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The process of making bags is lengthy

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Alpesh Patel, Director, Knack Packaging, discusses the company’s commitment to sustainability, their use of reprocessed materials, and the role of technology and automation in enhancing production efficiency.

What are the varieties of bags manufactured at your organisations? What is your manufacturing capacity?
We, at Knack Packaging, manufacture PP, HDPE and BOPP laminated woven bags. Our bags are not only used in the cement industry, but also are used in the fertiliser, seeds and grains industry.
Our manufacturing capacity is to manufacture approximately 3 crores to 3.5 crores bags in a month. On an everyday basis we manufacture approximately 1.1 million (11 lakh) bags. Our major production is of BOPP bags and BOPP pinch bags. Our facility is located in Ahmedabad, Gujarat.

Tell us about bags specific to the cement industry.
PP Bags (unlaminated) are traditional bags with an extended valve to fill in the cement. These PP unlaminated bags have a valve attached to them, which closes automatically when the bag gets full. The advantage of these bags is that it is low in cost, however, the disadvantage is that there is dust that keeps coming out of them. We manufacture these for the cement industry.
There are laminated bags that are made from traditional woven material with a coating on top which prevents cement from coming out of the bags or leaking from the bags. This is the other kind of bag that we manufacture, which is used in the cement industry. We also manufacture block bottom bags and pinch bottom bags.
Block bottom laminated bags are the second category of bags that we manufacture specific to the cement industry. This bag also contains a valve mouth where the cement flows in, when full, it locks the bag and then the bag is transferred to the facility for storage. Another value adding bag for the cement plant has a similar structure but with an additional layer of printing, which can be used from a branding point of view.
The next category of the product is the pinch bottom bags. These bags have an open mouth in which filling is much easier. Once filled, the bag is then sealed. This bag’s shape is the same as BOPP printed bags.
These categories of bags are manufactured at our facility, which are specially designed for
cement packaging.

What are the steps taken by you to make bag manufacturing a sustainable process?
We are exporters of bags to over 90 countries across the globe. As a manufacturing unit and our customers both understand the value of reducing our carbon footprint and bringing sustainability to the system and therefore, we have taken steps to make our manufacturing process sustainable in many ways.
We use 30 per cent reprocessed materials in making our products and are constantly involved in research and development with competent companies. This research and development has led to us starting to use and reprocess our in-house industrial waste and utilising the same in making our end products. We are also running trails on our pre-consumed waste materials and are sure we will be able to recycle the same and make them sustainable.
Our company is aiming to be carbon neutral from an electricity point of view. We have been working on the same for the past three years. Even now, approximately 60 per cent of the energy used in our company is green energy and in the coming months, we shall be utilising 100 per cent green energy. This is one of our first steps to reduce our carbon footprint and we plan to keep moving ahead with this endeavour.

Tell us about the material used for bag manufacturing. Is your organisation experimenting with newer materials to better the quality or make it more environment friendly?
With growing awareness about sustainability and the need to improve the environment, the cement industry has become more accepting of re-processed materials. This would mean that they also use bags made out of re-processed materials.
Some of our bags are manufactured with repurposed materials and have been placed at some cement plants for trials. However, we believe that it is the need of the hour for the world to bring more and more sustainability to every manufacturing process and facility.

Tell us about the role of automation and technology in your manufacturing process.
We use machines to turn our materials into final bags using European make and Indian make machines, which has led to huge development and enhanced production at our facility. We have however kept the weaving of the materials and making of the thread a traditional practice with the labour working on it.
We are focused on our technological advancement to provide the best possible quality product to our customers.

Cement bags are exposed to harsh environments. How equipped is your product to prevent cement wastage?
The first use of cement bags is, of course, at the cement manufacturing units for filling in cement. But the bags made for cement in the cement industry are often reused and that too multiple times. Cement makers themselves collect their used bags and burn them off in the kiln, which is in a minor proportion acting as an alternative fuel, thus reducing the need for coal or other fossil fuels for kiln operations.

What are the key challenges in providing packaging material for cement?
The process of making bags is lengthy, from making the thread and weaving to making the bags and getting customised printing. Earlier, the most challenging process was making the bags itself. However, with the advancement of technology, stable machinery etc., our processes are set and this challenge has been overcome.

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

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