Kiran Patil, Managing Director, Wonder Cement, speaks about the company’s focus on technological advancements, sustainability and community development to support its growth while mitigating regulatory and economic challenges.
What are your company’s plans for expanding cement production capacity? How are they aligned with the government’s industrial and infrastructure policies?
In the short term, we are focusing on optimising our existing facilities and ensuring that we achieve maximum efficiency in production. Our short-term plan focuses on increasing our current production capacity by 25 per cent over the next two years to meet the rising demand for cement in infrastructure projects. This will involve brown/green field expansion, upgrading technology, enhancing operational efficiencies, and debottlenecking existing plants to achieve better throughput.
We are pleased to announce the establishment of a fifth production line at our Nimbahera facility in Chittorgarh, Rajasthan. This expansion, set to be operational by mid-2025, is in response to the growing demand in the region. The new line will augment our production capacity by an additional 2.75 MTPA.
In the long term, we aim to increase our capacity within the next five years by establishing new plants in strategic locations across the region. These plans align well with the government’s industrial and infrastructure policies, such as the National Infrastructure Pipeline (NIP) and the push for affordable housing. These initiatives are driving demand for construction materials, and we are committed to supporting these efforts by ensuring a steady supply of high-quality cement.
At Wonder Cement, we are committed to significantly expanding our production capacity to meet the growing demands of the Indian market and to contribute to the nation’s infrastructure development. Our expansion strategy is carefully aligned with the government’s industrial and infrastructure policies to ensure that our growth supports national priorities.
How have the current policies, such as the focus on infrastructure development and the ‘Make in India’ initiative, influenced your expansion plans?
The government’s emphasis on infrastructure development and the ‘Make in India’ initiative have significantly influenced our expansion plans. Policies like the NIP, which aims to enhance the quality of infrastructure across the country, have created a robust demand for construction materials. The ‘Make in India’ initiative has provided us with a favourable environment for manufacturing, encouraging us to invest more in local production. While these policies have been beneficial, the challenge lies in navigating the regulatory complexities and obtaining timely approvals for new projects. However, the government’s proactive approach in simplifying procedures and promoting ease of doing business has been encouraging.
What is your assessment of the current regulatory policies? Are there any initiatives that could help your expansion plans?
The current regulatory environment for the cement industry is generally supportive, but there is room for improvement. Simplifying and speeding up the process for environmental clearances and land acquisition would significantly facilitate our expansion plans. Additionally, policies aimed at reducing logistical costs through better infrastructure, such as improved rail and road networks, would help us optimise our supply chain and distribution. The government’s focus on digitisation and transparency in regulatory processes is a positive step that we believe will further ease the challenges associated with expansion.
How is your company securing funding for these projects, and what role do government incentives play in this process?
We are planning an investment of approximately Rs 5,000 crore over the next five to seven years to support our expansion initiatives. This includes the establishment of new plants, upgrading existing facilities, and incorporating advanced technologies. We are securing funding through a combination of internal accruals and external financing. Government incentives, such as subsidies for setting up plants in certain regions and tax benefits under the ‘Make in India’ initiative, play a crucial role in making these investments viable. These incentives help us manage costs and enhance the overall feasibility of our projects.
How is your company addressing sustainability in your expansion plans?
At Wonder Cement, environmental sustainability is a core principle guiding our expansion plans. As we increase our production capacity, we are committed to implementing measures that minimise environmental impact and promote sustainable practices. Here are the steps we are taking to ensure our new production line aligns with these values:
- Energy efficiency: We are incorporating state-of-the-art technology to enhance energy efficiency in our operations. This includes using advanced machinery that consumes less energy and optimising our processes to reduce energy wastage. We are focusing on green power for plant operation. Recently we signed an agreement for solar power supply for our newly established grinding unit at Aligarh, U.P.
- Emission control: We are investing in cutting-edge emission control systems to significantly reduce greenhouse gas emissions. Our new facility will be equipped with high-efficiency bag filters, electrostatic precipitators, and continuous emission monitoring systems to ensure compliance with stringent environmental standards.
- Alternative fuels and raw materials: We are increasing the use of alternative fuels and raw materials in our production process. This not only reduces our dependency on non-renewable resources but also helps in lowering our carbon footprint.
- Water conservation: Water is a precious resource, and we are committed to its conservation. Our new line will incorporate advanced water recycling systems and rainwater harvesting mechanisms to ensure sustainable water use.
- Waste management: We are implementing comprehensive waste management strategies to minimise waste generation and promote recycling. This includes utilising industrial waste, such as fly ash and slag, in our cement production to reduce landfill waste.
- Green belt development: We are enhancing our green belt around the Nimbahera facility by planting more trees and maintaining natural vegetation. This helps in improving air quality and creating a sustainable environment.
- Community engagement: We are engaging with local communities to promote environmental awareness and sustainability practices.
Through various CSR initiatives, we aim to educate and involve the community in our environmental efforts.
By integrating these initiatives into our expansion plans, we ensure that our increased production capacity is achieved in an environmentally responsible manner, contributing to the long-term sustainability of our operations and the well-being of the community.
How is your company leveraging technology to enhance efficiency and capacity in your cement plants?
At Wonder Cement, we leverage cutting-edge technology to enhance our plants’ efficiency and capacity through a multifaceted approach focusing on automation, digitalisation, and sustainability. Our Advanced Process Control (APC) systems optimise production with real-time data and predictive analytics, improving efficiency and reducing energy consumption. IoT-enabled devices facilitate real-time monitoring and predictive maintenance, minimising downtime and costs. Centralised control rooms utilise sophisticated software for effective oversight and quick decision-making.
We incorporate robotics for precise, efficient material handling and explore AI and machine learning to predict equipment failures and optimise maintenance. Our adoption of Waste Heat Recovery Systems (WHRS) harnesses waste heat, reducing external energy reliance and lowering our carbon footprint. Sustainability drives our technological innovations, including investments in carbon capture and alternative fuels.
In new and expanded facilities, we plan to integrate smart manufacturing technologies, blockchain for supply chain transparency, and digital twins for real-time performance optimisation. These innovations position Wonder Cement at the forefront of the industry, ensuring high-quality products while upholding our commitment to sustainability and operational excellence.
What are the major challenges and risks associated with expansion?
The major challenges include regulatory delays, fluctuations in raw material prices, and uncertainties in the economic and political landscape. To mitigate these risks, we are focusing on diversifying our supply chain to reduce dependency on a single source of raw materials and mode of transport. We are also engaging with government authorities to ensure timely clearances and support. Additionally, we are adopting a phased approach to expansion to allow flexibility and adaptability in response to changing market conditions. Risk management frameworks and contingency planning are integral parts of our strategy to navigate these challenges.
How do your expansion plans consider the impact on local communities?
Our expansion plans are designed with a strong focus on social and economic development of local communities. We prioritise hiring from local talent pools and provide extensive training programs to enhance their skills. Our Corporate Social Responsibility (CSR) initiatives include healthcare, education and infrastructure development in the regions surrounding our plants. We are also investing in community welfare programs such as building schools, and healthcare centres and ensuring access to clean drinking water. By engaging with local communities and addressing their needs, we aim to foster a positive and sustainable relationship.
Overall, this showcases our commitment to growth, sustainability, and community development while aligning with national policies and leveraging advanced technologies. Wonder Cement’s expansion plans are designed to not only meet the increasing demand for cement in India but also to support and complement the government’s vision for industrial growth and infrastructure development. We are excited about the future and are dedicated to playing a pivotal role in the nation’s progress.
– Kanika Mathur