Concrete

Our large motors are engineered to boost productivity

Published

2 years ago

September 23, 2024

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Neeraj Kulkarni, Regional Division President – India, MEA and LatAm, Large Motors and Generators Division, ABB India, talks about opportunities for advanced, energy-efficient electrical equipment to support sustainable development across various sectors.

What are the growth trends in the Large Motor and Generator market in India, and what future opportunities does it hold?
Fueled by India’s rapid industrialisation and urbanisation, we are witnessing robust growth in the manufacturing and industrial sector. With India’s real GDP projected to expand between 6.5 per cent and 7 per cent in fiscal year 2024-25, there is a significant upsurge in demand across various sectors. This accelerating urbanisation is amplifying our reliance on essential materials such as steel, copper, and concrete and this trend underscores the critical need for advanced, energy-efficient electrical equipment to support the infrastructure that underpins our modern way of life – spanning residential, commercial, and transportation sectors.
Some of the key drivers of this growth include major infrastructure projects and smart city initiatives, which require high-capacity and reliable motors. Additionally, the priority to modernise and replace aging infrastructure with cutting-edge solutions is further pushing demand for advanced Large Motors and Generators offerings. As we transition towards cleaner energy sources, the need for efficient, high-performance electrical equipment and grid stability becomes even more pronounced. ABB is well-positioned to address these needs through our cutting-edge technology and tailored solutions for large motors, generators and synchronous condensers, ensuring that we continue to meet the evolving demands of the Indian market effectively.

How does ABB’s Large Motors and Generators technology specifically contribute to improving energy efficiency in the cement industry?
Energy efficiency is critical for developing a sustainable and cost-effective energy system. ABB’s Large Motors and Generators technology is pivotal in advancing energy efficiency within the cement industry by delivering exceptional performance and operational benefits.
Our high-efficiency induction motors, used in key applications such as crushers, mills, and kilns, significantly reduce energy consumption, leading to lower operational costs and reduced carbon emissions. By integrating these large motors with Variable Speed Drives, we provide precise control over motor speed and torque, optimising performance to meet the specific demands of the cement production process. Furthermore, ABB’s advanced condition monitoring solutions continuously monitor and manage motor and generator performance. These systems detect inefficiencies or variances in real time, enabling predictive maintenance and minimising downtime. This proactive approach ensures that equipment operates at peak efficiency, thus reducing overall energy consumption. Our large motors and generators are designed using advanced techniques such as high-efficiency sheet steel and optimised winding designs to help in minimising energy losses and enhancing overall system efficiency.

What are the key challenges faced by cement manufacturers in implementing energy-efficient technologies, and how does ABB support to overcome these challenges?
While the cement industry has been quick to adopt high-efficiency motors, implementing energy-efficient technologies presents several challenges. These include the complex and resource-intensive process of accurately measuring energy savings and benefits, as well as a gap in awareness and concerns about the affordability and accessibility of new technologies. Additionally, manufacturers often face difficulties optimising existing assets, such as choosing to replace old motors with similar models instead of upgrading to more efficient ones, balancing short-term convenience with long-term ROI and sustainability. Variations in energy costs, financial constraints, split incentives among stakeholders and an absence of supportive policies further complicate the adoption of energy-efficient technologies.
We are addressing these challenges with a comprehensive strategy designed to facilitate the adoption of higher efficiency technologies. Our solutions are crafted to deliver measurable improvements in energy efficiency while ensuring reliability and safety. We provide tailored integration and customisation services that align with existing systems, optimising performance. A testimonial to this solution is when we replaced a 30-year-old, 2.7MW synchronous motor that was driving a cement mill with a slipring motor, enhancing uptime, reliability and efficiency. ABB also offers extensive service support and training to help customers fully leverage our technologies. Additionally, we assist in evaluating the financial aspects and ROI of retrofit projects, providing expert guidance to navigate financial and regulatory obstacles. Through these efforts, our endeavour is to empower cement manufacturers to overcome barriers, leading to enhanced operational performance and sustainability.

