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Our data-driven approach optimises processes

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Tarun Mishra, Founder and CEO, Covacsis Technologies, speaks about how IoT and Industry 4.0 principles are revolutionising the cement industry, enhancing both operational and financial efficiency.

Covacsis Technologies has made significant strides in optimising operational and financial efficiency in real time. Can you provide an overview of how your technology framework integrates IoT and Industry 4.0 principles to achieve this?
Manufacturing shop floor will be more and more algorithm driven. In the time to come, the share of mainstream software technology will grow disproportionally in the machine. Covacsis Technologies has transformed operational and financial efficiency in the cement industry by integrating IoT and Industry 4.0 principles into our technology framework. Our approach leverages IoT devices to gather comprehensive data from various stages of cement production, which is then analysed using advanced data analytics and machine learning algorithms to deliver real-time insights and predictive analytics.

Key elements of our technology framework for the cement industry include:

  • Plug-and-play solution: Our system is designed for seamless integration and rapid deployment, often within three weeks, making it adaptable to various manufacturing environments.
  • Controller-agnostic data collection: IoT devices capture data from multiple sources within the cement manufacturing process, including temperature, pressure and flow metrics.
  • Advanced data analytics: Our framework processes collected data using sophisticated analytics and machine learning algorithms to enhance operational efficiency and predict maintenance needs.
  • Real-time insights: Continuous monitoring and analysis provide immediate insights, enabling swift adjustments to optimise performance and minimise downtime.
  • Key KPIs: We focus on key performance indicators such as overall equipment effectiveness (OEE), energy consumption and production rates, specifically tailored to the cement industry’s needs.

By applying these principles, Covacsis Technologies enables the cement industry to operate with greater agility, efficiency, and sustainability, driving significant improvements in operational and financial performance. Our data-driven approach optimises processes and make them future-ready.

How does Covacsis tailor its advanced analytics suite specifically for the cement industry, and what unique challenges in this sector does your technology address?
Covacsis has a farm of algorithms developed for end-to-end cement industry value stream from mines to dispatch. For example, mining operations have different operational challenges compared to kiln operation or mills operation. Covacsis’ IPF has hundreds of algorithms developed for mining, milling, kiln (dry vs wet process), bagging and despatch to address hyper local challenges related to productivity, quality, cost, safety and ESG.
Here are some of the illustrative use cases of Covacsis Intelligent plant framework in the
cement industry:

  • Grade-wise performance: IPF provides real-time comparisons of key performance indicators
    (KPIs) and asset performance during the manufacture of different cement grades using the same equipment. This helps in understanding and optimising performance across various
    product lines.
  • Specific power consumption breakdown: IPF integrates with energy management systems (EMS) to provide a detailed breakdown of power consumption by different drives and motors. It uses a root cause analysis (RCA) approach to identify which circuits or motors are consuming excess power and the reasons behind it. This insight helps in reducing overall power consumption and optimising energy efficiency.

Further to that Covacsis IPF offers a macro layer of algorithms, which cuts across the equipment and processes to analyse how kiln operation is likely to affect cement mills operational efficiencies or how change in C3S percentage will affect specific coal consumption of the kiln operation. In case of large enterprises with multiple plants spread across geographies, Covacsis Enterprise algorithms help management to see live heat maps of productivity, quality, cost, safety and ESG performances of individual plants in their supply chain network.

