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We prioritise environmental conservation and air quality

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With a detailed exploration of their state-of-the-art packaging processes, environmental conservation efforts and forward-thinking innovations, Dhananjay Singh Parmar, Senior Manager – Packing Plant, Udaipur Cement Works, talks about the company’s commitment to efficiency, sustainability and quality.

Tell us about the setup and process of cement packaging in your organisation.
At Udaipur Cement Works Limited (UCWL), our cutting-edge facility is equipped with a grinding and packing capacity of 2.2 million tonnes of cement annually, which is currently under expansion to reach 4.7 million tonnes per annum. Our packaging process utilises advanced FLS ventomatic single and double discharge packers, specifically the 8 spout model R-150 (clockwise / anti-clockwise) and 12 spout model R-150 anti-clockwise (2 nos and 1 no, respectively). These packers ensure both precision and efficiency in the packaging process. To further augment our capabilities, our in-house designed bulk cement loading and container loading arrangement have been installed. Notably, our packers feature in-built hardware for automatic correction of weight, enhancing overall accuracy. Additionally, we prioritise transparency by printing the week, month, and year on bags, along with the fly ash percentage, as they traverse the belt conveyor. A distinct code is also printed on bags despatched to each party or depot, seamlessly linked with delivery instructions.
Furthermore, we have initiated an innovative method to transport loose cement by a greener mode of transportation by shifting from diesel-based bulkers to electric-based rakes. We flagged off a one-of-its-kind consignment of bulk cement transport through container rake from Khemli to our Gujarat and Maharashtra markets in association with Container Corporation of India Ltd (CONCOR). With this, UCWL has become the first cement company in the north-west region to implement this inventive step towards achieving logistical efficiency and environmental conservation by saving around 20,000 kg CO2 per rake movement.

What steps is the industry taking to ensure that there is minimum wastage of product during the packaging process?
To minimise product wastage during packaging, the industry is adopting advanced technologies and automated systems. The cement gets recirculated in the system during packing operations, there is a hopper, which collects the cement and feeds it back to the bucket elevator. The product / cement which remains in the burst or torn bag during operations is re-circulated by feeding it in the bucket elevator.
At UCWL, we have also implemented a SAP-based transport management system that includes automatic bag counters and man-less weigh bridges. This not only enhances accuracy in the packaging process but also contributes to minimising product wastage, ensuring optimal utilisation of resources.

Is there any emission of dust during the bagging, packaging and pelletising process? What measures are being taken to control the same?
We prioritise environmental conservation and air quality. To address dust emissions during bagging and packaging, UCWL has invested in efficient emission control systems. Cement is packed in bags at packer with the help of pressure which generates dust. We have provided bag filters which collect the fugitive dust and are re-circulated in the system. Separate bag filters are provided for all three packers and bulker loading systems. These systems
capture particulate matter, controlling the release of pollutants into the atmosphere. Regular monitoring and maintenance ensure the effectiveness of these measures, aligning with our commitment to environmental regulations.

Tell us about the use of automation and technology in this last step of the cement manufacturing process?
Automation and technology play a pivotal role in the final steps of cement manufacturing at UCWL. The computerised operation of material extraction from silo to the loading of bags in trucks streamlines the process, requiring minimal manual intervention once the system is set up. The interconnected nature of our automated systems, including interlocking with hopper levels, ensures a seamless and error-free packaging process, optimising resource utilisation and zero errors. Our SAP-based transport management system, coupled with automatic bag counters and man-less weigh bridges, exemplifies our commitment to efficiency and precision. These technologies not only streamline the packaging process but also contribute to minimising errors and optimising resource utilisation.

Tell us about the material of bags used for packing smaller and bulk cement loads.
Our commitment to delivering a superior product is reflected in the meticulous selection of packaging materials at UCWL. For premium products, we employ high-quality laminated paper-based bags, while for other products, we opt for HDPE bags that adhere to industry standards. The choice of materials is carefully curated to guarantee durability and integrity during transportation and storage. To further ensure the strength of our bags, we conduct random sampling and drop tests, reaffirming our dedication to delivering a reliable and superior product to our customers.

