Concrete

We are committed to sustainable practices

Published

10 months ago

April 16, 2024

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Shrivats Singhania, Director and CEO of Udaipur Cement Works (UWCL), shares how the company has embraced cutting-edge technologies and sustainable practices to strengthen its logistics and minimise its carbon footprint.

What is your current production capacity and what are your plans for expansion?
Udaipur Cement Works Limited (UCWL) recently achieved a significant milestone with the inauguration of the newly installed cement grinding and packaging section at our Dabok Plant in Udaipur, Rajasthan. This state-of-the-art facility has nearly doubled our production capacity, from 2.2 million metric tonnes (MT) per annum to an impressive 4.7 million MT per annum.
This expansion wasn’t just about volume – it was a strategic move aligned with catering to the growing demand for high-quality cement in the region. It also allows us to enhance our efficiency and overall competitiveness in the market.
UCWL is committed to continuous improvement and growth within the cement industry. We are constantly looking for ways to expand our operations and better serve our customers.

With the growing production of cement industry wide, how is the cement industry managing its carbon footprint?
The growing production in the cement industry necessitates addressing our collective carbon footprint. At UCWL, we recognise this responsibility and are actively implementing several strategies to minimise our environmental impact. One key approach is embracing advanced technologies. Our recent expansion with the newly installed cement grinding and packaging section incorporates cutting-edge features that enhance efficiency and reduce energy consumption.
Additionally, we have commissioned a Waste Heat Recovery System (WHRS) that utilises waste heat of the pyro-process for power generation. This along with our Captive Solar Power Plants significantly increases our Green Energy share, exceeding 50 per cent of our total electrical consumption.
Furthermore, we recently doubled our Clinker Capacity. While clinker production can be energy-intensive, this expansion allows us to explore alternative fuels and optimise the overall production process, reducing our environmental impact per unit of cement produced.
These initiatives exemplify UCWL’s dedication to environmental stewardship. We are committed to continuous improvement and believe that innovation, coupled with responsible practices, can lead to a more sustainable future for the cement industry.

Tell us about the role of digitalisation and automation in the cement production process.
Digitalisation and automation play a pivotal role in revolutionising the cement production process by enhancing efficiency, productivity and product quality. UCWL has embraced cutting-edge technologies to optimise operations, improve product quality, reduce energy consumption, and ensure timely maintenance. By leveraging automation and digitalisation, UCWL is at the forefront of innovation in the industry, driving operational excellence and setting new benchmarks for efficiency and sustainability.

As the production of cement grows, how does it impact other processes such as logistics, transportation and distribution?
As cement production grows, so does the demand for efficient logistics and transportation. At UCWL, we recognise this link. Increased production volume necessitates a robust and adaptable logistics network to ensure timely and efficient product delivery. We are continuously evaluating and optimising our logistics network to meet this growing demand.
Beyond simply scaling our operations, we are committed to sustainable practices across the supply chain. We have implemented innovative strategies like CNG-powered truck distribution to reduce our carbon footprint during transportation.
These initiatives not only optimise logistics and distribution but also demonstrate UCWL’s unwavering commitment to environmental responsibility. We believe that sustainable practices and efficient operations go hand-in-hand, and we are actively working to achieve both.

What are the sustainability initiatives undertaken by your organisation?
UCWL prioritises sustainability as a core principle. We have actively embarked on a comprehensive journey to minimise our environmental impact and promote responsible practices across our entire operation. This commitment is evident in several key initiatives.
A pioneering first for the Indian cement industry, UCWL deployed a floating solar power plant, significantly reducing our reliance on fossil fuels and contributing to cleaner energy generation. We are also constantly exploring innovative methods for transporting loose cement, with the goal of minimising environmental impact and dust generation during transportation.
These initiatives, along with many others, exemplify UCWL’s unwavering commitment to sustainability. We strive for energy efficiency throughout our operations and are dedicated to environmental stewardship within the cement industry. We believe these efforts will pave the way for a more sustainable future for our company and the environment.