Your analytics suite offers dynamic decision-making capabilities in real time. Can you share examples of how this has improved operational efficiency in cement manufacturing plants?
Example1: Usually in the cement industry an hourly or two hourly sample of clinker is taken to the lab for multiple tests. Lab takes a couple of hours to publish the results. Between sample and test results there is a gap of 2-3 hours. If there were any abnormalities, let’s say a change in C3S percentage, in the sample can be acted upon only after test results are published.
Covacsis’ IPF algorithm will forecast C3S in real time and in case of any sensed abnormalities it will do detailed RCA to identify the variables which are potentially affecting C3S percentage negatively. This RCA is done by algorithm in real time and shared with process, quality and other stakeholders automatically to bring their attention to the ongoing or potential abnormalities. Such real time analysis helps the team to take immediate action rather than taking action after three hours.
Example 2: How the motor RPM, pressure difference in a vertical mill, table revolution speed and temperature difference together are affecting the fineness of the cement in a VRM. Covacsis has an off the shelf algorithm to do so for individual products such as OPC43, OPC53, PPC, etc.

Some of the other examples are listed below:
Real-time root cause analysis (RCA) and KPI computation:

  • Provides detailed insights into power consumption across different lines, products and operators.
  • Enables targeted actions to optimise energy usage.

A. Fuel savings/quality improvement: Real-time interventions in coal feed and monitoring of clinker quality parameters like C3S lead to substantial energy savings, typically ranging from 5-10 per cent.
B. Efficiency tracking of waste heat recovery systems (WHRS): Continuously monitors
the efficiency of WHRS, optimising energy recovery processes.
C. Alternative fuel and raw (AFR) material utilisation: Tracks and assesses the benefits of AFR usage, contributing to operational excellence and sustainability.

What are the key steps involved in implementing Covacsis’ technology in a cement factory? How do you ensure seamless integration with existing systems and processes?
Covacsis’ Intelligent Plant Framework (IPF) is a plug and play solution with advanced analytics capabilities. The vision is to create an agile, efficient and environmentally responsible manufacturing operation by leveraging the power of collaboration and data analytics. Below are the steps involved in implementing Covacsis’ IPF on the plant shop floor:

Site visit and kick-off meeting

  • Covacsis delivery team including the project manager, technical and functional expert plan a thorough study of the plant to understand the condition.
  • Post this Covacsis team plans a project kick off meeting with the relevant stakeholder to share a detailed project plan with timelines.

Real time data acquisition

  • Covacsis has indigenous library of more than ‘100’ drivers covering more than 97 per cent
    of Industrial control systems and its data acquisition capabilities covers non-standard controllers
    and protocols 100 per cent drivers are plug and play
  • Less than 2 hours to acquire data from a machine
  • The technical team maps out the data sources at the plant and established a connection with Covacsis edge gateway called LIU i.e. Local Interpreting Unit Real time data analytics
  • Covacsis’ functional experts maps out the requirement of the client for performing the real time analytics
  • Once the real time data starts flowing the Covacsis has industry wise pre-boxed analysis and KPI readily available that shall be customised according to users needs
  • It is inclusive of plug and play KPI and analysis around productivity, quality and cost
  • It takes less than 5 mins to configure a new KPI
  • IPF solution is inclusive of customisable stakeholder wise dashboard, report, alerts and notification
  • User has access to various trends, charts, six sigma analysis and compare engine to generate insights from the data

Post go-live support

  • Covacsis provides an ongoing support to the client Advanced analytics
  • Once the real-time data is visible, as a next step Covacsis involves senior consultants and industry experts to drive improvements and optimisations for key use cases.

AI and ML modelling
Based on the data analytics Covacsis also works on building AI use cases targeting the client needs. A few use cases encountered in the cement industry are:

  • Kiln efficiency prediction
  • Kiln breakdown forecasting
  • Coal mix optimiser

By following these steps, Covacsis ensures a seamless integration of their technology, enhancing the overall efficiency and productivity of cement manufacturing plants.

Machine learning and big data play crucial roles in your technology framework. How do these technologies enhance predictive maintenance and optimise production processes in the cement industry?
Data plays the most important role in any algorithm. Big data and fast data are only adding to the logistics performance of any algorithm and platform. Covacsis is a decade old and most mature platform in the world. Covacsis’ SaaS infrastructure is already handling more than 350 billion of cement process and operation data on a daily basis with a compounding daily growth rate of 1 per cent. This provides a significant advantage to Covacsis towards building algorithms and ensuring the value efficacy of these algorithms for the industry. This unparalleled capacity of Covacsis has encouraged multiple OEMs and cement plants to partner with them and realise the success in the quickest possible time without any gestation period.

