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Proactive Maintenance

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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.

Concrete

Cement Makers’ Margins To Fall Rs 50-75 Per Tonne Amid West Asia Conflict

Crisil Sees Margins Easing Despite Steady Demand

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Crisil said operating margins of Indian cement manufacturers are expected to decline by Rs 50-75 per tonne (t) this fiscal to Rs 925-950 per t due to higher input costs triggered by the West Asia conflict. The analysis covered 18 cement companies accounting for nearly 90 per cent of India’s domestic cement capacity and noted margins had improved sharply to around Rs 1,000 per t in fiscal 2026.

Crisil noted that the reduction would be driven mainly by higher power and fuel costs, which account for about 30 per cent of total costs, as petcoke and imported coal prices have surged amid geopolitical uncertainties. Freight costs, which account for about a quarter of total costs, are also expected to remain elevated because of higher diesel prices. The impact on profitability is likely to be more pronounced in the first half of the fiscal year before easing commodity prices moderate cost pressures later.

The rating agency said steady domestic demand and strong balance sheets should keep credit profiles stable despite the moderation in margins. Green energy currently accounts for 35-40 per cent of the sector’s total electricity consumption and is expected to partly cushion higher energy costs. Operating cash flows are likely to remain resilient, supported by projected 6-7 per cent growth in cement demand this fiscal.

Crisil highlighted that demand growth will be driven primarily by infrastructure spending, which meets about one-third of sector consumption, and by a nearly 18 per cent higher budgetary allocation for core ministries that should support project execution. Weaker rural housing demand amid pressure on agricultural incomes from a possible below-average monsoon may be offset by improved urban housing demand supported by favourable home-loan rates and a strong pipeline of Pradhan Mantri Awas Yojana-Urban projects. Ongoing capacity additions will keep capital expenditure elevated and may lift net debt to EBITDA to between 1.2 and 1.4 times from around 1.0 time last fiscal, though ratios are expected to remain healthy.

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Concrete

UltraTech Board Approves Rs 50 bn Fundraise Via NCDs

Company to issue half a million debentures for expansion plan

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UltraTech Cement’s board of directors has approved raising Rs 5,000 crore (Rs 50 bn) through non?convertible debentures issued in rupees.

The finance committee cleared a proposal to issue up to 500,000 fully paid, unsecured, listed, rated, redeemable, rupee?denominated, non?convertible, non?cumulative debentures of Rs 1 lakh each (Rs 0.1 mn each), aggregating to the Rs 5,000 crore programme.

As of June 2026 the firm reported net debt of Rs 15,875 crore (Rs 158.75 bn) and said its capacity expansion projects under execution are backed by capital expenditure of about Rs 17,000 crore (Rs 170 bn) over the next two to two?and?a?half years.

UltraTech spent Rs 9,500 crore (Rs 95 bn) on capital expenditure in financial year 2026 and in April the group crossed 200.1 mn tonnes per annum of domestic grey cement capacity and 205.5 mn tonnes per annum of global capacity.

The chief financial officer indicated the company would take consolidated capacity beyond 242 mn tonnes per annum, with grey cement capacity reaching 212.7 mn tonnes per annum by the end of financial year 2027. He noted the net debt?to?earnings before interest, taxes, depreciation and amortisation ratio stood at 0.87 times as of June 2026 and the company was confident of ending financial year 2027 with the ratio below one time.

In the first quarter of financial year 2026?27 UltraTech’s net profit attributable to owners rose 16.8 per cent year?on?year to Rs 2,599.3 crore (Rs 25.993 bn) and revenue from operations increased 15.9 per cent to Rs 24,648.20 crore (Rs 246.482 bn). The board approval is expected to complement internal cash flows as the company advances its expansion programme.

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Concrete

Lokesh Lays Stone For Rs 31 Billion Cement Unit In Kadapa

Line-2 expansion to make Kadapa a major cement hub

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Andhra Pradesh Education and IT Minister Nara Lokesh on Wednesday laid the foundation stone for the Line-2 expansion of Dalmia Bharat Cement at Chinnakomerla village in Mylavaram Mandal in Kadapa district. The project carries an investment of Rs 31 billion (bn) and is slated for completion by the third quarter of the financial year 2028. The expansion is intended to boost industrial growth and employment generation across the Rayalaseema region.

Once commissioned, the Kadapa facility will become Dalmia Bharat’s largest integrated cement manufacturing ecosystem in southern India, creating over 1,000 direct and indirect jobs and opening new business avenues for regional micro, small and medium enterprises and transport operators. Lokesh said the expansion signalled growing corporate confidence in the state and reflected the practical ease of doing business that secured repeat investment.

He placed the project within the government’s wider economic targets and recalled the Yuvagalam padayatra commitment to generate two million (mn) jobs within five years, noting that the state would cultivate talent while industry created opportunities. Lokesh highlighted Andhra Pradesh’s competitive pursuit of major manufacturing accounts, mentioning past successes and a personal initiative to engage global investors when persuading them to anchor expansion in the state.

The plant will leverage Kadapa’s abundant limestone reserves to scale production and sustainability. Clinker capacity is planned to rise from two point five million tonnes per annum (mn tpa) to six point one mn tpa, while overall cement output will increase from three point six mn tpa to nine point six mn tpa. The unit is designed to operate on over eighty per cent renewable energy and deploy waste heat recovery, zero liquid discharge, water recycling and advanced AI systems to optimise efficiency. Industries Minister TG Bharat, BC Welfare Minister S. Savitha and Jammalamadugu MLA C. Adinarayana Reddy attended the ceremony.

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