What measures are being taken to protect cement from moisture from bagging to transporting stage?
Preserving the quality of our cement from bagging to the transportation stage is paramount. Rigorous measures are in place to protect the product from moisture, including the use of moisture-resistant packaging materials and adherence to best practices in handling and storage. Cement is stored in silos, and the packing process begins only when transportation is imminent. The loaded trucks are covered with tarpaulin to prevent any moisture-related issue. These measures guarantee that our customers receive cement of the highest quality, unaffected by moisture.

Tell us about the most challenging aspect of bagging and palletising in the cement manufacturing process?
One of the most intricate challenges in the despatch of cement is striking the delicate balance between speed and precision. At UCWL, the extraction of cement from silos and the packaging process are synchronised to ensure efficiency. The empty bags used for packaging are stored separately in a covered godown. The constant challenge lies in maintaining an efficient and error-free packaging process while upholding the highest standards of quality and zero wastage. Our commitment to overcoming these challenges is reflected in our pursuit of continuous improvement and innovation in our processes, driving the evolution of our operational efficiency.

What innovations would you like to see in this domain that can further help optimise and better the packaging process for the cement industry?
In the ever-evolving landscape of the cement industry, we envision innovations that further optimise the packaging process. Continuous advancements in automation, artificial intelligence and sustainable packaging materials are areas where we see potential for improvement. Some of these could be like:
Biodegradable and compostable bags: Traditional HDPE bags are major contributors to landfill waste. Biodegradable and compostable alternatives made from materials like algae, mycelium, or even agricultural waste could be a game-changer. Imagine planting your empty cement bag and watching it nourish your garden!
Interactive and informative packaging: QR codes or augmented reality features on cement bags could offer a wealth of information for users. Imagine scanning a bag to access mixing instructions, safety tips, or even video tutorials for specific applications.
Reusable and refillable containers: Bulk cement delivery is already common for large projects, but smaller-scale reusable containers could gain traction for individual consumers or smaller construction jobs. Think sturdy, refillable plastic or metal containers that could be easily transported and returned for refills, reducing waste and potentially lowering costs.
Automated robotic packaging systems: The integration of advanced robotic systems in the packaging process can enhance speed, accuracy, and efficiency. Robotic arms could automate tasks such as bagging, stacking, and sealing, reducing reliance on manual labour and minimising the risk of errors.
Embracing these innovations can enhance efficiency, reduce environmental impact and contribute to the overall progress of the cement industry. We remain committed to staying at the forefront of such advancements to better serve our customers and contribute to a sustainable future.