Could you provide examples of how ABB’s solutions have been successfully integrated into cement plants to enhance operational efficiency and reduce energy consumption?
ABB has successfully integrated its advanced solutions into cement plants in India, significantly enhancing operational efficiency and reducing energy consumption. A notable example is of a cement plant in the central part of India with production capacity of approximately 2.6 MTPA, which sought to improve its energy efficiency and reliability while maintaining high production standards. To address these demands, we provided high-efficiency modular induction motors to replace older, less efficient units. This upgrade resulted in substantial improvements in energy efficiency. Additionally, we installed variable speed drives to precisely control the speed of motors driving critical equipment such as mills and fans. This integration allowed for optimal motor performance, finely regulated energy usage, and significant reductions in overall energy consumption. For grinding units, our tailored offerings of large induction motors and drives for high pressure grinding rolls have brought significant operational efficiencies to our clients.

In what ways do ABB’s products contribute to the long-term sustainability and cost-effectiveness of cement manufacturing operations?
ABB’s products play a crucial role in enhancing the long-term sustainability and cost-effectiveness of cement manufacturing operations by prioritising safety, reliability, maintainability, and efficiency. Our large motors are engineered to boost productivity while minimising energy consumption, extending equipment lifespan, and reducing downtime. By adhering to stringent safety regulations and technical requirements, our offerings are designed to meet specific customer needs, thereby lowering carbon footprints and operational costs. ABB was the first company in India to launch IE4 motors for LV motors many years ago. We are now the first company in India to offer IE4 class efficiency for HV motors as per the new IEC standards IEC/EN 60034-30-3 for direct on-line high voltage motors.
Also, ABB’s commitment to sustainability is reflected in our optimised designs that offer a competitive total cost of ownership (TCO). Our advanced digital offerings, including remote monitoring, preventive and predictive maintenance, and diagnostic solutions, provide comprehensive lifecycle support. This blend of local expertise and global experience ensures that cement plants can achieve operational excellence and sustainability over the long term.

How does ABB’s customer-centric innovation approach ensure that the energy efficiency solutions provided meet the specific needs of the cement industry?
Our customer-centric approach is pivotal in ensuring solutions are precisely aligned with the unique needs of the cement industry. With deep industry and domain expertise, our technical teams fully understand the specific challenges and requirements inherent in cement manufacturing. This knowledge allows us to offer tailored solutions that address the operational demands of the sector effectively. We engage closely with our customers to gain insights into their specific needs and operational contexts, leading to the creation and implementation of customised solutions. These solutions, designed with flexibility, allow seamless integration with existing plant infrastructure and processes and minimises disruptions during implementation, ensuring that new technologies enhance rather than disrupt current operations. Furthermore, our commitment to continuous improvement is reflected in our iterative innovation process. By actively seeking and incorporating customer feedback, we refine and enhance our solutions to address emerging challenges and capitalise on new opportunities within the cement industry
Recently, we launched the ABB MV Titanium, the world’s first medium voltage, speed-controlled motor concept designed for 1-to-5-megawatt motors. This innovative solution represents a major step in our commitment to energy efficiency and sustainability, potentially achieving up to 40 per cent energy savings in applications like pumps, compressors, and fans. Given that these motors account for about 10 per cent of global electricity use, retrofitting with this technology could significantly cut CO2 emissions, equivalent to taking over 1000 coal-fired power
stations offline.

– Kanika Mathur

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Concrete

Martin Engineering Appoints Ashwini Khunte as India General Manager

Published

5 hours ago

October 30, 2026

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Martin Engineering names Ashwini Khunte India General Manager to strengthen operations and drive growth across key bulk material handling sectors.

Pune

Martin Engineering, a global provider of bulk material handling solutions, has appointed Ashwini Khunte as General Manager of its India business, strengthening its leadership as the company expands its presence across the country’s cement, mining, steel, power and infrastructure sectors.

