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Regulatory and compliance challenges play a significant role

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Piyush Joshi, Associate Vice President – Systems and Technical Cell, Wonder Cement, shares their strategies and initiatives aimed at enhancing energy efficiency in cement production, showcasing their commitment to sustainability through innovation and advanced technology.

Can you provide an overview of your company’s current initiatives and strategies to enhance energy efficiency in cement production?
At Wonder Cement, our commitment to energy efficiency is integral to our operational philosophy, encompassing every facet of our production process. One of our cornerstone initiatives is the deployment of Vertical Roller Mills (VRMs), which are recognised for their superior energy efficiency compared to traditional ball mills. These VRMs are equipped with high-efficiency separators, significantly reducing the energy required for cement grinding while maximising output.
We have also invested substantially in Waste Heat Recovery Systems (WHRS) across our facilities. These systems effectively capture waste heat from our kilns, converting it into usable electricity. This approach not only diminishes our dependency on external energy sources but also supports our sustainability objectives by curbing greenhouse gas emissions. Additionally, we have optimised our operational processes through the implementation of energy-efficient lighting, the utilisation of variable frequency drives (VFDs) on motors, and the execution of regular energy audits to identify and mitigate inefficiencies. Our unwavering dedication to innovation and the adoption of cutting-edge technology ensures that Wonder Cement remains a leader in energy efficiency within the cement industry.

What are the key challenges your company faces in implementing energy-efficient practices in the cement manufacturing process?
While our energy efficiency efforts have yielded significant results, the implementation of such practices within the cement manufacturing process presents several challenges. Chief among these is the substantial capital investment required to upgrade existing infrastructure to more energy-efficient alternatives. Integrating new energy efficient systems with existing infrastructure can be technically challenging and may cause temporary disruptions in production processes. Although the long-term benefits of these upgrades are evident, the initial financial outlay can be substantial, particularly when applied across multiple production sites.
Another persistent challenge is the variability in raw material quality, which can directly impact the efficiency of our kilns and mills. Fluctuations in the chemical composition of raw materials necessitate frequent adjustments in our processes, potentially leading to suboptimal energy consumption. Furthermore, the inherently energy-intensive nature of cement production, especially during the clinkerisation process, means that achieving significant reductions in energy use often requires comprehensive overhauls of traditional methods rather than incremental improvements.
Regulatory and compliance challenges play a significant role. Ensuring that our energy efficiency measures align with both local and international environmental standards is a complex process, particularly in regions with stringent regulations. Despite these challenges, Wonder Cement is steadfast in its commitment to overcoming obstacles through continuous innovation, strategic collaboration, and a focus on sustainable practices.

How do advancements in technology contribute to improving energy efficiency in your cement plants? Can you provide some examples?
Technological advancements are pivotal in enhancing energy efficiency within Wonder Cement plants. One of the key innovations we have embraced is the integration of automation and digitalisation throughout our production processes. By implementing advanced process control (APC) systems, we can monitor and optimise our operations in real-time, ensuring the most efficient use of energy at all times. These systems leverage data analytics and machine learning algorithms to predict and address energy inefficiencies proactively, resulting in substantial energy savings.
Another significant technological advancement is the incorporation of alternative fuels within our kilns. By utilising waste-derived fuels, such as refuse-derived fuel (RDF) and biomass, we reduce our reliance on traditional fossil fuels. This not only lowers our carbon footprint but also enhances the energy efficiency of our kilns by maintaining a consistent energy input with minimal fluctuations. The adoption of smart sensors and Internet of Things (IoT) devices has further augmented our energy management capabilities. These technologies provide real-time insights into energy consumption across various stages of production, enabling rapid identification and resolution of inefficiencies. For example, our predictive maintenance programs, powered by IoT, allow us to foresee equipment failures and schedule maintenance proactively, thereby reducing downtime and ensuring continuous, efficient operations.

What role does renewable energy play in your overall strategy for energy efficiency, and how is it integrated into your cement manufacturing operations?
Renewable energy is a fundamental component of Wonder Cement’s broader energy efficiency strategy. We have integrated renewable energy sources, such as solar and wind power, into our manufacturing operations to reduce our reliance on non-renewable energy. Our solar power plants, strategically positioned across our manufacturing sites, contribute significantly to our overall energy needs. By generating clean energy on-site, we not only reduce our electricity costs but also achieve substantial reductions in carbon emissions, underscoring our commitment to sustainability.
In addition to on-site renewable energy generation, we have entered into power purchase agreements (PPAs) with renewable energy providers. These agreements guarantee a consistent supply of green energy to our plants, further diminishing our reliance on grid power derived from fossil fuels. Moreover, our participation in carbon credit markets, facilitated by the integration of renewable energy, has opened up additional revenue streams while reinforcing our role as a responsible corporate citizen.
Our approach to renewable energy extends beyond electricity generation. We are actively exploring the potential of renewable fuels for our kiln operations. Through partnerships with research institutions and technology providers, we are investigating the viability of hydrogen and other renewable energy sources to further reduce our carbon footprint and enhance energy efficiency.

