Economy & Market
Predictive maintenance is a top priority in industrial IoT
Published
2 years agoon
By
Roshna
Kapil Agarwal, Senior Vice President and Local Division Manager, Process Industries, ABB India, discusses how advanced digital solutions are revolutionising the cement industry by enhancing operational efficiency, reliability, and sustainability.
How does ABB Ability™ Knowledge Manager help cement plants connect business KPIs to operations and optimise their performance?
ABB Ability™ Knowledge Manager (KM) is a true manufacturing operations management solution which, in a single platform, integrates data from operational, control, production, quality, downtime and business systems and converts data into actionable information.
At its core, ABB Ability™ Knowledge Manager offers industry-specific process and quality data warehousing, presenting information in a meaningful way. This single, powerful tool meets various needs: production information and downtime management, production scheduling, energy cost tracking and benchmarking, plant emissions monitoring and alarm analytics. Its user-friendly and intuitive statistical analysis tools boost both production and quality.
Statistical production analysis offers powerful tools to monitor quality-related process variables effectively. It helps verify if these variables are randomly scattered around the mean and normally distributed, and it detects variability and process changes to prevent instability. Some key tools we use include X charts (Shewhart), EWMA charts, CUSUM charts, histograms, and multivariable X-Y correlation graphs.
To enhance transparency across a plant or fleet of plants, our KM is available via a mobile app for smartphones and tablets. This allows plant and company managers to view operational performance anytime, anywhere. ABB Ability™ KM is highly scalable to meet customer needs, with flexibility for plant-level, regional, and enterprise-level deployment. It helps cement customers track processes, quality, operations, emissions, and downtime using standardised custom templates, IoT connectors and seamless ERP integration, all backed by excellent security policies.
How does ABB’s shift from reactive to predictive maintenance impact the operational efficiency and reliability of cement plants?
Predictive maintenance is a top priority in industrial IoT because it combines data, domain expertise, IoT platforms and AI. This combination allows manufacturers to predict anomalies in their plants. I believe, by using a modern asset optimisation system, cement manufacturers can shift from reactive to predictive maintenance strategies, avoiding unnecessary maintenance and reducing operating costs. This is achieved through the vast amount of data generated by smart devices connected in the plant, such as motor control centers, numerical relays, smart transmitters, and various asset models for motors, transformers, grinding circuits and conveyors.
ABB Ability™ Predictive Maintenance service leverages digital applications for quick detection of impending issues, root-cause analysis with recommendations, and assessment of severity levels and health indexes. It offers ready-to-use standard models that are easy to deploy and scale, helping to identify active conditions, assess health with severity and ensure easy deployment.
What are the key features of ABB’s AI-based Asset Performance Management (APM) suite, and how does it enhance asset optimisation in cement plants?
Predictive asset models can help cement plants operate with fewer workers, and to manage operations remotely. An APM solution, powered by predictive asset models, would give the remote teams full visibility into data that would tell them the health of all the assets in the plant. Think of AI-enabled APM as the most cost-effective way to extend the life of the aging (and newer) assets, to decide on the optimal timing for scheduled maintenance turnarounds (one of the biggest costs in a plant) and plan better. The new AI-based APM helps develop models, algorithms, dashboards and reports using a maintenance-oriented platform. It integrates with enterprise-level systems and evolves into digital strategic asset management. This makes transitioning from predictive to prescriptive maintenance and management possible.
ABB was approached by one of Asia’s largest manufacturers of grey cement, ready mix concrete and white cement. The customer has 19 integrated plants, one clinkerisation plant, 25 grinding units and seven bulk terminals. Working together with ABB domain experts, the company used maintenance-oriented algorithms that alerted the client to the potential failure of a particular part or electronic device, allowing it to perform predictive rather than reactive maintenance. Combined with a range of other digital solutions, including ABB Ability™ Expert Optimizer and ABB Ability™ Collaborative Operations, the customer was able to achieve ROI in eight months, a reduction in costs by 3-5 per cent and increase in the life cycle of assets. In this way, cement manufacturers can fully utilise the power of digitalisation to reduce energy usage and emissions, paving the way for the smart, sustainable and profitable cement plants of the future
With increasing digitalisation, how does ABB ensure the cybersecurity of cement plant operations and protect against potential cyber threats?
More and more cement producers on the digitalisation path would like to take a more proactive approach to cyber security. ABB’s analytics solutions and services continuously monitor, diagnose and resolve security issues, helping safeguard people, assets and reputation. Because technology and cyber threats can both change unpredictably, the strategy needs to be reviewed periodically, including performing simulations under different circumstances, like a major ransomware incident.
