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Increasing Process Efficiency

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The efficient handling of cement, from production to transportation, is paramount. This article is a case study about the transformative impact of ELGi’s oil-free compressors adopted by a leading Indian cement major.

India is the second-largest cement-producing country in the world1, accounting for more than 8 per cent of the global installed capacity2. The cement industry is vital to global infrastructure development, providing the building blocks for our roads, bridges and buildings. With a major infrastructure push from the government and technological advancements for environment-friendly processes, the cement industry is looking forward to promising growth potential. Also, with the excellent quality and quantity of limestone deposits throughout the country, the cement industry promises enormous growth potential.
Initiatives by the Government of India, such as the expansion of railways, housing for all and smart cities, combined with the additional requirement of cement for urban households, will lead to more consumption in the coming years. Cement is a sector that relies heavily on industrial machinery and processes to ensure efficient production. Among this crucial equipment is the air compressor, which plays a pivotal role in cement transportation.

Cement production in India
With the increase in overall requirement for cement, there is also a need for time-efficient and quick processes to meet the ever-growing demands. Manufacturing cement involves complex processes such as mixing, drying and grinding a mixture of clay, limestone and silica into a composite mass. This mixture is then heated and burnt in a preheater and kiln. Following this, when the mixture is cooled in an air-cooling system, clinker is produced, a semi-finished form of cement. The clinker is cooled by air and ground with gypsum to form cement. The material’s bulky nature results in high transportation costs that have led cement manufacturers to set up clinker units near limestone mines and grinding units near coastal areas to help cut down logistics costs considerably. However, some challenges need to be resolved to enhance process efficiency.

Customer challenge
A prominent Indian cement major with numerous plants and units spread across different countries looked out for an efficient compressed air solution to facilitate unloading cement from ships into bulkers and transferring cement to their plant silos. It is vital to quickly load and unload the cement to avoid holding the ship for too long in the dock and prevent penalties. Further, bulkers are used for transporting cement to the cement silos, which also requires swift implementation to avoid trucks lining up. While handling large volumes of material, transporting cement through pipes is more efficient than packing in bags. Compressed air is crucial for quickly loading and unloading cement from trucks.

Application of compressed air
A single silo has the capacity of accommodating nine trucks filled with cement. For unloading, pipes are connected to the trucks. A pipe with compressed air discharged at two bars of pressure goes into the truck, and another pipe is connected to move the cement into the silo. Once the pressure reaches zero, it signals that the entire material has been transferred to the silo, and the pipe is removed. A similar process transfers the cement from ships to trucks. It is crucial that the equipment doesn’t break down during the entire process and the air supply is sufficient. The downtime also needs to be minimal to maintain operational quality and speed.

Smart savings
The cement major chose ELGi air compressors because they were indigenous with low maintenance costs. The cement major shifted from reciprocating air compressors to ELGi’s OF 132 L oil-free screw air compressors after a careful audit of their needs.
ELGi’s solution reduced power consumption and faster cement transfer, supported by quick customer service response and reliable technical support. The ELGi team also retrofitted its existing variable-frequency drives (VFDs) on its air compressors to regulate motor speed for cases when there was less cement than usual to unload. As bulkers unloaded faster with ELGi compressors, fewer bulkers were needed overall, thus resulting in huge savings.
Here are some key benefits of the shift to ELGi’s Oil Free Compressed Air Solution:

  • ELGi’s Programmable Logic Controller (PLC) system makes operating air compressors easy.
  • Earlier, it would take 45 minutes to unload a truck, but after using ELGi air compressors, unloading time reduced to 20 minutes, a drop of 50 per cent.
  • Since ELGi air compressors use less energy, the customer’s power consumption is reduced, translating into significant cost savings.

ELGi’s oil-free and energy-efficient air compressors helped the cement major to increase its productivity. Ship unloading into bulkers and bulkers unloading into cement silos at the plant both happened quicker than earlier, resulting in substantial time and cost savings. Low maintenance costs and reduced power consumption also increased efficiency.
The cement manufacturer has switched to ELGi air compressors for its plants all over India. As the cement industry grows, ELGi air compressors will continue to enable the Indian cement major to transport cement faster, ensuring high energy efficiency, productivity and significant energy and maintenance cost savings.

References
1 beeindia.gov.in
2www.ibef.org

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

Dalmia Bharat Acquires Jaiprakash Associates Cement Assets for ₹2,850 Crore

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Dalmia Cement executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra, to acquire 5.2 MnTPA of cement capacity across Madhya Pradesh and Uttar Pradesh.

Dalmia Cement (Bharat) announced on May 22, 2026 that it had signed a Business Transfer Agreement with Jaiprakash Associates Limited and Adani Infra (India) Limited for the acquisition of cement plants located at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh. The deal was struck at an enterprise value of ₹2,850 crore and is expected to close within two weeks of execution.

The acquired assets from Jaiprakash Associates include 5.2 MnTPA of cement capacity and 3.3 MnTPA of clinker capacity. The package also covers 99 MW of thermal power capacity and railway sidings at Rewa, Chunar, and a common siding at Churk. This infrastructure gives the acquisition immediate operational utility beyond just production tonnage.

The transaction has a long backstory. Dalmia Cement had originally entered into a framework agreement with Jaiprakash Associates in December 2022, covering the sale of these business assets along with a long-term clinker supply arrangement. However, before the deal could be completed, Jaiprakash Associates was admitted to insolvency proceedings under the Insolvency and Bankruptcy Code. The earlier agreements could not be consummated as a result.

In an official statement, Puneet Dalmia, Managing Director & CEO, Dalmia Bharat, said, “I am very excited about addition of these assets in our portfolio. This serves as a great strategic fit for Dalmia. It helps us move forward in our journey to be a pan India player and provide a strong head start to serve the high potential markets in Central region. I am optimistic that the expansion potential of these assets along with close proximity with Dalmia’s captive mines will help us create a capacity hub for the future”.

Following the approval of Adani Group’s resolution plan for Jaiprakash Associates under the IBC framework, Dalmia approached the new management to revive discussions. The fresh Business Transfer Agreement was executed to settle all pending disputes, legal proceedings, and arbitration matters arising from the original framework agreement with Jaiprakash Associates.

Expanding market reach

Dalmia added, “Our familiarity with these assets under the earlier tolling arrangement gives us a deep understanding of the facilities and helps us establish strong connect with channel partners and vendors. We believe that this will help us in faster ramp up of capacities and quicker inroads into the market. As we look forward, I am very confident that we will be able to leverage the strengths of Dalmia to operate these assets in a manner where we can maximise value creation for all our stakeholders.”

With the addition of these plants, Dalmia Bharat’s total installed cement capacity will rise to 54.7 MnTPA upon consummation. The company has further expansion projects underway at Belgaum, Pune, and Kadapa, which are expected to take overall capacity to 66.7 MnTPA by Q2 to Q3 FY28.

The Central India location of the Jaiprakash Associates plants gives Dalmia Bharat faster access to markets in Madhya Pradesh and Uttar Pradesh than a greenfield build would have allowed. The company also cited debottlenecking and brownfield expansion as near-term opportunities at the acquired sites. Dalmia Bharat said the assets were expected to contribute positively to EBITDA and overall returns, given the pricing environment in the region and the company’s cost structure.

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