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Ultratech sources VRM from Gebr. Pfeiffer

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Ultratech Cement will once again use the state-of-the-art vertical roller mill technology from Gebr. Pfeiffer, to build three new clinker production lines.

As Ultratech Cement gears up for its three new clinker production lines, a corresponding follow-up order was awarded to Gebr. Pfeiffer SE, Germany, and its Indian subsidiary Gebr. Pfeiffer (India).

As the largest cement plant operator in India and one of the top ten in the world, Ultratech Cement from Mumbai, India, is contributing to shaping the future of the cement industry. At their Happy 3 plant, the cement raw material will be ground in an MVR 5000 R-4 mill. With a 5,300-kW drive, this mill can grind approx. 705 tph to a product fineness of 1.5 per cent R 212 µm. The integrated SLS 5300 VR high-efficiency classifier, with optimised flow and electrical efficiency, separates the product to achieve the target fineness.

For the grinding of approx. 45 t/h of pet coke or approx. 90 t/h of coal, three vertical roller mills of the type MPS 3550 BK will be supplied. These are equipped with a 1,300-kW gearbox, as standard. By using Pfeiffer MPS mills, Ultratech is able to process both pet coke and coal, as well as any mixture of these two materials, at the same speed of the grinding bowl, thus avoiding three expensive frequency converters. The new coal mills will be equipped with an integrated high-efficiency classifier type SLS 3750 BK of the latest design. 

It is important for UltraTech’s stock of spare parts that the latest MVR mills are characterised by grinding rollers based on the R=C principle, as this brings significant advantages for the customer. It means that these mills are equipped with grinding rollers that, equipped with the corresponding grinding elements, can be used, along with the appropriate power modules, for raw meal grinding as well as for cement grinding.

As the components of rollers, grinding roller suspension system, roller arms in cement and raw mills are identical with the ones which the customer has already received from Gebr. Pfeiffer, he requires a smaller number of spare parts in stock. This is because the components mentioned can be used for all his cement and raw mills.

The MVR 5000 R-4 mill for the Happy 3 plant has four actively redundant grinding rollers and can also be operated with two grinding rollers in the event of planned or unplanned maintenance work. This mill can then still produce approximately 70 per cent of the nominal capacity, so that the cement rotary kiln can continue to be fed with raw material.

The MVR mills are equipped by Gebr. Pfeiffer with the modern systems for preventive, maintenance-oriented condition monitoring. This will enable the customer to implement modern, digital maintenance concepts. The MPS mills will be prepared to include such options at a later point in time.

Order execution will be jointly by the subsidiary Gebr. Pfeiffer (India) and Gebr. Pfeiffer SE (Germany). The entire customer support and plant engineering will be carried out by competent Pfeiffer engineers in Noida.

The core components, such as gearbox, grinding bowl, grinding roller suspension system and the grinding rollers, are supplied from Europe by Gebr. Pfeiffer SE. The remaining components, such as the foundation parts, the housings, the classifiers and most of the plant components will be provided by Gebr. Pfeiffer (India).

The Customer Support Centre in Noida, being close to the customer, will later also provide support for the plants. This can be done in real terms by sending personnel to the plants or via remote data access.

For this purpose, Gebr. Pfeiffer offers hardware and software solutions, which are supported by competent technical personnel during normal office hours, if possible, in the local language. The picture shows an MVR mill of similar size (Type MVR 5000 R-4).

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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Concrete

Cement Prices to Stay Flat in Q2 FY27 as Costs Squeeze Margins

HDFC Securities warns monsoon slowdown and higher fuel costs

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HDFC Securities has said the cement industry is unlikely to register a sequential increase in prices in Q2 FY27 as monsoon-related demand moderation coincides with rising fuel and packaging costs that will squeeze margins. The brokerage observed that price gains remained modest, with increases of two to three per cent quarter-on-quarter across regions, and noted subdued offtake in May with improvement in June as a delayed monsoon supported construction activity. The brokerage added that modest pricing gains so far have been insufficient to offset the input cost escalation.

The report stated that input cost pressures intensified in Q1 FY27 owing to the West Asia conflict, which pushed up coal and pet coke prices and is expected to keep fuel costs elevated, with a likely peak in Q2 FY27. It assessed that total variable costs, including packing, could rise by around Rs 150 per t quarter-on-quarter and that lower offtake and seasonal operating deleverage could further raise operating expenditure by about Rs 50 per t quarter-on-quarter.

Overall, cement prices were estimated to remain flat in Q2 FY27 as monsoon-led demand weakness offsets limited upside in realisation, and rising fuel costs alongside seasonal deleverage were expected to compress industry margins by over Rs 100 per t quarter-on-quarter to below Rs 880 per t. The brokerage indicated that the combined impact of energy inflation and higher packing expenditure would be the principal drivers of margin contraction in the near term. HDFC Securities projected a recovery in margins in H2 FY27 should the West Asia turmoil subside and energy and packing costs cool off.

The brokerage expressed optimism on long-term demand fundamentals and said improving realisation together with an anticipated cost cool-off should support a margin rebound from H2 FY27 onward, underpinning favourable industry prospects over the medium term. Its outlook rests on monsoon normalisation and a decline in imported fuel prices in the second half of the fiscal year.

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Dalmia Bharat Begins Rs 31 Bn Green Cement Unit in Kadapa

New Andhra Pradesh plant to add 9.6 MTPA cement capacity by FY28

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Dalmia Bharat Limited recently laid the foundation stone for its second manufacturing unit at Kadapa in Andhra Pradesh. The company will invest Rs 31 billion in developing the next-generation integrated cement manufacturing facility.
The foundation-laying ceremony was attended by Nara Lokesh, Andhra Pradesh Minister for Information Technology, Electronics and Communications, Real-Time Governance and Human Resources Development, along with Puneet Dalmia, Managing Director and Chief Executive Officer, Dalmia Bharat, senior government officials and company representatives.
Scheduled to be commissioned by the third quarter of FY28, the Kadapa unit will become Dalmia Bharat’s largest integrated manufacturing facility in southern India. It will have a clinker production capacity of 6.1 million tonnes per annum and a cement manufacturing capacity of 9.6 million tonnes per annum.
The facility is designed to produce what the company describes as one of the world’s greenest cements. It is also expected to generate approximately 1,000 direct and indirect employment opportunities while supporting local MSMEs, transporters, contractors and service providers.
Lokesh said the investment reflected Dalmia Bharat’s confidence in Andhra Pradesh and aligned with the state’s objective of promoting sustainable industrialisation, job creation and technology-led economic growth.
Puneet Dalmia said the project represented the company’s long-term vision of developing low-carbon cement manufacturing assets. He added that the facility would establish new benchmarks in operational efficiency and sustainability while supporting India’s infrastructure and environmental goals.
Dalmia Bharat will also expand its regional community development programmes in education, healthcare, skill development and welfare through its DIKSHa and Gram Parivartan initiatives.
The company currently has an installed cement manufacturing capacity of 54.7 million tonnes across 19 manufacturing units in 12 states. It is also the first cement company globally to commit to the RE100, EP100 and EV100 initiatives.

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