Tell us about the major challenges that may arise in the cement plant and how they are managed.
The cement industry operates in a dynamic landscape, and UCWL recognises that our plants can face several challenges. These can range from managing energy consumption to minimising environmental impact and maintaining peak operational efficiency.
At UCWL, we take a proactive approach to address these challenges. Energy consumption is a significant concern across the industry. We combat this by embracing cutting-edge technologies like automation and digitalisation. These advancements optimise processes, minimise energy waste, and maximise output, leading to greater efficiency in our production.
Minimising our environmental footprint is another top priority. We are committed to implementing sustainable practices throughout our operations. A prime example is our pioneering deployment of a floating solar power plant, the first of its kind in the Indian cement industry. This significantly reduces our reliance on fossil fuels and contributes to cleaner energy generation. Additionally, we utilise WHRS, which not only reduces our environmental impact but also contributes to energy efficiency.
Finally, maintaining peak operational efficiency is crucial for our success. We believe in continuous improvement and are constantly seeking new solutions to further optimise our operations. By proactively addressing these challenges through a combination of innovative solutions, sustainable practices and a commitment to continuous improvement, UCWL effectively manages its plants. This allows us to deliver high-quality cement while minimising our environmental impact.

Tell us about the future outlook of the organisation
The future outlook of UCWL is characterised by a strong emphasis on sustainability, innovation, and growth. By continuing to invest in green energy, automation, and digitalisation, UCWL is poised to maintain its position as a key player in the cement industry.
The company’s strategic vision focuses on meeting market demands, driving operational efficiency and upholding its commitment to sustainability and quality. With a forward-looking approach, UCWL is well-positioned to navigate industry challenges and capitalise on opportunities for continued success and leadership in the cement sector.

–Kanika Mathur

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Concrete

Global Start-Up Challenge Launched to Drive Net Zero Concrete Solutions

Innovandi Open Challenge aims to connect start-ups with GCCA members to develop innovations

Published

1 day ago

February 21, 2025

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Start-ups worldwide are invited to contribute to the global cement and concrete industry’s efforts to reduce CO2 emissions and combat climate change. The Global Cement and Concrete Association (GCCA) and its members are calling for applicants for the Innovandi Open Challenge 2025.

Now in its fourth year, the Innovandi Open Challenge aims to connect start-ups with GCCA members to develop innovations that help decarbonise the cement and concrete industry.

The challenge is seeking start-ups working on next-generation materials for net-zero concrete, such as low-carbon admixtures, supplementary cementitious materials (SCMs), activators, or binders. Innovations in these areas could help reduce the carbon-intensive element of cement, clinker, and integrate cutting-edge materials to lower CO2 emissions.

Thomas Guillot, GCCA’s Chief Executive, stated, “Advanced production methods are already decarbonising cement and concrete worldwide. Through the Innovandi Open Challenge, we aim to accelerate our industry’s progress towards net-zero concrete.”

Concrete is the second most widely used material on Earth, and its decarbonisation is critical to achieving net-zero emissions across the global construction sector.

Concrete

StarBigBloc Acquires Land for AAC Blocks Greenfield Facility in Indore

The company introduced NXTGRIP Tile Adhesives alongside its trusted NXTFIX and NXTPLAST brands.

Published

3 days ago

February 19, 2025

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StarBigBloc Building Material, a wholly-owned subsidiary of BigBloc Construction, one of the largest manufacturers of Aerated Autoclaved Concrete (AAC) Blocks, Bricks and ALC Panels in India has acquired land for setting up a green field facility for AAC Blocks in Indore, Madhya Pradesh. Company has purchased approx. 57,500 sq. mts. land at Khasra No. 382, 387, 389/2, Gram Nimrani, Tehsil Kasrawad, District – Khargone, Madhya Pradesh for the purpose of AAC Blocks business expansion in central India. The total consideration for the land deal is Rs 60 million and Stamp duty.

StarBigBloc Building Material Ltd currently operates one plant at Kheda near Ahmedabad with an installed capacity of 250,000 cubic meters per annum, serving most part of Gujarat, upto Udaipur in Rajasthan, and till Indore in Madhya Pradesh. The capacity utilisation at Starbigbloc Building Material Ltd for the third quarter was 75 per cent. The planned expansion will enable the company to establish a stronger presence in Madhya Pradesh and surrounding regions. Reaffirming its commitment to the Green Initiative, it has also installed a 800 KW solar rooftop power project — a significant step toward sustainability and lowering its carbon footprint.

Narayan Saboo, Chairman, Bigbloc Construction said “The AAC block industry is set to play a pivotal role in India’s construction sector, and our company is ready for a significant leap forward. The proposed expansion in Indore, Madhya Pradesh aligns with our growth strategy, focusing on geographic expansion, R&D investments, product diversification, and strategic branding and marketing initiatives to enhance visibility, increase market share, and strengthen stakeholder trust.”