Can you discuss any specific projects or upgrades your company has undertaken to reduce energy consumption and increase efficiency in your cement production facilities?
Wonder Cement has embarked on several key projects aimed at reducing energy consumption and enhancing efficiency across our production facilities. A prominent example is the installation of high-efficiency clinker coolers, designed to maximise heat recovery from the clinker. This recovered heat is then utilised to preheat raw materials, significantly reducing the energy required for subsequent grinding processes. Another critical upgrade involves the widespread implementation of variable frequency drives (VFDs) across our production lines. VFDs allow us to adjust motor speeds based on real-time load requirements, ensuring that we use only the necessary amount of energy for each operation. This has led to considerable energy savings, particularly in our grinding and milling processes.
We have also modernised our lighting systems by transitioning to LED technology, which is notably more energy-efficient and durable compared to traditional lighting solutions. This transition not only reduces our energy consumption but also lowers maintenance costs. Our commitment to continuous improvement is further demonstrated through regular energy audits and the implementation of advanced energy management systems (EMS) that meticulously track and optimise energy usage across all our facilities.

How do you measure and monitor energy efficiency in your cement manufacturing processes, and what metrics are most critical for your company?
Precise measurement and monitoring of energy efficiency are paramount to achieving our sustainability objectives. We have established a robust energy management system (EMS) that delivers real-time data on energy consumption across every stage of our production process. This system is equipped with advanced metering and monitoring tools that track energy usage at granular levels, enabling us to swiftly identify inefficiencies and implement corrective measures.
Among the critical metrics we monitor are specific energy consumption (SEC), which quantifies the energy required to produce a unit of cement, and thermal energy consumption (TEC), which tracks the energy utilised during the clinkerisation process. By closely monitoring these metrics, we can assess the effectiveness of our energy efficiency initiatives and make informed decisions to further optimise our operations. In addition to continuous monitoring, we conduct regular energy audits to evaluate our performance against industry benchmarks and identify opportunities for improvement. These audits, conducted by both internal teams and external experts, ensure that our energy management practices remain objective, accurate, and aligned with industry best practices. The insights gained from these audits are instrumental in refining our energy management strategies and setting ambitious targets for energy reduction.
To promote energy efficiency through innovations, we are having groups of employees at every
production centre for identification, evaluation and execution of new ideas related to energy efficiency for continual improvement.

What partnerships or collaborations has your company engaged in to promote and enhance energy efficiency within the cement industry?
Collaboration is a cornerstone of Wonder Cement’s approach to enhancing energy efficiency within the cement industry. We actively engage with various stakeholders, including technology providers, industry associations, and research institutions, to promote and advance our energy efficiency initiatives.
Our partnerships with technology providers are instrumental in integrating state-of-the-art solutions into our operations, ensuring that we remain at the forefront of energy efficiency advancements. Additionally, our participation in industry associations and knowledge-sharing platforms enables us to exchange best practices with our peers and stay informed about emerging trends and technologies.
We also collaborate with research institutions to explore innovative materials and processes that can further reduce our energy consumption. These collaborations have led to pilot projects where novel solutions are tested and validated before being implemented on a larger scale across our production facilities. Through these partnerships, we are not only advancing our energy efficiency goals but also contributing to the broader sustainability of the cement industry.

How does your company balance the need for energy efficiency with maintaining high production levels and meeting market demands?
We recognise the importance of balancing energy efficiency with maintaining high production levels and meeting market demands. Achieving this balance requires a strategic approach that integrates energy efficiency into every aspect of our production process without compromising on output quality or quantity.
One of the key strategies we employ is the use of advanced process control (APC) systems that optimise our operations in real-time. These systems enable us to maintain consistent production levels while minimising energy consumption by adjusting process parameters based on real-time data. This ensures that we achieve maximum efficiency without disrupting our production schedules. We also emphasise continuous improvement through the application of lean manufacturing principles, which focus on the elimination of waste and the efficient use of resources. By streamlining our processes and reducing inefficiencies, we can maintain high production levels while minimising energy usage. Additionally, our investment in employee training ensures that our workforce is equipped with the necessary knowledge and skills to operate our facilities efficiently, contributing to both productivity and energy efficiency.