Khunte brings more than a decade of experience with Martin Engineering, having joined its Indian operations in 2013 as a Design Engineer, shortly after the company established its presence in the country in 2012.

A mechanical engineer by qualification, she spent her initial five years developing bulk material handling solutions in collaboration with the company’s operations team. During this period, she gained extensive experience addressing operational challenges in the steel, cement and coal industries. She subsequently moved into project engineering, managing major engineering, procurement and construction (EPC) and original equipment manufacturer (OEM) projects from initial enquiry to commissioning. Her responsibilities later expanded to overseeing Martin Engineering’s conveyor product portfolio in India, involving customer engagement, technical presentations and site visits across heavy industries.

In 2024, Khunte was promoted to Head of Sales & Marketing for the company’s Europe, Middle East, Africa and India (EMEAI) region. The position broadened her international market exposure and strengthened her strategic and commercial leadership capabilities.

Commenting on her appointment, Ashwini Khunte, General Manager, Martin Engineering India, said: “India represents a tremendous opportunity for Martin Engineering. The country’s continued investment in cement, mining, steel, power and infrastructure is creating increasing demand for safer, cleaner and more productive bulk material handling, and that’s exactly what we do. My priority will be to build on the strong foundations already established in India, while continuing to develop our people, strengthen customer relationships and bring practical solutions to the challenges faced by our industry.”

Robert Whetstone, Area Vice President – EMEAI, Martin Engineering, highlighted Khunte’s technical expertise, market understanding and leadership experience.

“Ashwini brings an exceptional combination of technical understanding, customer knowledge and commercial leadership. She has grown as Martin Engineering has grown, and has consistently demonstrated outstanding capability to transform her expertise into practical solutions. Her knowledge of the Indian market, together with her international experience, makes her ideally suited to lead our India business through its next stage of growth for years to come.”

Since establishing its Indian business in 2012, Martin Engineering has expanded its local workforce, manufacturing capabilities and dealership network. The company supplies conveyor products, transfer point solutions, material flow aids, training and technical support to bulk material handling industries. Khunte’s appointment positions the company to further strengthen customer relationships and expand its solutions portfolio in India’s growing industrial and infrastructure markets.

Concrete

CII Calls for Greater Alternative Fuel Use in Cement Industry

Published

1 day ago

October 29, 2026

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The Confederation of Indian Industry (CII), through its Green Business Centre and Energy Efficiency Council, inaugurated the 16th Conference on Alternative Fuel and Raw Material Usage (AFR) in Goa on 27 October 2026. The two-day conference brought together more than 350 industry leaders, policymakers, waste management experts and technology providers to explore strategies for accelerating alternative fuel adoption in India’s cement industry.

Held under the theme ‘Preparation for Net-Zero: Alternative Fuels & Raw Material in Cement Manufacturing’, the conference focused on reducing dependence on conventional fuels, improving waste utilisation and strengthening circular economy practices across cement manufacturing operations.

E R Raj Narayanan, Chairman, AFR Conference 2026, and Business Head and Chief Manufacturing Officer, UltraTech Cement, highlighted the industry’s progress in alternative fuel adoption. He emphasised the need to scale implementation, strengthen supply chains and extend circularity beyond fuel substitution to alternative raw materials through technological innovation and industry collaboration.

Harish Adconkar, Managing Director, Goa Waste Management Corporation, highlighted Goa’s progress in scientific waste management and refuse-derived fuel (RDF) production. He stated that approximately 765,000 tonnes of RDF had been supplied to cement plants, contributing to an estimated displacement of 320,000–560,000 tonnes of coal. He emphasised the importance of consistent RDF offtake and stronger coordination between urban local bodies, waste management agencies and cement manufacturers.