What are some common challenges you encounter when digitising cement manufacturing operations, and how does Covacsis address these challenges?
Digitising cement manufacturing operations presents several common challenges. Covacsis addresses these challenges through innovative solutions and integrated technologies.

Here are the key challenges and how Covacsis tackles them:
Manual data and data present in different systems:
Challenge: Data spread across systems like DCS, EMS, LIMS, ERP and SAP makes it hard to consolidate and analyse.
Solution: Covacsis’ IOT solution LIUTM has got in-built capability to source data from all possible sources such as DCS, LIMS, Historians, ERP etc and bring it to one unified platform. The platform can also be integrated with energy meters or existing EMS systems as per applicability. Covacsis’ platform offers off-the-shelf digital logbooks to replace manual logbooks with 100 per cent digital logbooks. Covacsis guarantees that all types of data from disparate sources are captured in real time with zero or minimalistic manual intervention.
As per various global reports many digital projects globally are yielding low return because of ineffective IOT data layer. Covacsis on the contrary delivers zero risk to the project through its effective design and mature product spanned over decades and guarantees ROI.

Detrimental cost towards deploying sensors in the value stream
Challenge: Installing physical sensors throughout the plant can be expensive, time-consuming and reason for suboptimal ROI.
Solution: Covacsis employs soft sensors as preference to the hard sensors wherever applicable. These soft sensors are algorithms that use existing data sets in the plants to compute specific conditions and measurements. This reduces the need for additional hardware, cutting costs and simplifying implementation leading to high ROI.
Collaboration among different departments
Challenge: Siloed data and departmental operation practices can hinder effective communication and collaboration between departments
Solution: Covacsis’ IPF platform provides multiple perspectives about an event to different departments and its users in real time. Users across different departments and roles can do collaborative analysis and RCA of an event to make an appropriate decision. For example, how a certain coal mix is affecting the kiln zone temperature leading to quality of the clinker coupled with increased specific energy consumption.
This same incident may be of interest to the quality, production, energy and costing team. Covacsis provides corresponding analytics, a dashboard based on the departmental KPIs and specific analysis. These stakeholders then collaborate and brainstorm to find a common solution and have better alignment. Such collaboration in real time increases the plant efficiency significantly.

Inter plant performance benchmarking in case of similar assets and similar process
Challenge: Different plant data reside within the wall of individual plants. Comparing macroeconomic performance across plants is impossible.
Solution: Covacsis’ IPF is designed to aggregate multiple plant’s data at unified enterprise datalike (historian), which then further used for relative baselining and relative performance analysis across same and similar asset base or product or processes.

Digital upskilling and change management
Challenge: It’s not natural for a plant operation team to get in the groove of the digital mindset
quickly leading to very slow adoption with compromised ROI.
Solution: Covacsis’ lab offers a focused change intervention to ensure effective adoption in the fastest possible manner. A series of training workshops and programmes are organised to help staff transition to digital workflows, focusing on areas like real-time monitoring, energy management and predictive maintenance.

How do you envision the future of digitalisation in the cement industry?
What new technologies or advancements do you think will become integral to cement manufacturing?
The future of digitalisation in the cement industry is poised to revolutionise various aspects of production, significantly enhancing efficiency and sustainability.
Key advancements we foresee include:

Decarbonisation:

  • Digital technologies will play a crucial role in reducing carbon emissions throughout the production process. Advanced analytics and AI will help optimise processes, ensuring minimal CO2 output.
  • Implementing carbon capture and storage (CCS) technologies, integrated with real-time monitoring systems, will enable plants to manage and reduce their carbon footprint more effectively.