Looking ahead, what are your company’s strategic priorities for further improving energy efficiency, and how do you plan to address future energy challenges in the cement industry?
Looking ahead, Wonder Cement is committed to further advancing our energy efficiency through a combination of technological innovation, process optimisation, and strategic investments. Our primary focus will be on expanding our use of renewable energy sources, particularly solar and wind power, to meet a larger portion of our energy needs. We are also exploring the potential of emerging technologies, such as carbon capture and utilisation (CCU) and hydrogen-based fuels, to further reduce our carbon footprint and enhance energy efficiency.
In addition to technological advancements, we plan to continue our efforts in process optimisation through the implementation of advanced data analytics and artificial intelligence (AI) in our energy management systems. These tools will enable us to identify and address inefficiencies in real-time, ensuring that we maintain optimal energy usage at all times.
We are also committed to expanding our collaborations with industry stakeholders, research institutions, and technology providers to drive innovation and share best practices in energy efficiency. By staying at the forefront of industry trends and continuously challenging ourselves to improve, we are confident that we can meet the future energy challenges of the cement industry while maintaining our position as a leader in sustainability.

– Kanika Mathur

Concrete

Driving Sustainability Through Innovation

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The 15th Cement Expo 2025 will spotlight India’s cement industry’s growth, innovation, and sustainability, showcasing cutting-edge solutions for a greener future.

The cement industry in India, the second-largest in the world, is on the cusp of remarkable growth as it continues its transition toward sustainability, innovation, and expansion. The 15th Cement Expo 2025, scheduled for November 12-13, 2025, at the Yashobhoomi Convention Centre in Delhi, will be the premier event where the industry’s foremost stakeholders converge to explore state-of-the-art technologies and solutions.
Co-located with the 11th Indian Cement Review Conference and the 9th Indian Cement Review Awards, the expo promises to be a pivotal event for professionals in the cement, construction, and infrastructure sectors. This year’s theme, “Driving Sustainability Through Technology,” highlights the sector’s commitment to decarbonisation, efficiency, and technological advancement. With India poised to add 80 to 100 million tonnes of cement capacity by 2024-25, the event will address the urgent need for sustainable, low-carbon solutions to meet the growing demand.
Before we look ahead to the 15th Cement Expo, let’s reflect on the remarkable success of the Cement Expo Forum 2025, held on March 5-6, 2025, in Hyderabad. The event attracted over 500 industry professionals and featured groundbreaking discussions on sustainability, logistics, and decarbonisation. Key sponsors and partners, such as ABB, Gebr Pfeiffer, JK Cement, and Flender Drives, showcased their latest innovations, contributing to the forum’s success.
Pratap Padode, Founder and President of First Construction Council, spoke at the event, noting, “The PPP pipeline is complemented by a provision of Rs 1.5 trillion in interest-free loans to states, earmarked for capital expenditure. With this, we have a solid plan in place. What needs to be done is to ensure that the PPP actually takes off as envisaged. To make this happen, trust must be established, and policies must be investor-friendly. Telangana, in this regard, has demonstrated ease of doing business exceptionally well.”
He added, “These financial injections into the infrastructure sector are expected to create a ripple effect, driving demand for cement as a key material in construction and development projects. The growing demand for cement is evident as infrastructure projects continue to rise across the country.”
The forum also provided invaluable networking opportunities, with attendees gaining insights from over 35 distinguished speakers and connecting with more than 50 exhibitors. The event laid a strong foundation for the upcoming Expo, showcasing the significant strides the cement industry is making toward a greener, more efficient future.
The 15th Cement Expo 2025 will focus on advancing the industry’s next big step toward sustainable growth. With India’s cement sector making significant progress in decarbonisation, a key focus will be on technologies and innovations that support carbon capture, low-carbon cement production, and energy-efficient solutions.
The expo will feature over 50 exhibitors representing all aspects of the cement industry. Whether you are a manufacturer, raw material supplier, technology provider, or logistics partner, the Cement Expo 2025 offers an ideal platform to showcase your products and solutions. Attendees will have the opportunity to explore the latest advancements in cement production technology, automation, logistics, and environmental solutions, all geared toward building a greener and more sustainable future.
Exhibitor profiles will include cement manufacturers, raw material suppliers, technology and automation solutions providers, environmental and sustainability solutions providers, cement packaging and logistics, construction equipment manufacturers, admixtures and chemical suppliers, and concrete reinforcement and structural systems.

