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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UltraTech Cement FY26 PAT Crosses Rs 80 bn

Company reports record sales, profit and 200 MTPA capacity milestone

Published

10 hours ago

April 29, 2026

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UltraTech Cement reported record financial performance for Q4 and FY26, supported by strong volumes, higher profitability and improved cost efficiency. Consolidated net sales for Q4 FY26 rose 12 per cent year-on-year to Rs 254.67 billion, while PBIDT increased 20 per cent to Rs 56.88 billion. PAT, excluding exceptional items, grew 21 per cent to Rs 30.11 billion.

For FY26, consolidated net sales stood at Rs 873.84 billion, up 17 per cent from Rs 749.36 billion in FY25. PBIDT rose 32 per cent to Rs 175.98 billion, while PAT increased 36 per cent to Rs 83.05 billion, crossing the Rs 80 billion mark for the first time.

India grey cement volumes reached 42.41 million tonnes in Q4 FY26, up 9.3 per cent year-on-year, with capacity utilisation at 89 per cent. Full-year India grey cement volumes stood at 145 million tonnes. Energy costs declined 3 per cent, aided by a higher green power mix of 43 per cent in Q4.

The company’s domestic grey cement capacity has crossed 200 MTPA, reaching 200.1 MTPA, while global capacity stands at 205.5 MTPA. UltraTech also recommended a special dividend of Rs 2.40 billion per share value basis equivalent to Rs 240.

Concrete

Towards Mega Batching

Optimised batching can drive overall efficiencies in large projects.

Published

1 day ago

April 28, 2026

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India’s pace of infrastructure development is pushing the construction sector to work at a significantly higher scale than previously. Tight deadlines necessitate eliminating concreting delays, especially in large and mega projects, which, in turn, imply installing the right batching plant and ensuring batching is efficient. CW explores these steps as well as the gaps in India’s batching plant market.

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Large-scale infrastructure and building projects typically involve concrete consumption exceeding 30,000-50,000 cum per annum or demand continuous, high-volume pours within compressed timelines, according to Rahul R Wadhai, DGM – Quality, Tata Projects.

Considering the daily need for concrete, “large-scale concreting involves pouring more than 1,000–2,000 cum per day while mega projects involve more than 3,000 cum per day,” says Satish R Vachhani, Advanced Concrete & Construction Consultant…

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Concrete

Andhra Offers Discom Licences To Private Firms Outside Power Sector

Policy allows firms over 300 MW to seek distribution licences

Published

2 days ago

April 27, 2026

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The Andhra Pradesh government will allow private firms that require more than 300 megawatt (MW) of power to apply for distribution licences, making the state the first to extend such licences beyond the power sector. The policy targets information technology, pharmaceuticals, steel and data centres and aims to reduce reliance on state utilities as demand rises for artificial intelligence infrastructure.

Approved applicants will be able to procure electricity directly from generators through power purchase agreements, a change officials said will create more competitive tariffs and reduce supply risk. Licence holders will use the Andhra Pradesh Transmission Company (APTRANSCO) network on payment of charges and will not need a separate distribution network initially.

Licences will be granted under the Electricity Act, 2003 framework, with the Central and State electricity regulators retaining authority over terms and approvals. The recent Electricity (Amendment) Bill, 2025 sought to lower entry barriers, enable network sharing and encourage competition, while the state commission will set floor and ceiling tariffs where multiple discoms operate.

Industry players and original equipment manufacturers welcomed the policy, saying competitive supply is vital for large data centre investments. Major projects and partnerships such as those involving Adani and Google, Brookfield and Reliance, and Meta and Sify Technologies are expected to benefit as capacity expands in the state.

Analysts noted India’s data centre capacity is forecast to reach 10 gigawatts (GW) by 2030 and cited International Energy Agency estimates that global data centre electricity consumption could approach 945 terawatt hours by the same year. A one GW data centre needs an equivalent power allocation and one point five times the water, which authorities equated to 150 billion litres (150 bn litres).

Advisers warned that distribution licences will require close regulation and monitoring to prevent misuse and to ensure tariffs and supply obligations are met. Officials said the policy aims to balance investor requirements with regulatory oversight and could serve as a model for other states.