Power consumption:

  • The use of IoT sensors and AI-driven analytics will allow for more precise control of power usage, leading to significant energy savings.
  • Smart grids and renewable energy sources will become more prevalent, with digital systems managing energy flow to maximise efficiency and sustainability.

Effective use of alternative fuels and raw materials (AFR):

  • Digital tools will enhance the utilisation of alternative fuels and raw materials, ensuring optimal blending and maintaining high-quality cement production.
  • Predictive maintenance and real-time monitoring will reduce downtime and improve the overall efficiency of using AFR.

Economy & Market

The Road Ahead Begins Here

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The future of India’s roads took centrestage at RAHSTA Expo 2026, where policymakers, contractors and industry leaders came together under one roof. The event blended thought leadership, technology showcase and industry recognition into a single powerful platform.

India’s roads and highways community gathered in full strength at the Jio World Convention Centre, Mumbai, for the 16th edition of the RAHSTA Expo (Roads and Highways Sustainable Technologies & Advancement). Over two action-packed days, the event brought together policymakers, contractors, consultants, developers, equipment manufacturers, material suppliers, technology providers and investors to deliberate on the future of India’s ,infrastructure while showcasing the latest innovations driving the sector.

The event culminated in the prestigious RAHSTA Awards, where Shri. Ajay Tamta, Union Minister of State for Road Transport & Highways, felicitated organisations and professionals for their outstanding contributions to road construction, engineering, safety, sustainability and technology. With leading contractors, senior government officials, industry veterans and technology providers under one roof, the event reaffirmed RAHSTA’s position as one of India’s most influential platforms for the roads, highways, bridges and tunnels ecosystem.

Organised by FIRST Construction Council in association with ASAPP Info Global Group, RAHSTA has steadily evolved beyond an exhibition into a platform where policy, technology, engineering and business converge to address the opportunities and challenges shaping India’s next generation of transport infrastructure.

Beyond expansion, towards value

The conference opened with a thought-provoking address by Pratap Padode, Founder and Editor-in-Chief, Construction World, who observed that India’s highways sector has reached an important inflection point. Introducing this year’s theme – ‘From Expansion to Value: The Next Phase of India’s Highways’ – he noted that while the country has successfully expanded its road network over the past two decades, the industry’s priorities are now shifting towards building infrastructure that delivers greater lifecycle value, durability, safety and operational efficiency. With funding pressures, asset monetisation and evolving project models changing the sector’s dynamics, he said the focus must now move beyond kilometres constructed to the quality and long-term performance of every asset.

Dr Brijesh Dixit, Managing Director, Maharashtra State Infrastructure Development Corporation (MSIDC), reminded delegates that successful infrastructure delivery is ultimately a collective effort. Emphasising on collaboration between government, industry and engineering professionals, he remarked, “There is no loser in a winning team, and there is no winner in a losing team,” urging stakeholders to work together to deliver projects with quality, financial sustainability and technological excellence.

Delivering the keynote address, Bidur Kant Jha, Director, New Technologies for Highway Development, Ministry of Road Transport & Highways (MoRTH), outlined the Government’s long-term vision for India’s highway network. Highlighting the country’s 6.26 million km roads network, he spoke about the growing adoption of digital planning tools such as BIM and GIS, bridge health monitoring systems and Integrated Smart Transport Corridors under the Vision 2047 roadmap. He emphasised that while India remains open to global innovations, every new technology must be adapted to Indian conditions before large-scale deployment.

Addressing the gathering during the awards ceremony, Tamta underlined the increasing role of specialised equipment and modern construction technologies in executing complex infrastructure projects across diverse terrains. Referring to challenging tunnel projects in Uttarakhand, he noted how advanced machinery has transformed execution capabilities, while also acknowledging the rapid evolution of Indian contractors into globally competitive infrastructure companies. Recognising excellence through industry awards, he said, motivates organisations to continually raise performance standards and embrace innovation.