ABB realises that its customers are concerned about protecting against and minimising the risk of a cybersecurity incident. While asset owners have prime responsibility for any incident response procedures, ABB actively monitors for any cybersecurity threats that pose a potential impact to ABB control systems. All in all, ABB is well positioned as a systems integrator – a factor that is foundational to the company’s cybersecurity strategy in the industrial controls arena. There are two aspects to this. The first is that the customer can trust that implementation of a third party solution in ABB’s reference architecture will result in optimal value. The second is that the cement manufacturer can rest assured that if there is a failure or a problem with implementation, it will, in all probability, not impede the availability or safety of assets and will ease their recovery. ABB has been ensuring its customers by following the highest level of security policies during design, development, deployment and communications by adhering to the industry best practices.
– Kanika Mathur
Concrete
Cement Makers Reaffirm Commitment to Sustainable Growth
Published
1 day agoon
June 5, 2026By
admin
World Environment Day spotlight on innovation and circularity
On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.
The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.
“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.
He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.
According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.
Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.
He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.
On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.
Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.
Author: Jignesh Kundaria, Director and CEO, Fornnax Technology
World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.
One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.
India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.
However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.
As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.
At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.
On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.
Concrete
Dalmia Bharat Acquires Jaiprakash Associates Cement Assets for ₹2,850 Crore
Published
2 weeks agoon
May 25, 2026By
admin
Dalmia Cement executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra, to acquire 5.2 MnTPA of cement capacity across Madhya Pradesh and Uttar Pradesh.
Dalmia Cement (Bharat) announced on May 22, 2026 that it had signed a Business Transfer Agreement with Jaiprakash Associates Limited and Adani Infra (India) Limited for the acquisition of cement plants located at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh. The deal was struck at an enterprise value of ₹2,850 crore and is expected to close within two weeks of execution.
The acquired assets from Jaiprakash Associates include 5.2 MnTPA of cement capacity and 3.3 MnTPA of clinker capacity. The package also covers 99 MW of thermal power capacity and railway sidings at Rewa, Chunar, and a common siding at Churk. This infrastructure gives the acquisition immediate operational utility beyond just production tonnage.
The transaction has a long backstory. Dalmia Cement had originally entered into a framework agreement with Jaiprakash Associates in December 2022, covering the sale of these business assets along with a long-term clinker supply arrangement. However, before the deal could be completed, Jaiprakash Associates was admitted to insolvency proceedings under the Insolvency and Bankruptcy Code. The earlier agreements could not be consummated as a result.
In an official statement, Puneet Dalmia, Managing Director & CEO, Dalmia Bharat, said, “I am very excited about addition of these assets in our portfolio. This serves as a great strategic fit for Dalmia. It helps us move forward in our journey to be a pan India player and provide a strong head start to serve the high potential markets in Central region. I am optimistic that the expansion potential of these assets along with close proximity with Dalmia’s captive mines will help us create a capacity hub for the future”.
Following the approval of Adani Group’s resolution plan for Jaiprakash Associates under the IBC framework, Dalmia approached the new management to revive discussions. The fresh Business Transfer Agreement was executed to settle all pending disputes, legal proceedings, and arbitration matters arising from the original framework agreement with Jaiprakash Associates.
Expanding market reach
Dalmia added, “Our familiarity with these assets under the earlier tolling arrangement gives us a deep understanding of the facilities and helps us establish strong connect with channel partners and vendors. We believe that this will help us in faster ramp up of capacities and quicker inroads into the market. As we look forward, I am very confident that we will be able to leverage the strengths of Dalmia to operate these assets in a manner where we can maximise value creation for all our stakeholders.”
With the addition of these plants, Dalmia Bharat’s total installed cement capacity will rise to 54.7 MnTPA upon consummation. The company has further expansion projects underway at Belgaum, Pune, and Kadapa, which are expected to take overall capacity to 66.7 MnTPA by Q2 to Q3 FY28.
The Central India location of the Jaiprakash Associates plants gives Dalmia Bharat faster access to markets in Madhya Pradesh and Uttar Pradesh than a greenfield build would have allowed. The company also cited debottlenecking and brownfield expansion as near-term opportunities at the acquired sites. Dalmia Bharat said the assets were expected to contribute positively to EBITDA and overall returns, given the pricing environment in the region and the company’s cost structure.
Cement Makers Reaffirm Commitment to Sustainable Growth
Building a Greener Future Together
JK Lakshmi Advances LC3 Cement Expansion
Burnpur Cement Reports Standalone Net Loss Of Rs 207.4 Million
Ramco Cements Campaign Wins Six Kyoorius Honours
Cement Makers Reaffirm Commitment to Sustainable Growth
Building a Greener Future Together
JK Lakshmi Advances LC3 Cement Expansion
Burnpur Cement Reports Standalone Net Loss Of Rs 207.4 Million

