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We implement rigorous raw material testing

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Manish Samdani, Head – Quality Control, Udaipur Cement Works Limited (UCWL), shares a comprehensive view on optimising cement grinding processes and enhancing plant performance.

Can you provide an overview of the grinding process in your cement manufacturing plant and its significance in the overall production process?
In UCWL, we use the following types of mills for grinding raw materials and cement:

  • Vertical Roller Mill (VRM): We employ the M/s Loesche (LM 38.4) and Gebr. Pfeiffer (MVR 6000C6) technology for raw material and cement grinding respectively. The VRM is a type of grinding mill that combines crushing, grinding, drying, and classification functions into a single compact unit. It operates by rotating a grinding table, equipped with rollers, while the raw materials are fed into the mill from the top. The rollers exert grinding pressure on the material, resulting in comminution and fine grinding. The ground material is then conveyed upwards and collected in a cyclone separator, while the coarse particles are returned to the grinding table for further grinding. The use of VRM technology allows for efficient grinding and improved energy utilisation. We are operating a mill with lowest power i.e., 12.5 KWh/MT with 10 per cent on 90 micron for raw material grinding.
  • CPI and LNVT Ball Mill: CPI and LNVT is a renowned manufacturer of grinding equipment for the cement industry. Their ball mills are widely used for grinding cement clinker, gypsum, and other materials into a fine powder. The ball mill operates by rotating a horizontal cylinder, filled with steel balls, which impact and grind the material as it rotates. The ground material is discharged through the adjustable central diaphragm, while the coarse particles are returned for further grinding. CPI optimises material flow and thin linear plate, which increases the overall area of grinding also as a highly efficient dynamic separator with top feeding.
  • Both the VRM and ball mill technologies provide effective grinding solutions for raw materials and cement production, each with its advantages and specific applications. The choice of the grinding mill depends on various factors such as the type of raw materials, desired fineness, production capacity, and energy efficiency requirements.

What are the main challenges you face in the grinding process, and how do you address these challenges to maintain efficiency and product quality?
At UCWL, the main challenges in the grinding process include high energy consumption, maintaining consistent product fineness, and managing moisture content in raw materials. To address these issues, UCWL uses energy-efficient VRMs, optimising parameters and employing SMARTA control systems to reduce energy usage. Consistency in product fineness is achieved through the use of online and offline PHD analysers and real-time quality control measures. Additionally, proper mixing and covered storage of raw materials help minimise moisture variations, ensuring efficient and high-quality grinding.

  • Energy consumption: Grinding is an energy-intensive process, and high energy consumption can lead to increased operational costs. UCWL utilises energy-efficient grinding mills like the VRM, which consumes 23-24 kWh/MT for PPC cement compared to higher consumption in ball mills. The optimisation of grinding process parameters and the use of SMARTA advanced control systems help reduce energy usage without compromising product quality.
  • Consistency in product fineness: Achieving and maintaining consistent product fineness is crucial for the quality of the final cement product. UCWL employs both online and offline PHD analysers for continuous monitoring and control of the grinding process. Advanced instrumentation and automation systems, along with real-time quality control measures, ensure the desired particle size distribution is maintained.
  • Moisture content in raw materials: High moisture content in raw materials can lead to difficulties in grinding and affect the efficiency of the grinding process and quality. UCWL ensures proper mixing of raw materials and optimal storage conditions by utilising a covered storage yard, minimising variations in moisture content.
  • Process and quality variability: Variability in raw material properties can lead to fluctuations in the grinding process, affecting product quality and efficiency.

We implement rigorous raw material testing and quality control procedures to ensure consistent feed quality. Real-time data is used to adjust process parameters, compensating for any variations in raw material properties. By addressing these challenges with advanced technologies, continuous monitoring, and strict quality control measures, UCWL maintains high efficiency and superior product quality in its grinding operations.

How do grinding aids contribute to the efficiency of the grinding process in your plant? What types of grinding aids do you use?
Grinding aids are chemical additives used in the cement manufacturing process to improve the efficiency and effectiveness of the grinding process. At UCWL, grinding aids play a crucial role in enhancing the performance of the grinding equipment and ensuring high-quality cement. We are using glycol-based grinding aid, which is reducing the energy required for grinding, improving one day’s strength by 2 to 3 MPa. These chemical additives lead to more efficient use of the grinding equipment, resulting in higher throughput and lower energy consumption. They also improve the flow properties of the ground material, reducing blockages and downtime. By enabling higher mill output and optimising overall mill performance, grinding aids contribute to cost savings, increased productivity, and improve product quality in the cement manufacturing process.

Can you discuss any recent innovations or improvements in grinding technology that have been implemented in your plant?
UCWL has recently implemented several innovations and improvements in grinding technology to enhance efficiency and productivity. Key among these is the integration of SMARTA and RAMCO systems for the automation of grinding systems. The SMARTA system optimises the grinding process parameters through advanced analytics and real-time monitoring, leading to significant energy savings and improved product quality. Meanwhile, the RAMCO system provides comprehensive automation, ensuring consistent control over the grinding operations and reducing the likelihood of human error. These systems enable better predictive maintenance, minimising downtime and extending the lifespan of grinding equipment. By adopting these cutting-edge technologies, UCWL has not only improved operational efficiency but also maintained high standards of product quality, positioning itself at the forefront of the cement manufacturing industry.