Meanwhile, Dr Sanjay Mukherjee, IAS, Metropolitan Commissioner, MMRDA, highlighted that infrastructure development must increasingly focus on integrated urban mobility. Reflecting on Mumbai’s engineering journey – from its historic underground utility network to the Coastal Road and other transformative projects – he underlined that future infrastructure planning must seamlessly integrate roads, metro systems and public transport to create efficient, multimodal cities.

Uttar Pradesh takes centrestage

One of the highlights of the second day was Uttar Pradesh’s comprehensive presentation on its infrastructure-led industrial transformation.

Srihari Pratap Shahi, IAS, Additional CEO, Uttar Pradesh Expressways Industrial Development Authority (UPEIDA), demonstrated how the state’s expanding expressway network is evolving into a catalyst for industrial development through integrated manufacturing and logistics clusters. Expressways, he noted, are no longer merely transport corridors but engines of economic competitiveness.

Building on this narrative, Deeksha Jain, IAS, Additional Chief Executive Officer, Uttar Pradesh State Industrial Development Authority (UPSIDA), showcased the state’s rapidly expanding industrial ecosystem supported by extensive expressway connectivity, dedicated freight corridors, airports, industrial townships and investor-friendly policies. She highlighted Uttar Pradesh’s strong manufacturing growth, expanding industrial land bank, plug-and-play infrastructure and increasing use of digital governance to facilitate investments.

Further underlining the significance of the platform, Deepak Kumar, IAS, Infrastructure & Industrial Development Commissioner, Government of Uttar Pradesh, remarked, “RAHSTA provides an excellent platform for states to showcase our infrastructure progress and investment ecosystem. Uttar Pradesh has transformed significantly over the past decade, backed by more than 34 investor-friendly industrial policies, and platforms like RAHSTA help communicate these developments to industry stakeholders from across the country.”

Ideas that shaped the industry conversation

The two-day conference featured seven panel discussions, each examining a critical dimension of India’s evolving roads and highways sector.

The opening discussion on ‘Financing Roads & Highways in a Capital-Constrained Era’ brought together experts from Cube Highways, NIIF, SBI Capital Markets, Centrum Capital and Bandhan Infra Fund, who examined how the financing landscape is changing. Discussions revolved around asset monetisation, InvITs, institutional investments and new funding structures, with panellists agreeing that better project preparation, transparent governance and predictable returns will be crucial for attracting long-term capital into infrastructure.

Attention then shifted to execution realities during the panel on ‘Contractors’ Perspective: Execution Realities, Risks & the Quality Imperative.’ Representatives from GHV Infra Projects, PNC Infratech, NCC and Maccaferri candidly discussed the challenges of delivering projects amid contractual complexities, land acquisition delays, rising costs and tight timelines. While execution pressures remain significant, the discussion reinforced that better collaboration across the project value chain is essential for achieving both speed and quality.

Day 2 opened with a technically rich discussion on ‘Designing Roads for Sustainability, Durability & Climate Resilience’. Experts from CSIR-CRRI, IIT Bombay, IIT Madras, Zydex Group and SRMB Steel explored advanced pavement technologies, recycled materials, climate-resilient designs and scientific construction practices that can significantly improve durability while lowering lifecycle costs. Sustainability, they agreed, must become an integral part of road design rather than an afterthought.

The subsequent session on ‘Bridges & Tunnels: Complex Engineering, Safety & Future Readiness’ highlighted the growing complexity of India’s infrastructure projects. Panellists discussed advances in structural engineering, digital monitoring, risk management and safety practices that are enabling the successful delivery of increasingly ambitious bridge and tunnel projects across the country.

Technology remained a recurring theme during the discussion on ‘Technology as a Risk-Mitigation Tool for Developers & Investors’. Experts explained how AI, BIM, drones, predictive analytics, digital twins and intelligent monitoring systems are helping improve project planning, minimise execution risks, strengthen quality assurance and enhance asset management throughout the infrastructure lifecycle.