11th Indian Cement Review Conference

Held alongside the Expo, the 11th Indian Cement Review Conference will offer delegates invaluable insights into the latest trends and innovations shaping the cement industry. Focusing on sustainability, the conference will address critical issues such as energy efficiency, plant design, and emerging technologies like carbon capture and automation.
Industry leaders will share their expertise in technical forums, while specialised activities, such as plant tours and energy audits, will provide practical guidance on improving operations and efficiency. This is a prime opportunity to network with industry stakeholders, gain hands-on experience with new technologies, and acquire actionable knowledge to enhance your business.

9th Indian Cement Review Awards

The 9th Indian Cement Review Awards will recognise the fastest-growing cement companies and industry leaders for their outstanding contributions to the sector. This prestigious event will serve as a platform to honour the pioneers of innovation, sustainability, and performance within the cement industry, highlighting the sector’s commitment to growth and environmental responsibility.
As we look forward to the 15th Cement Expo 2025, we invite you to join us for two exciting days of networking, learning, and innovation. This event offers a unique opportunity to be part of the next wave of growth and sustainability in the global cement sector.

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Concrete

Transforming Interior Spaces: Trendy Wall Putty Designs to Enhance Your Home

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When it comes to interior design, walls are more than just structural elements—they serve as the canvas for self-expression, setting the mood and personality of a space. While paint and wallpaper have long been the go-to choices for wall finishes, wall putty is emerging as a game-changer in home décor. With its smooth finish, durability, and versatility, wall putty opens a world of creative possibilities. In this article, we explore trendy wall putty designs that can elevate your interiors, turning ordinary walls into extraordinary design statements.
Wall Putty is a Must-Have in Modern Homes
Wall putty is no longer just a preparatory material for painting; it plays a significant role in modern home aesthetics. It enhances the finish of walls, making them smoother, stronger, and resistant to cracks and moisture. Additionally, high-quality putty like Birla White Wall Putty ensures better paint adhesion, resulting in long-lasting vibrancy.
Beyond its functional benefits, wall putty allows homeowners to experiment with textures and patterns, giving walls a designer touch without the hassle of high-maintenance materials like stone or wood. Whether you’re aiming for a minimalist, rustic, or ultra-modern aesthetic, wall putty designs can help achieve the look effortlessly.
Trendy Wall Putty Designs for Stunning Interiors
1. Textured Wall Putty for a Tactile Appeal
Textured walls are a popular interior trend, adding depth and dimension to living spaces. By using wall putty, homeowners can create a variety of textures, including:
  • Rustic Texture: Mimicking natural stone or aged plaster for an earthy, vintage feel.
  • Wave Patterns: Adding a sense of movement and fluidity to walls, perfect for living rooms and entryways.
  • Sand Finish: A subtle grainy effect that provides a sophisticated touch.
Textured putty walls work exceptionally well in accent areas, such as behind a television unit or as a backdrop for artwork.
2. Sleek and Smooth Walls for a Luxurious Look
For those who prefer a refined and elegant aesthetic, a smooth putty finish is ideal. A flawlessly smooth wall creates a premium appearance, amplifying the impact of high-quality paints. Opting for a high-performance putty like Birla White WallCare Putty ensures a glass-like finish that complements modern and contemporary interiors.
This design is perfect for:
  • Monochrome interiors where walls serve as a sleek backdrop.
  • High-gloss or matte-painted walls that need a seamless base.
  • Spaces with minimal décor where the walls themselves make a statement.
3. Geometric & Abstract Patterns for a Contemporary Edge
Wall putty can be artistically applied to create striking geometric or abstract patterns, adding a unique character to interiors.
Popular designs include:
  • Chevron or Herringbone: A dynamic, sophisticated look that pairs well with both modern and mid-century décor.
  • 3D Raised Panels: Using putty to craft subtle raised patterns, adding a sculptural effect to the wall.
  • Asymmetrical Shapes: For a bold and avant-garde touch.
  • These patterns work best in bedrooms, study areas, or accent walls in open spaces.
4. Venetian Plaster for a Luxe European Aesthetic
Venetian plaster, an age-old technique, is making a grand comeback in modern interiors. With wall putty, you can achieve this exquisite marble-like effect, which exudes luxury and timeless charm.
This design works well for:
  • Statement walls in living rooms and foyers.
  • Elegant dining areas where a touch of opulence is desired.
  • Boutique-style bedrooms with a rich, textured finish.
A high-quality white cement-based putty can replicate this effect beautifully, making the walls look naturally luminous.
5. Dual-Tone or Ombre Walls for a Soft Gradient Effect
The ombre effect, a gradient transition between two colors, is a trendy and artistic way to enhance interiors. When applied over a smooth wall putty base, the gradient blends seamlessly, offering a dreamy, watercolor-like appeal.
This style is perfect for:
  • Children’s rooms or play areas, creating a fun and dynamic atmosphere.
  • Bedrooms with a soothing pastel gradient for a calming effect.
  • Dining spaces where a bold color fade adds character.
6. Metallic & Glossy Finishes for a Chic Look
For homeowners who love glamour and sophistication, combining wall putty with metallic paints or glossy finishes can create a high-end appeal. The smooth base of putty enhances the reflective qualities of metallic shades like gold, silver, or bronze, resulting in an opulent and dramatic effect.
Best suited for:
  • Luxurious master bedrooms and dressing areas.
  • Accent walls in dining rooms or home bars.
  • Commercial spaces like boutiques and salons.
How to Achieve the Best Wall Putty Designs
  • Choose the Right Putty: Opt for a premium wall putty like Birla White WallCare Putty to ensure durability, a smooth finish, and long-lasting appeal.
  • Prepare the Surface: Ensure the walls are clean, dry, and free from loose particles before application.
  • Apply in Layers: Depending on the design, putty can be applied in single or multiple layers for the desired effect.
  • Use the Right Tools: Trowels, spatulas, sponges, or patterned rollers help create specific textures and patterns.
  • Seal with Paint or Polish: Once the putty is dry, finishing it with paint, polish, or protective coatings enhances its aesthetic and durability.
Conclusion
Wall putty has evolved beyond its traditional role, now serving as a medium for creative interior design. Whether you prefer textured finishes, sleek smooth walls, or artistic patterns, wall putty designs can elevate your home’s aesthetics while offering durability and elegance. By selecting the  best putty for wall and application technique, you can transform your interior walls into stunning masterpieces, setting the perfect backdrop for your lifestyle.
For high-quality wall finishes that stand the test of time, Birla White WallCare Putty ensures both beauty and performance, making your dream interiors a reality.