Bigbloc Construction has recently expanded into construction chemicals with Block Jointing Mortar, Ready Mix Plaster, and Tile Adhesives, tapping into high-demand segments. The company introduced NXTGRIP Tile Adhesives alongside its trusted NXTFIX and NXTPLAST brands, ensuring superior bonding, strength, and performance.

In May 2024, the board of directors approved fund-raising through SME IPO or Preferential issue to support expansion plans of Starbigboc Building Material subject to requisite approvals and market conditions, Starbigboc Building Material aims to expand its production capacity from current 250,000 cubic meters per annum to over 1.2 million cubic meters per annum in the next 4-5 years. Company is targeting revenues of Rs 4.28 billion by FY27-28, with an expected EBITDA of Rs 1.25 billion and net profit of Rs 800 million. In FY23-24, the company reported revenues of Rs 940.18 million, achieving a revenue CAGR of over 21 per cent in the last four years.

Incorporated in 2015, BigBloc Construction is one of the largest and only listed AAC block manufacturer in India, with a 1.3 million cbm annual capacity across plants in Gujarat (Kheda, Umargaon, Kapadvanj) and Maharashtra (Wada). The company, which markets its products under the ‘NXTBLOC’ brand, is one of the few in the AAC industry to generate carbon credits. With over 2,000 completed projects and 1,500+ in the pipeline, The company’s clients include Lodha, Adani Realty, IndiaBulls Real Estate, DB Realty, Prestige, Piramal, Oberoi Realty, Tata Projects, Shirke Group, Shapoorji Pallonji Group, Raheja, PSP Projects, L&T, Sunteck, Dosti Group, Purvankara Ltd, DY Patil, Taj Hotels, Godrej Properties, Torrent Pharma, GAIL among others.

Concrete

World Cement Association Calls for Industry Action

The cement industry is responsible for 8 per cent of global CO2 emissions

Published

4 days ago

February 18, 2025

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The cement industry is responsible for 8 per cent of global CO2 emissions—a staggering figure that demands urgent action, particularly as 2024 marked the first year the planet surpassed the 1.5°C global warming limit. Recognising this critical juncture, the World Cement Association (WCA) has released a landmark White Paper, “Long-Term Forecast for Cement and Clinker Demand”, which projects a sharp decline in long-term cement and clinker demand. By 2050, annual clinker production is expected to fall below 1 Gt from its current level of 2.4 Gt, with far-reaching implications for global carbon emissions and the viability of carbon capture projects.

WCA CEO Ian Riley underscores the complexity of this challenge:
“Carbon capture remains a vital tool for tackling emissions in hard-to-abate sectors like cement. However, flawed demand assumptions and the fragmented nature of cement production globally could undermine the feasibility of such projects. Industry stakeholders must rethink their strategies and embrace innovative, sustainable practices to achieve meaningful emissions reductions.”

Key Findings from the WCA White Paper
The WCA White Paper provides a comprehensive roadmap for the industry’s decarbonisation journey, highlighting the following critical insights:
1. Declining Cement and Clinker Demand: Global cement demand is expected to drop to approximately 3 billion tonnes annually by 2050, while clinker demand could decline even more steeply, reaching just 1.5 billion tonnes annually.
2. Implications for Carbon Capture and Storage (CCS): With reduced clinker production, the need for CCS is expected to decline, necessitating a shift in investment and policy priorities.
3. Alternative Materials and Clinker-Free Technologies: These innovations hold transformative potential for reshaping demand patterns and cutting emissions.
4. Supply Chain Optimisation: Enhancing logistics and reducing waste are key strategies for adapting to evolving market dynamics.

A Path to Lower Emissions
Clinker production, the largest source of CO2 emissions in cement manufacturing, generates one-third of emissions from fuel combustion and two-thirds from limestone decomposition. According to our white paper, transitioning to lower-carbon fuels could reduce specific fuel emissions per tonne of clinker by nearly 70% by 2050. Overall CO2 emissions from cement production are forecast to decline from 2.4 Gt in 2024 to less than 1 Gt by 2050, even before factoring in carbon capture technologies.

Ian Riley emphasised: “This white paper provides actionable insights to help the cement industry accelerate its decarbonisation journey. By prioritising innovation and collaboration, the industry can achieve substantial emissions reductions and align with global climate goals.”