The construction equipment panel brought together leading industry experts to examine how technology, sustainability and digitalisation are redefining construction equipment in an era of rising cost pressures. Discussions centred on enhancing productivity, reducing lifecycle costs and preparing the industry for India’s infrastructure ambitions leading up to 2047.

The conference concluded with an engaging CXO Forum on ‘Rebuilding Confidence in India’s Roads & Highways Sector’, where senior industry leaders emphasised that stronger governance, better project preparation, digitalisation, transparent contracting and closer public-private collaboration will be essential to sustain India’s infrastructure growth over the coming decades.

Technology and recognition under one roof

Beyond the conference halls, RAHSTA Expo reflected the technological transformation underway across India’s road infrastructure ecosystem. Leading equipment manufacturers, technology companies and material suppliers showcased advanced construction equipment, intelligent digital platforms, pavement technologies, structural materials and productivity-enhancing solutions designed to improve project efficiency and asset performance. The exhibition created valuable opportunities for contractors, consultants, government agencies and project developers to evaluate new technologies while interacting directly with solution providers.

The event also served as a celebration of excellence through the RAHSTA Awards 2026, which recognised outstanding achievements across road construction, contracting, materials, equipment, technology, safety, sustainability and infrastructure development. Presented by Minister Tamta, the awards honoured organisations that are setting new benchmarks for quality, innovation and execution across India’s roads sector.

RAHSTA Expo 2026 also received extensive support from across the infrastructure ecosystem. Alongside leading corporate sponsors, the event was backed by industry bodies including the Builders Association of India (BAI), Construction Equipment Rental Association (CERA), Consulting Engineers Association of India (CEAI), International Road Federation (IRF), CSIR-CRRI, CILT India, All India Transporters Welfare Association, Hydraulic Trailer Owners Association (HTOA), Gujarat Contractors Association, Bitumen Forum, Fluid Power Society of India, Indian Institute of Material Management, Ministry of Ports, Shipping and Waterways, Gati Shakti Vishwavidyalaya and Mumbai First, reflecting the industry’s collective commitment to advancing India’s road infrastructure.

As the curtains came down on the two-day event, one message resonated throughout the conference: India’s highways story is entering a new chapter. While expansion will continue, the future will increasingly be defined by smarter planning, stronger partnerships, digital transformation, sustainable engineering and long-term value creation. By bringing together the entire infrastructure value chain on a single platform, RAHSTA Expo 2026 once again demonstrated why it has become one of the country’s most influential forums for shaping the future of roads, highways, bridges and tunnels.

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Economy & Market

Fornnax Names Lukas Baur as Authorised Service Partner to Bolster EU Operations

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Strapline: Fornnax Technology has appointed NOBA Maschinenservice’s Lukas Baur as its authorised service partner for the European Union, strengthening its commitment to delivering fast, reliable, and localised after-sales support across the region.

Fornnax Technology, a leading manufacturer of industrial shredding solutions, has announced the appointment of Mr. Lukas Baur of NOBA Maschinenservice as its authorised service partner for the European Union. The partnership, formalised under the authorisation of Fornnax CEO Mr. Jignesh Kundaria, reinforces the company’s commitment to providing dependable, localised service support to its expanding customer base across Europe.

Strengthening Service Through Proven Expertise

With over two decades of experience in servicing, maintaining, and overhauling industrial shredders, Mr. Baur brings extensive technical expertise to the partnership. His capabilities span welding, hardfacing, shaft and knife rebuilding, complex assembly, hydraulics, and complete electrical engineering services, delivered in collaboration with a trusted partner company based in Halle/Saale.

Operating from Worbis, Germany, Mr. Baur is strategically positioned to provide emergency support across the European Union within 24 hours, covering an operational radius of approximately 1,000 kilometres.