Dr L P Singh, Director General, National Council for Cement and Building Materials, identified AFR as an important opportunity for decarbonisation and resource efficiency. Drawing parallels with the industry’s successful utilisation of fly ash, he stressed the need to address quality, technological and economic challenges to expand alternative fuel adoption.

Dr Sharad P Kale, Special Advisor to the Chief Minister of Goa and former Head of Technology Transfer and Collaboration at BARC, emphasised treating waste as a resource. He highlighted decentralised biodegradable waste processing, reduced food waste and improved resource recovery as essential measures for minimising landfill dependence.

Kiran Ananth, Executive Director, Energy Efficiency, Renewable Energy and Green Entrepreneurship, CII-Green Business Centre, noted that India’s cement production reached approximately 491 million tonnes in FY2025-26, while the industry’s thermal substitution rate (TSR) stood at 7.5 per cent, with around 7 million tonnes of alternative fuels utilised annually.

He added that the industry had invested over Rs 12 billion in co-processing infrastructure during the past six years. Improving RDF supply reliability and quality assurance would be crucial to maximising the utilisation of existing infrastructure and accelerating industrial decarbonisation.

The conference also featured discussions on advanced AFR co-processing technologies, waste pre-processing solutions and industrial best practices for improving fuel substitution and resource recovery.

A publication titled ‘From Waste to Kiln: Scaling the Use of MSW-Derived RDF in Indian Cement Plants’ was launched during the inaugural session. The report identified inconsistent RDF supply and quality as major barriers to achieving higher thermal substitution rates.

According to the publication, many cement kilns already possess the technical capability to achieve higher alternative fuel substitution. However, variations in RDF availability, moisture content, particle size and calorific value continue to limit utilisation. The report emphasised the need to strengthen waste segregation, pre-processing and aggregation systems to establish reliable RDF supply chains.

The conference’s second-day agenda includes discussions on innovative domestic and industrial waste management solutions, alternative raw materials for low-carbon cement and strategies to increase alternative fuel utilisation across India’s cement manufacturing sector.

Concrete

Sameera Group Enters Industrial and Logistics Real Estate

Rs. 1.5 bn project to support manufacturing and supply-chain firms

Published

2 days ago

October 28, 2026

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Sameera Group has entered the industrial and logistics real estate segment with a 450,000 sq ft development in Sriperumbudur, Chennai. The group will invest Rs. 1.5 bn in the project, expanding beyond residential plotted developments into business-to-business real estate.

The proposed park will serve light manufacturing, e-commerce, third-party logistics and other supply-chain businesses. Building plan approvals have been secured, with construction expected to begin shortly. The development is scheduled to become operational within 12 to 15 months.

Sameera Group Managing Director and Chief Executive Officer Jayakumar Murugesan said the project marked the next stage of the company’s growth after nearly four decades in land acquisition and real estate development. He attributed the choice of Sriperumbudur to its industrial activity and growth prospects.

The Grade A development will include internal movement routes and shared infrastructure for modern manufacturing and logistics operations. The group is pursuing Indian Green Building Council (IGBC) Platinum certification and plans to provide rooftop solar readiness, rainwater harvesting, wastewater recycling, energy and water monitoring, and electric vehicle charging facilities.

The project is being developed amid increased demand for industrial and warehousing space in Chennai. Knight Frank’s India Warehousing Market Report 2026 recorded 8.3 mn sq ft of warehousing transactions in the city during 2025, up 42 per cent from the previous year, with manufacturing accounting for 59 per cent of demand. The Sriperumbudur-Oragadam cluster contributed 77 per cent of transactions.

Sameera Group plans to develop 5 to 6 mn sq ft across a larger industrial and logistics portfolio over the next five years, involving an estimated investment of Rs. 18 bn. Land has been acquired for projects in Chennai, Hosur and Bengaluru. Established in 1982, the group has developed more than 900 acres, sold over 13,700 residential plots, and currently has 35 projects under development and 28 in its pipeline.