How do you ensure that your grinding equipment is energy-efficient and environmentally sustainable?
At UCWL, energy efficiency and environmental sustainability are achieved through several strategic measures. The use of energy-efficient equipment, such as Vertical Roller Mills (VRM), reduces energy consumption significantly compared to traditional ball mills. Advanced control systems like SMARTA and RAMCO optimise grinding parameters and provide real-time monitoring to enhance efficiency and product quality. Regular and predictive maintenance schedules ensure that equipment operates at peak performance, minimising downtime and extending lifespan. Additionally, energy management systems, including regular audits and continuous monitoring, help identify and address inefficiencies. UCWL also employs emission control technologies to minimise environmental impact, complying with regulations and promoting sustainable practices such as using alternative fuels, recycling waste products, and reducing the carbon footprint. These comprehensive efforts ensure that UCWL’s grinding operations are both energy-efficient and environmentally sustainable.

What role does R&D play in optimising your grinding processes and the selection of grinding aids?
Research and Development (R&D) at UCWL plays a pivotal role in optimising grinding processes and selecting effective grinding aids. Our R&D team focuses on process optimisation by exploring new methods to improve early strength and reduce energy consumption.
The UCWL team conducted approximately 80 to 90 R&D trials with various grinding aids to identify the most suitable formulations. These extensive trials helped in understanding the impact of different additives on grinding efficiency and product quality. Moreover, UCWL developed an in-house grinding aid, which, after successful plant-scale trials, resulted in a 2 mpa increase in initial strength and a 5 per cent increase in mill output. This in-house solution demonstrates the significant contributions of R&D in enhancing grinding performance, improving product quality, and achieving cost efficiency. Through continuous innovation and rigorous testing, R&D ensures that UCWL remains at the forefront of technological advancements in the cement industry.
Innovative technologies, such as advanced control systems, control charts and real-time monitoring tools, are developed and integrated to ensure consistent quality. Continuous improvement initiatives ensure ongoing optimisation, integrating feedback from production and quality control teams to address emerging challenges. Through these comprehensive efforts, R&D at UCWL ensures efficient, high-quality and sustainable grinding operations.

Can you share any specific examples or case studies where improvements in the grinding process have significantly benefited your plant’s performance?
The implementation of grinding aids at UCWL has led to significant improvements in the consumption of fly ash in Portland Pozzolana cement (PPC)
and a reduction in power consumption over the past four fiscal years. The data below illustrates these improvements:
Fly ash consumption (percentage):

  • FY 2020-21: 25.9 per cent
  • FY 2021-22: 27.7 per cent
  • FY 2022-23: 30.9 per cent
  • FY 2023-24: 32.5 per cent

Power consumption (kWh/MT):

  • FY 2020-21: 31.2 kWh/MT
  • FY 2021-22: 30.6 kWh/MT
  • FY 2022-23: 28.2 kWh/MT
  • FY 2023-24: 26.5 kWh/MT

By using grinding aids, UCWL has managed to increase the fly ash content in PPC from 25.9 per cent in FY 2020-21 to 32.5 per cent in FY 2023-24. This increase in fly ash usage not only improves the sustainability of the cement by utilising more industrial by-products but also enhances the overall performance of the cement. Concurrently, power consumption has decreased from 31.2 kWh/MT to 26.5 kWh/MT over the same period, demonstrating the effectiveness of grinding aids in reducing energy requirements and operational costs. These improvements highlight the critical role of grinding aids in optimising the grinding process, contributing to both economic and environmental benefits at UCWL.

What trends or advancements in grinding processes and grinding aids do you foresee impacting the cement manufacturing industry in the near future?
In the near future, the cement manufacturing industry is expected to be significantly impacted by several trends and advancements in grinding processes and grinding aids. Advanced grinding technologies, such as high-efficiency vertical roller mills (VRMs) and high-pressure grinding rolls (HPGRs), are enhancing energy efficiency and grinding performance.
Innovations in grinding aids are focusing on novel chemical additives and sustainable options that reduce energy consumption and environmental impact. Automation and digitalisation are driving improvements through real-time process optimisation and predictive maintenance, leading to better efficiency and reduced downtime.
Additionally, energy efficiency is being addressed through waste heat recovery systems and more energy-efficient equipment. The use of alternative materials and additives, along with a strong emphasis on reducing the carbon footprint, is also shaping the future of cement manufacturing. These advancements collectively aim to improve operational efficiency, lower costs and promote environmental sustainability in the industry.

Concrete

Adani’s Strategic Emergence in India’s Cement Landscape

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Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.

India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.

Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:

  • September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
  • December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
  • August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
  • April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
  • Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
  • Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
  • Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
  • Orient Cement: It would serve as a principal manufacturing facility following the merger.

Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:

  • By FY 2026: Reach 118 MTPA
  • By FY 2028: Target 140 MTPA

These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).

Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.

Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.

Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.

Challenges potentially include:

  • Integration challenges across systems, corporate cultures, and plant operations
  • Regulatory sanctions for pending mergers and new capacity additions
  • Environmental clearances in environmentally sensitive areas and debt management with input price volatility

When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.

Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.

About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.

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Concrete

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

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PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.

Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

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Concrete

Driving Measurable Gains

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Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.

Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.

Beyond energy efficiency, the retrofit significantly improved operational parameters:

  • Lower thermal stress on equipment
  • Extended lubricant drain intervals
  • Reduction in CO2 emissions and operational costs

These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.

Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:

  • Enhanced component protection
  • Extended oil life under high loads
  • Stable performance across fluctuating temperatures

By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.

Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.

A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

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