Supporting this capability is a well-equipped service infrastructure comprising 12 Mercedes Sprinter service vans, a team of 24 skilled technicians, specialised bearing-change tools, a fully equipped hydraulic workshop, and a 1,000-square-metre facility with a five-ton crane track. Together, these resources position his team to manage the complete spectrum of Fornnax’s European service requirements efficiently and reliably.

Partnership Driven by Industry Insight

Having spent years servicing Eldan, Lindner, and Vecoplan shredders across the European recycling industry, Mr. Baur’s decision to collaborate with Fornnax is rooted in his understanding of market needs and customer expectations. His experience has provided valuable insight into what recycling plant operators require—not only from their machinery but also from the service teams supporting them.

According to Mr. Baur, Fornnax’s reputation for robust machine construction, superior wear protection, and maintenance-friendly design made the partnership a natural fit.

The collaboration comes at a time when Europe’s tyre recycling industry is facing mounting challenges, including rising cost pressures, shrinking margins, delayed investments, and a shortage of skilled labour. Mr. Baur believes these conditions reinforce the need for technically strong service partners capable of delivering rapid, dependable support.

Commenting on the partnership, he said, “Fornnax, with its exceptional price-performance ratio and superior quality, has the potential to become a market leader in Europe. We would like to be their service partner in this journey.”

Comprehensive Support Across the Equipment Lifecycle

As Fornnax’s authorised service partner, Mr. Baur will oversee the complete lifecycle support of the company’s equipment throughout the European Union. His responsibilities will include installation, commissioning, preventive maintenance, emergency repairs, and spare parts support across mechanical, hydraulic, and electrical systems.

Looking ahead, he also plans to develop a centralised spare parts distribution hub for European customers, particularly if Fornnax establishes a warehouse facility in Worbis to facilitate faster deliveries. To further strengthen service coverage, Mr. Baur intends to expand operations by adding two to three additional service teams and vehicles each year, progressively increasing capacity across the continent.

A Shared Commitment to Customer Excellence

Highlighting the strategic importance of the partnership, Mr. Jignesh Kundaria, Director and CEO of Fornnax, said:

“We strongly believe that by continuously improving our service quality and customer satisfaction index, we can build long-term relationships with our customers. Higher customer satisfaction leads to greater trust, which significantly increases repeat orders and ultimately drives sustained growth in our sales revenue.”

This customer-first philosophy underpins Fornnax’s strategy of building a dedicated European service partner network instead of relying solely on remote support. With Mr. Baur joining this network, customers across the European Union will benefit from faster response times, expert technical assistance, and dedicated on-ground support from a partner with extensive experience in high-throughput shredding operations.

Mr. Baur’s appointment also reflects Fornnax’s broader ambition to establish itself as the preferred shredding solutions provider for the European recycling industry, marking another important milestone in the company’s international growth strategy.

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Concrete

Nuvoco Vistas launches Limla cement plant, expands Gujarat footprint

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Nuvoco Vistas opens a 2 MMTPA grinding unit at Limla, entering Gujarat and advancing its target of 35 MMTPA capacity by FY 2028.

Surat (Gujarat)

Nuvoco Vistas Corporation Ltd, a part of Nirma Group and one of India’s leading building materials company, has inaugurated the Limla Cement Plant in Surat (Gujarat), one of Vadraj Cement Limited’s (VCL) principal manufacturing facilities. The commissioning represents a key milestone in Nuvoco’s acquisition and restoration of VCL, while supporting the company’s expansion across the Western Indian cement market.

Vadraj Cement Limited is a subsidiary of Nuvoco Vistas Corporation Limited and has installed cement capacity of 6 MMTPA across its assets. The Limla inauguration therefore represents the first operational step in the acquired platform’s wider revival, while the Kutch facilities provide clinker supply, mineral security and coastal logistics support for the western business.