  • Kanika Mathur

Concrete

India Sets Up First Carbon Capture Testbeds for Cement Industry

Five CCU testbeds launched to decarbonise cement production

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The Department of Science and Technology (DST) recently unveiled a pioneering national initiative: five Carbon Capture and Utilisation (CCU) testbeds in the cement sector, forming a first-of-its-kind research and innovation cluster to combat industrial carbon emissions.
This is a significant step towards India’s Climate Action for fostering National Determined Contributions (NDCs) targets and to achieve net zero decarbonisation pathways for Industry Transition., towards the Government’s goal to achieve a carbon-neutral economy by 2070.
Carbon Capture Utilisation (CCU) holds significant importance in hard-to-abate sectors like Cement, Steel, Power, Oil &Natural Gas, Chemicals & Fertilizers in reducing emissions by capturing carbon dioxide from industrial processes and converting it to value add products such as synthetic fuels, Urea, Soda, Ash, chemicals, food grade CO2 or concrete aggregates. CCU provides a feasible pathway for these tough to decarbonise industries to lower their carbon footprint and move towards achieving Net Zero Goals while continuing their operations efficiently. DST has taken major strides in fostering R&D in the CCUS domain.
Concrete is vital for India’s economy and the Cement industry being one of the main hard-to-abate sectors, is committed to align with the national decarbonisation commitments. New technologies to decarbonise emission intensity of the cement sector would play a key role in achieving of national net zero targets.
Recognizing the critical need for decarbonising the Cement sector, the Energy and Sustainable Technology (CEST) Division of Department launched a unique call for mobilising Academia-Industry Consortia proposals for deployment of Carbon Capture Utilisation (CCU) in Cement Sector. This Special call envisaged to develop and deploy innovative CCU Test bed in Cement Sector with thrust on Developing CO2 capture + CO2 Utilisation integrated unit in an Industrial set up through an innovative Public Private Partnership (PPP) funding model.
As a unique initiative and one of its first kind in India, DST has approved setting up of five CCU testbeds for translational R&D, to be set up in Academia-Industry collaboration under this significant initiative of DST in PPP mode, engaging with premier research laboratories as knowledge partners and top Cement companies as the industry partner.
On the occasion of National Technology Day celebrations, on May 11, 2025 the 5 CCU Cement Test beds were announced and grants had been handed over to the Test bed teams by the Chief Guest, Union Minister of State (Independent Charge) for Science and Technology; Earth Sciences and Minister of State for PMO, Department of Atomic Energy, Department of Space, Personnel, Public Grievances and Pensions, Dr Jitendra Singh in the presence of Secretary DST Prof. Abhay Karandikar.
The five testbeds are not just academic experiments — they are collaborative industrial pilot projects bringing together India’s top research institutions and leading cement manufacturers under a unique Public-Private Partnership (PPP) model. Each testbed addresses a different facet of CCU, from cutting-edge catalysis to vacuum-based gas separation.
The outcomes of this innovative initiative will not only showcase the pathways of decarbonisation towards Net zero goals through CCU route in cement sector, but should also be a critical confidence building measure for potential stakeholders to uptake the deployed CCU technology for further scale up and commercialisation.
It is envisioned that through continuous research and innovation under these test beds in developing innovative catalysts, materials, electrolyser technology, reactors, and electronics, the cost of Green Cement via the deployed CCU technology in Cement Sector may considerably be made more sustainable.
Secretary DBT Dr Rajesh Gokhale, Dr Ajai Choudhary, Co-Founder HCL, Dr. Rajesh Pathak, Secretary, TDB, Dr Anita Gupta Head CEST, DST and Dr Neelima Alam, Associate Head, DST were also present at the programme organized at Dr Ambedkar International Centre, New Delhi.

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Concrete

JK Lakshmi Adopts EVs to Cut Emissions in Logistics

Electric vehicles deployed between JK Puram and Kalol units

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JK Lakshmi Cement, a key player in the Indian cement industry, has announced the deployment of electric vehicles (EVs) in its logistics operations. This move, made in partnership with SwitchLabs Automobiles, will see EVs transporting goods between the JK Puram Plant in Sirohi, Rajasthan, and the Kalol Grinding Unit in Gujarat.
The announcement follows a successful pilot project that showcased measurable reductions in carbon emissions while maintaining efficiency. Building on this, the company is scaling up EV integration to enhance sustainability across its supply chain.
“Sustainability is integral to our vision at JK Lakshmi Cement. Our collaboration with SwitchLabs Automobiles reflects our continued focus on driving innovation in our logistics operations while taking responsibility for our environmental footprint. This initiative positions us as a leader in transforming the cement sector’s logistics landscape,” said Arun Shukla, President & Director, JK Lakshmi Cement.
This deployment marks a significant step in aligning with India’s push for greener transport infrastructure. By embracing clean mobility, JK Lakshmi Cement is setting an example for the industry, demonstrating that environmental responsibility can go hand in hand with operational efficiency.
The company continues to embed sustainability into its operations as part of a broader goal to reduce its carbon footprint. This initiative adds to its vision of building a more sustainable and eco-friendly future.
JK Lakshmi Cement, part of the 135-year-old JK Organisation, began operations in 1982 and has grown to become a recognised name in Indian cement. With a presence across Northern, Western, and Eastern India, the company has a cement capacity of 16.5 MTPA, with a target to reach 30 MT by 2030. Its product range includes ready-mix concrete, gypsum plaster, wall putty, and autoclaved aerated fly ash blocks.

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Concrete

Holcim UK drives sustainable construction

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Holcim UK has released a report titled ‘Making Sustainable Construction a Reality,’ outlining its five-fold commitment to a greener future. The company aims to focus on decarbonisation, circular economy principles, smarter building methods, community engagement, and integrating nature. Based on a survey of 2,000 people, only 41 per cent felt urban spaces in the UK are sustainably built. A significant majority (82 per cent) advocated for more green spaces, 69 per cent called for government leadership in sustainability, and 54 per cent saw businesses as key players. Additionally, 80 per cent of respondents stressed the need for greater transparency from companies regarding their environmental practices.

Image source:holcim

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