for improved safety, extended equipment life and cost effectiveness in the manufacturing sector.

Oil condition monitoring can provide important information about the condition of the machine through oil analysis. Lubricant in any machine is like blood in the human body. Just as a blood test can help a doctor diagnose an illness and inform a treatment plan, similarly an oil analysis can provide an effective way to know the machine condition and inform it to take maintenance decisions.
Once the oil test laboratory is within the plant, the test reports are made available to the machine maintenance team within a timeline of 48 hours. Timely action helps reduce the expensive mechanical maintenance costs and improves machine life and productivity, leading to the plant’s profitability.
Normally, the oil testing laboratories are far away from the plant. They are mostly in a different city, and these laboratories provide test reports after 10 to 15 days. However, those reports are of no use in machine maintenance as mechanical damage starts to set in within 48 hours in any machine. Hence, it is important to have an on-site oil test laboratory within the plant.
Oil condition monitoring, covering moisture (water presence in the oil), particle contamination, wear debris analysis or loss of additives level, etc. are the parameters that clearly bring out any machine’s internal condition. This reporting leads to timely maintenance decisions by the mechanical team. These reports also help improve the reliability of the machine being tested.
Thus, an oil testing laboratory within the plant site is instrumental in greatly improving the value of machine life and reducing a major cost of mechanical maintenance. These improvements and cost reductions in turn lead to cost savings, profitability and enhance efficiency in manufacturing.

OIL ANALYSIS AT SITE LABORATORY
Oil analysis is an important activity used to check oil health, oil contamination, oil cleanliness level, and machine wear. Its main purpose is to verify that a lubricant in the machine is operating with the oil in good condition i.e. the oil is free from any contamination due to continued usage in the machine over a period of time.
An on-site oil testing laboratory helps to form a system for early detection of oil degradation, contamination, and machine wear. Early detection has several benefits that ensure a healthier environment for the employees and the machinery, such as improved safety, early detection and warning of machine degradation, and increased equipment availability and effectiveness.
Once the oil testing laboratory is established within the plant, thereafter, the next step is to prepare department-wise, machine-wise oil testing schedules. These schedules ensure that there is periodic oil testing and subsequent corrective measures can be taken by the mechanical team. This kind of reporting and availability of the
on-site laboratory leads to a more proactive mechanical maintenance.
Almost 82 per cent of wear-related failures are the direct result of particle contamination.
It is a well-known fact that lubricating oils in a machine never dies. Once the contaminants are removed and the oil cleaned to its original level, the oil can be made as good as ‘new’. Hence, a good oil filtration and accurate additives treatment at site assumes considerable importance in ‘oil conservation’ in the industry. By conducting the above activity about 40 per cent to 50 per cent conservation of the lubricant oil can be achieved.
Hence, having a site condition monitoring laboratory not only improves the life of the machines, it also reduces mechanical maintenance costs and can bring a large economic change in the cement manufacturing sector. Besides, oil can also be recycled to its original level. Thus, having an on-site oil testing laboratory is paramount important and profitable for all large industries.

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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

4 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

6 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

6 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.