Nuvoco completed its acquisition of Vadraj Cement Limited, then under the Corporate Insolvency Resolution Process, after paying a consideration of Rs 1,800 crore in June 2025. VCL’s asset portfolio comprises a clinker unit at Kutch and a grinding unit at Limla in Surat. It also includes high-quality captive limestone reserves and a captive jetty at Kutch, supporting more efficient logistics. Following the takeover, Nuvoco began an extensive programme of restoration, refurbishment and expansion at both locations, leading to the commissioning of the Limla plant.

The Limla Cement Plant is expected to support a phased increase in sales volumes across Gujarat. It will also help Nuvoco supply neighbouring markets in Western Maharashtra and release cement capacity from its northern plants, which can consequently be redirected towards markets in North India. The plant will manufacture a full portfolio comprising Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. It will additionally produce the complete Nuvoco Duraguard range, including the premium Nuvoco Duraguard Microfibre product. The acquisition is also expected to generate operational synergies with Nuvoco’s existing plants at Nimbol and Chittorgarh in Rajasthan, improving logistics optimisation and market reach across important regional markets.

The grinding unit at the Limla Cement Plant was completed ahead of schedule, with 2 MMTPA of capacity now inaugurated to expand Nuvoco’s operating scale and customer reach. After Vadraj Cement’s assets become fully operational, plants in North and West India are expected to account for nearly 40 per cent of Nuvoco’s total cement capacity. This will broaden the company’s manufacturing network, strengthen access to high-growth markets and support its plan to increase consolidated cement capacity to 35 MMTPA by FY 2028, reinforcing its longer-term growth strategy.

Commenting on the development, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said: “The inauguration of the Limla Grinding Unit in Surat is an important milestone in Nuvoco’s growth journey and demonstrates our commitment to disciplined, value-accretive expansion. Gujarat is strategically significant for Nuvoco, with substantial opportunities arising from infrastructure investment, industrial growth, rapid urbanisation and continuing demand from the housing and construction sectors. The facility strengthens our regional footprint, improves operational flexibility and increases our ability to serve customers across northern and western markets with greater reliability and efficiency.”

He added: “Through the Vadraj acquisition, we have refurbished and restarted a strategically important asset, returning it to operations in record time through strong execution and collaboration between teams. The achievement demonstrates our ability to create value from acquired assets, fulfil our commitments and retain the confidence of stakeholders. It also highlights the strength of our project delivery capabilities and our continued focus on building sustainable, profitable growth over the long term.”

Nuvoco Vistas Corporation Limited is a building materials company whose vision is to build a safer, smarter and more sustainable world. It is among the leading players in East India and has a significant presence across North and West India. Nuvoco began operations in 2014 with a greenfield cement plant at Nimbol, Rajasthan. It later acquired Lafarge India Limited, which had entered India in 1999, followed by Emami Cement Limited in 2020 and Vadraj Cement Limited in April 2025. The company has also announced an expansion in eastern India through a new grinding mill at the Arasmeta Cement Plant, supported by several debottlenecking programmes involving equipment upgrades, process improvements and internal capacity initiatives. These developments place Nuvoco on track to achieve total cement capacity of approximately 35 MMTPA. The company reported total income of Rs 11,362 crore in FY 2025-26, reflecting its continuing growth trajectory.

Nuvoco operates a diversified portfolio across three segments: Cement, Ready-Mix Concrete and Modern Building Materials. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem, covering Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. Its pan-India RMX business provides value-added products under Concreto for performance concrete, Artiste for decorative concrete, InstaMix for ready-to-use bagged concrete, X-Con covering M20 to M60 grades, and Ecodure for specialised green concrete. Nuvoco has supplied materials to projects including the Mumbai-Ahmedabad Bullet Train, Birsa Munda Hockey Stadium in Rourkela, Aquatic Gallery at Science City in Ahmedabad, and metro railway projects in Delhi, Jaipur, Noida and Mumbai.

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