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Dalmia Bharat to add 6 MnTPA Cement Capacity in Maharashtra and Karnataka

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  • Investment in alignment with the strategic goal of becoming a PAN India company and achieving 75 MnT capacity by FY28
  • Increases capacity primarily to meet growing demand in Western India along with existing regions

Dalmia Bharat Limited, one of India’s leading cement companies, through its subsidiaries, has announced a strategic investment of approximately Rs 3,520 Crore in the states of Maharashtra and Karnataka. As part of this initiative, the company will establish a 3.6 MnTPA clinker unit and a 3 MnTPA grinding unit at its existing Belgaum plant, Karnataka coupled with a new greenfield split grinding unit with a capacity of 3 MnTPA in Pune, Maharashtra. The capex will be funded through a combination of debt and internal accruals. With this expansion, Dalmia Bharat’s total installed cement capacity will increase to 55.5 MnTPA, after considering the ongoing expansion of 2.9 MnT at Assam and Bihar. These new units are expected to be commissioned by Q4 FY27.

The Belgaum Grinding Unit will cater to the underserved Southern Maharashtra markets while enhancing share in the existing region by improving penetration. On the other hand, Pune Grinding Unit will entirely cater to the untapped Western Maharashtra markets. The initiative is a part of the company’s vision to be a PAN India player and achieve 75 MnTPA capacity by FY28 and 110-130 MnT by 2031.

Speaking on the development, Mr. Puneet Dalmia, Managing Director & CEO, Dalmia Bharat Limited, said, “This investment is a significant step in our Phase II expansion strategy, bringing us closer to strengthen our position as a pan-India player and to reach intermittent goal of 75 MnT capacity by FY28. The increase in our production capacity is primarily to meet the growing infrastructure demand in Western India.” He further added, “We remain committed in realising our goals of capacity expansion, while staying focused on operational excellence and creating long-term value for our stakeholders. The capacity additions will also continue to be in line with Dalmia Bharat’s sustainability-driven approach and its commitment to supporting India’s infrastructure and development goals.”

About Dalmia Bharat: Founded in 1939, Dalmia Bharat Limited (DBL) (BSE/NSE Symbol: DALBHARAT) is one of India’s pioneering cement companies headquartered in New Delhi. With a growing capacity, currently pegged at 46.6 MnT, Dalmia Bharat Limited (including its subsidiaries) is the fourth-largest cement manufacturing company in India by installed capacity. Spread across 10 states and 15 manufacturing units.  Dalmia Cement (Bharat) Limited, a subsidiary of Dalmia Bharat Limited, prides itself at having one of the lowest carbon footprint in the cement world globally. It is the first cement company to commit to RE100, EP100 and EV100 (first triple joiner) – showing real business leadership in the clean energy transition by taking a joined-up approach.

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