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Our gears and drives are accurately aligned

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Piyush Joshi, Associate Vice President – Systems and Technical Cell, Wonder Cement, talks about the pivotal role of advanced gears, drives and motors in optimising the efficiency and reliability of their cement manufacturing plant.

How do advancements in gear technology impact the efficiency and performance of cement manufacturing processes?
Advancements in gear technology have significantly enhanced the efficiency and performance of cement manufacturing processes at Wonder Cement. Modern gears, crafted from high-strength alloys and featuring advanced surface treatments, offer superior durability and wear resistance. This results in reduced friction and energy loss, allowing for more efficient power transmission. Precision engineering and innovative designs enable gears to handle higher loads with greater reliability, minimising downtime and maintenance costs. By integrating these state-of-the-art gear systems, Wonder Cement achieves optimal operational performance, ensuring that our production lines run smoothly and efficiently. The improved efficiency not only lowers energy consumption but also contributes to a more sustainable manufacturing process, aligning with our commitment to environmental stewardship and operational excellence. The incorporation of advanced technologies, including artificial intelligence (AI) and machine learning (ML), represents a significant innovation in the cement industry. At Wonder Cement, these state-of-the-art tools have been instrumental in optimising operations, reducing energy consumption and enhancing overall productivity.

What are the most common types of drives used in cement plants, and how do they contribute to operational reliability?
At Wonder Cement, the most common types of drives used in our cement plants are variable frequency drives (VFDs) and gear drives. VFDs are integral for their ability to precisely control motor speed and torque, optimising the performance of various equipment such as conveyors, crushers, and grinders. This control enhances energy efficiency and ensures that machinery operates within optimal parameters, reducing wear and tear. Gear drives, known for their robustness, provide the necessary torque multiplication to handle heavy loads typical in cement production. Their design prioritises durability and reliability, minimising downtime and maintenance needs.
By employing these advanced drives, Wonder Cement achieves exceptional operational reliability, ensuring consistent production, meeting targets, and maintaining high-quality standards. This focus on reliable drives is crucial for sustaining our competitive edge and operational excellence in the demanding cement manufacturing environment.

Explain the role of motors and their specifications in cement production.
In cement production, motors are crucial as they drive key processes such as raw material handling, crushing, grinding and kiln rotation. The performance and efficiency of these motors directly influence the plant’s overall productivity. High-efficiency motors reduce energy consumption and operational costs, enabling the plant to operate sustainability and economically. Motor specifications, such as power rating, efficiency class and thermal management capabilities, are essential for ensuring consistent and reliable operation under demanding conditions.
We prioritise motors with high power density and superior thermal properties to maintain optimal performance, even in harsh environments. By selecting motors that meet these stringent specifications, we enhance the efficiency, reliability, and longevity of our equipment, ensuring that our cement production processes run smoothly and efficiently, ultimately contributing to our commitment to quality and operational excellence.

How do you ensure the longevity and durability of gears in the harsh conditions typical of cement manufacturing?
Ensuring the longevity and durability of gears in the harsh conditions of cement manufacturing is a priority for us. We utilise high-strength alloy gears and apply advanced surface treatments to enhance their wear and corrosion resistance. Our maintenance strategy includes regular lubrication with high-quality lubricants and adherence to strict preventive maintenance schedules.
We have adopted the total lubrication concept for maintaining world class lubrication practices. Routine inspections help identify potential issues early, allowing for timely interventions. We also invest in advanced gear monitoring systems that continuously track performance and wear, enabling predictive maintenance. This proactive approach not only extends the lifespan of our gears but also minimises downtime and maintenance costs, ensuring uninterrupted and efficient plant operations. Through these comprehensive measures, we uphold the reliability and durability of our gears, maintaining optimal performance even in the most demanding environments.

What are the key factors to consider when selecting drives and motors for different stages of the cement production process?
When selecting drives and motors for different stages of the cement production process at Wonder Cement, several key factors must be considered to ensure optimal performance and efficiency. Firstly, load requirements are crucial – motors and drives must be capable of handling the specific loads of each stage, from raw material extraction to final grinding. The operating environment is another critical factor, as equipment must withstand harsh conditions like high temperatures and dust.
Energy efficiency is paramount to reduce operational costs and environmental impact. Compatibility with existing systems ensures seamless integration and smooth operations. Additionally, maintenance needs should be evaluated to minimise downtime and prolong equipment lifespan. Lastly, reliability and durability are essential to ensure continuous production without frequent breakdowns. By meticulously assessing these factors, Wonder Cement ensures that each drive and motor selection supports robust, efficient and reliable cement manufacturing processes.

