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Our technology pinpoints excess energy use

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Dries Van Loon, Vice President – Products, Nanoprecise Sci Corp, talks about the transformative impact of their advanced solutions on the cement industry.

Provide an overview of your company’s current initiatives and strategies to enhance energy efficiency in cement production. How does Nanoprecise’s predictive maintenance technology specifically benefit the cement industry, and what makes it unique compared to other industries?
Nanoprecise’s predictive maintenance technology offers key benefits for the cement industry by providing real-time monitoring of equipment, predicting faults before they occur, and optimising maintenance schedules. This helps reduce unplanned downtime, lower energy consumption, and cut greenhouse gas emissions. What sets Nanoprecise apart is its focus on the unique needs of cement manufacturing, where equipment operates under harsh conditions and efficiency is crucial.
By integrating AI and IoT, Nanoprecise delivers precise insights into machinery performance, enhancing operational efficiency and environmental sustainability. Our technology pinpoints excess energy use and high emissions in processes and equipment. By tackling these inefficiencies, Nanoprecise’s predictive maintenance solutions directly cut energy consumption and GHG emissions while enhancing operation efficiency. For example, if a motor’s energy use rises due to faults, the system alerts the team to
resolve the issue, reducing both wasted energy and associated emissions.

Can you elaborate on the importance of your IP68-certified IoT hardware in ensuring reliable data collection in the dusty environments of cement plants?
Conditions in the cement industry are some of the harshest among industries; most critical equipment and its instrumentation are exposed to natural elements as well as high heat, humidity and dust. Accurately certified hardware ensures reliability and repeatability of the data collected and transmitted to ensure timely insights. Instead of constantly addressing instrumentation issues, the hardware will reliably inform you about the status of critical equipment, allowing for timely and effective maintenance decisions and enhancing your productivity.

How does your customised AI-based health analytics platform cater to the specific needs and challenges of cement manufacturing plants?
Rotating equipment is the most critical in the cement-making process. Issues with slow-speed kilns, dryers, high-speed gearboxes of conveyors and critical fans can shut down the process for extended periods, causing big financial losses.
Partnering with Nanoprecise can eliminate this unplanned downtime. Our platform additionally tracks changes in energy consumption, directly linking inefficiencies and emerging mechanical or electrical issues to lost kilowatt-hours (kWh) and associated costs. This enables you to prioritise maintenance actions that will significantly impact energy savings and cost reduction.

How does your 6-in-1 wireless IoT sensor enhance the ability of cement manufacturers to monitor equipment health remotely, particularly in confined or challenging spaces?
Our wireless IoT sensors, with their easy installation, magnet mount and compact size, significantly reduce the cost of an implementation project (the gateway hardware installation and IT project typically take more than 1/2 of the initial installation project cost) but also reduce the time to scale as any IT project and gateway installation across an industrial environment takes time to prepare and execute. Due to the direct cellular connectivity from each sensor, there is no need for vendor-proprietary gateways and networks to be deployed for the sensors to communicate. If cellular connectivity in a plant is limited, the customer’s WiFi network can also be used for our sensors to connect to directly. Often, this is already available and can be a shared resource for multiple IoT and modernisation projects.

Can you explain how your AI algorithms predict the Remaining Useful Life (RUL) of critical components and the impact of these predictions on maintenance planning and operational efficiency?
The true value of any predictive maintenance programme is a combination of three types of outputs.

  • Accurate change detection: This helps to understand any change is present on the equipment and how it impacts normal operating conditions.
  • Root cause identification: A maintenance action can only be defined based on an accurate root cause. So, any detected changes should
    be linked to an actionable root cause, allowing proper preparation and execution of the maintenance task.
  • Remaining useful life: This allows maintenance planners to understand the severity of a developing issue and ensure the maintenance task can be planned in a timeline with minimal impact on operations without increased risk of lost production.

Many PdM systems provide the first output by flagging general changes. However, this needs to be actionable data for the maintenance and operations team as it would require more in-depth investigation. The value for any PdM Solution is created only if the correct maintenance action is planned based on the insights created from the data. Here is where Nanoprecise has been relentlessly focused in the past years to be a true value adder for our current and future customers. Additionally, we are the only predictive maintenance solution on the market that combines predictive maintenance and energy consumption due to any process inefficiencies or developing faults. This feature allows for linking maintenance and process issues to measurable impact on energy consumption, ensuring a plant can run as efficiently as possible.

What specific solutions does Nanoprecise offer to combat the adverse effects of dust on machinery in cement plants, ensuring optimal performance and longevity?
Our solution of IP68 hardware has been specifically designed for the harsh requirements of a cement plant. Our sensors are fully enclosed while in operation and can work autonomously for 3-5 years. This design ensures that the focus is on the reliability of the equipment, not on the IoT hardware, giving you confidence in the performance of our product.

How does your technology handle the challenges of monitoring diverse and intricate machinery, such as kilns, mills, crushers and conveyors, in cement plants?
To monitor the wide variety of applications specific to the cement industry, from slow speed to high speed, our sensors can be configured to ensure proper data is collected for each type of application. For slow-speed applications, our total collection time can be extended to ensure a sufficient number of shaft revolutions are captured, which is the only way to identify the root causes of issues.
Additionally, our unique combination of Triax Vibration, Ultrasound, Temperature and Flux
into the same sensor hardware allows for a full picture of the machine health and identify developing
faults in an early stage regardless of application or operating speed.

In what ways does predictive maintenance help in mitigating the environmental impact of cement manufacturing, particularly in terms of reducing carbon emissions?
When predictive maintenance is an integral part of a company’s maintenance practices it will increase equipment efficiency and directly impact the total energy consumed for the same output for any equipment.
With the Nanoprecise solution fully integrated, our end users not only receive actionable insights with defined ‘remaining useful life’, but also continuous data on the impact to energy consumption and its effect on carbon emissions. This is crucial in prioritising maintenance tasks not purely based on potential saved downtime and repair cost, but also on the highest energy impact, ensuring that maintenance tasks have a significant, measurable contribution to reducing carbon emissions.

What future trends do you foresee in the realm of IT initiatives for the cement industry, and how is Nanoprecise preparing to address these trends?
With cybersecurity being at the top of every IT department’s concern, implementing any outside solution will require compliance with ever more strict IT requirements. At Nanoprecise, we have ensured our system is designed from the ground up with stringent security requirements, from data encryption and secure data transfer to cyber security for our cloud environment. By adopting direct cellular and WiFi communication protocols, we do not need to be integrated inside the customer’s IT environment, making implementation easier as end-to-end data security is entirely handled by our solution.
Additionally, we are proud to be the first and one of the few IIoT solutions that have been SOC 2 Type 2 compliant for multiple years. This assures our entire company and infrastructure is compliant with the most stringent security requirements and continuously adapted to new cyber security threats, as it’s a rapidly developing risk that needs continuous adoption.

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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