How does the maintenance of gears, drives, and motors affect the uptime and productivity of a cement plant?
The maintenance of gears, drives and motors is pivotal to maximising uptime and productivity in our cement plant. Regular maintenance ensures that these critical components operate efficiently, preventing unexpected breakdowns that can halt production and cause costly delays. By implementing a proactive maintenance strategy, including predictive maintenance techniques, we can identify potential issues before they escalate, allowing for timely repairs and replacements. This approach minimises unscheduled downtime, enhances the reliability of our equipment, and extends its lifespan. Consequently, our cement plant maintains a high level of operational efficiency, consistently meeting production targets and maintaining product quality. Ultimately, meticulous maintenance of gears, drives, and motors is integral to sustaining the seamless and productive operations that define Wonder Cement’s commitment to excellence.

What are the challenges faced in integration of modern motors into existing cement manufacturing infrastructure?
Integrating modern motors into existing cement manufacturing infrastructure presents several challenges. Compatibility with older systems, space constraints, and the need for extensive rewiring are significant issues. Modern motors often require different control systems and may not fit into the existing space configurations. Moreover, the integration process can disrupt ongoing operations, leading to potential downtime and production losses. However, the benefits of modern motors, including improved efficiency and performance, outweigh these challenges.
We address these challenges through careful planning, meticulous execution and thorough testing, ensuring a seamless transition that minimises disruption and maximises the long-term benefits of the upgraded infrastructure.

How important is the alignment and synchronisation of gears and drives in ensuring the smooth operation of cement production equipment?
The alignment and synchronisation of gears and drives are paramount in ensuring the smooth operation of cement production equipment. Proper alignment ensures that power is transmitted efficiently, minimising energy loss and reducing wear on components. Synchronisation guarantees that all moving parts work together harmoniously, preventing issues such as vibration and premature failure.
We prioritise precision alignment and synchronisation to maintain the reliability and efficiency of our production processes. Our gears and drives are accurately aligned and synchronised, and we are able to minimise downtime, maximise productivity and uphold the highest standards of operational excellence.

What role does predictive maintenance play in managing the performance and lifespan of gears, drives and motor?
Predictive maintenance plays a crucial role in managing the performance and lifespan of gears, drives, and motors in the cement industry. By leveraging advanced monitoring technologies and data analytics, Wonder Cement predicts potential failures and schedule maintenance proactively. This approach helps to minimise unexpected downtime, reduce maintenance costs, and optimise the overall productivity of our cement plants. With predictive maintenance, we can detect issues before they escalate, allowing us to address them efficiently and effectively, thus ensuring that our gears, drives, and motors operate at their peak performance levels for extended periods, ultimately enhancing the lifespan of these critical components.
In conclusion, gears, drives and motors are the backbone of Wonder Cement’s manufacturing process. Through continuous advancements, meticulous selection, and proactive maintenance, we ensure that our operations run smoothly, efficiently and reliably, meeting the demands of the modern cement industry.

– Kanika Mathur

Concrete

India Sets Up First Carbon Capture Testbeds for Cement Industry

Five CCU testbeds launched to decarbonise cement production

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The Department of Science and Technology (DST) recently unveiled a pioneering national initiative: five Carbon Capture and Utilisation (CCU) testbeds in the cement sector, forming a first-of-its-kind research and innovation cluster to combat industrial carbon emissions.
This is a significant step towards India’s Climate Action for fostering National Determined Contributions (NDCs) targets and to achieve net zero decarbonisation pathways for Industry Transition., towards the Government’s goal to achieve a carbon-neutral economy by 2070.
Carbon Capture Utilisation (CCU) holds significant importance in hard-to-abate sectors like Cement, Steel, Power, Oil &Natural Gas, Chemicals & Fertilizers in reducing emissions by capturing carbon dioxide from industrial processes and converting it to value add products such as synthetic fuels, Urea, Soda, Ash, chemicals, food grade CO2 or concrete aggregates. CCU provides a feasible pathway for these tough to decarbonise industries to lower their carbon footprint and move towards achieving Net Zero Goals while continuing their operations efficiently. DST has taken major strides in fostering R&D in the CCUS domain.
Concrete is vital for India’s economy and the Cement industry being one of the main hard-to-abate sectors, is committed to align with the national decarbonisation commitments. New technologies to decarbonise emission intensity of the cement sector would play a key role in achieving of national net zero targets.
Recognizing the critical need for decarbonising the Cement sector, the Energy and Sustainable Technology (CEST) Division of Department launched a unique call for mobilising Academia-Industry Consortia proposals for deployment of Carbon Capture Utilisation (CCU) in Cement Sector. This Special call envisaged to develop and deploy innovative CCU Test bed in Cement Sector with thrust on Developing CO2 capture + CO2 Utilisation integrated unit in an Industrial set up through an innovative Public Private Partnership (PPP) funding model.
As a unique initiative and one of its first kind in India, DST has approved setting up of five CCU testbeds for translational R&D, to be set up in Academia-Industry collaboration under this significant initiative of DST in PPP mode, engaging with premier research laboratories as knowledge partners and top Cement companies as the industry partner.
On the occasion of National Technology Day celebrations, on May 11, 2025 the 5 CCU Cement Test beds were announced and grants had been handed over to the Test bed teams by the Chief Guest, Union Minister of State (Independent Charge) for Science and Technology; Earth Sciences and Minister of State for PMO, Department of Atomic Energy, Department of Space, Personnel, Public Grievances and Pensions, Dr Jitendra Singh in the presence of Secretary DST Prof. Abhay Karandikar.
The five testbeds are not just academic experiments — they are collaborative industrial pilot projects bringing together India’s top research institutions and leading cement manufacturers under a unique Public-Private Partnership (PPP) model. Each testbed addresses a different facet of CCU, from cutting-edge catalysis to vacuum-based gas separation.
The outcomes of this innovative initiative will not only showcase the pathways of decarbonisation towards Net zero goals through CCU route in cement sector, but should also be a critical confidence building measure for potential stakeholders to uptake the deployed CCU technology for further scale up and commercialisation.
It is envisioned that through continuous research and innovation under these test beds in developing innovative catalysts, materials, electrolyser technology, reactors, and electronics, the cost of Green Cement via the deployed CCU technology in Cement Sector may considerably be made more sustainable.
Secretary DBT Dr Rajesh Gokhale, Dr Ajai Choudhary, Co-Founder HCL, Dr. Rajesh Pathak, Secretary, TDB, Dr Anita Gupta Head CEST, DST and Dr Neelima Alam, Associate Head, DST were also present at the programme organized at Dr Ambedkar International Centre, New Delhi.

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Concrete

JK Lakshmi Adopts EVs to Cut Emissions in Logistics

Electric vehicles deployed between JK Puram and Kalol units

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JK Lakshmi Cement, a key player in the Indian cement industry, has announced the deployment of electric vehicles (EVs) in its logistics operations. This move, made in partnership with SwitchLabs Automobiles, will see EVs transporting goods between the JK Puram Plant in Sirohi, Rajasthan, and the Kalol Grinding Unit in Gujarat.
The announcement follows a successful pilot project that showcased measurable reductions in carbon emissions while maintaining efficiency. Building on this, the company is scaling up EV integration to enhance sustainability across its supply chain.
“Sustainability is integral to our vision at JK Lakshmi Cement. Our collaboration with SwitchLabs Automobiles reflects our continued focus on driving innovation in our logistics operations while taking responsibility for our environmental footprint. This initiative positions us as a leader in transforming the cement sector’s logistics landscape,” said Arun Shukla, President & Director, JK Lakshmi Cement.
This deployment marks a significant step in aligning with India’s push for greener transport infrastructure. By embracing clean mobility, JK Lakshmi Cement is setting an example for the industry, demonstrating that environmental responsibility can go hand in hand with operational efficiency.
The company continues to embed sustainability into its operations as part of a broader goal to reduce its carbon footprint. This initiative adds to its vision of building a more sustainable and eco-friendly future.
JK Lakshmi Cement, part of the 135-year-old JK Organisation, began operations in 1982 and has grown to become a recognised name in Indian cement. With a presence across Northern, Western, and Eastern India, the company has a cement capacity of 16.5 MTPA, with a target to reach 30 MT by 2030. Its product range includes ready-mix concrete, gypsum plaster, wall putty, and autoclaved aerated fly ash blocks.

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Holcim UK drives sustainable construction

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Holcim UK has released a report titled ‘Making Sustainable Construction a Reality,’ outlining its five-fold commitment to a greener future. The company aims to focus on decarbonisation, circular economy principles, smarter building methods, community engagement, and integrating nature. Based on a survey of 2,000 people, only 41 per cent felt urban spaces in the UK are sustainably built. A significant majority (82 per cent) advocated for more green spaces, 69 per cent called for government leadership in sustainability, and 54 per cent saw businesses as key players. Additionally, 80 per cent of respondents stressed the need for greater transparency from companies regarding their environmental practices.

Image source:holcim

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