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

Cement Makers’ Margins To Fall Rs 50-75 Per Tonne Amid West Asia Conflict

Crisil Sees Margins Easing Despite Steady Demand

Published

1 week ago

July 29, 2026

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Crisil said operating margins of Indian cement manufacturers are expected to decline by Rs 50-75 per tonne (t) this fiscal to Rs 925-950 per t due to higher input costs triggered by the West Asia conflict. The analysis covered 18 cement companies accounting for nearly 90 per cent of India’s domestic cement capacity and noted margins had improved sharply to around Rs 1,000 per t in fiscal 2026.

Crisil noted that the reduction would be driven mainly by higher power and fuel costs, which account for about 30 per cent of total costs, as petcoke and imported coal prices have surged amid geopolitical uncertainties. Freight costs, which account for about a quarter of total costs, are also expected to remain elevated because of higher diesel prices. The impact on profitability is likely to be more pronounced in the first half of the fiscal year before easing commodity prices moderate cost pressures later.

The rating agency said steady domestic demand and strong balance sheets should keep credit profiles stable despite the moderation in margins. Green energy currently accounts for 35-40 per cent of the sector’s total electricity consumption and is expected to partly cushion higher energy costs. Operating cash flows are likely to remain resilient, supported by projected 6-7 per cent growth in cement demand this fiscal.

Crisil highlighted that demand growth will be driven primarily by infrastructure spending, which meets about one-third of sector consumption, and by a nearly 18 per cent higher budgetary allocation for core ministries that should support project execution. Weaker rural housing demand amid pressure on agricultural incomes from a possible below-average monsoon may be offset by improved urban housing demand supported by favourable home-loan rates and a strong pipeline of Pradhan Mantri Awas Yojana-Urban projects. Ongoing capacity additions will keep capital expenditure elevated and may lift net debt to EBITDA to between 1.2 and 1.4 times from around 1.0 time last fiscal, though ratios are expected to remain healthy.

Concrete

UltraTech Board Approves Rs 50 bn Fundraise Via NCDs

Company to issue half a million debentures for expansion plan

Published

1 week ago

July 28, 2026

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UltraTech Cement’s board of directors has approved raising Rs 5,000 crore (Rs 50 bn) through non?convertible debentures issued in rupees.

The finance committee cleared a proposal to issue up to 500,000 fully paid, unsecured, listed, rated, redeemable, rupee?denominated, non?convertible, non?cumulative debentures of Rs 1 lakh each (Rs 0.1 mn each), aggregating to the Rs 5,000 crore programme.

As of June 2026 the firm reported net debt of Rs 15,875 crore (Rs 158.75 bn) and said its capacity expansion projects under execution are backed by capital expenditure of about Rs 17,000 crore (Rs 170 bn) over the next two to two?and?a?half years.

UltraTech spent Rs 9,500 crore (Rs 95 bn) on capital expenditure in financial year 2026 and in April the group crossed 200.1 mn tonnes per annum of domestic grey cement capacity and 205.5 mn tonnes per annum of global capacity.

The chief financial officer indicated the company would take consolidated capacity beyond 242 mn tonnes per annum, with grey cement capacity reaching 212.7 mn tonnes per annum by the end of financial year 2027. He noted the net debt?to?earnings before interest, taxes, depreciation and amortisation ratio stood at 0.87 times as of June 2026 and the company was confident of ending financial year 2027 with the ratio below one time.

In the first quarter of financial year 2026?27 UltraTech’s net profit attributable to owners rose 16.8 per cent year?on?year to Rs 2,599.3 crore (Rs 25.993 bn) and revenue from operations increased 15.9 per cent to Rs 24,648.20 crore (Rs 246.482 bn). The board approval is expected to complement internal cash flows as the company advances its expansion programme.

Concrete

Lokesh Lays Stone For Rs 31 Billion Cement Unit In Kadapa

Line-2 expansion to make Kadapa a major cement hub

Published

2 weeks ago

July 20, 2026

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Andhra Pradesh Education and IT Minister Nara Lokesh on Wednesday laid the foundation stone for the Line-2 expansion of Dalmia Bharat Cement at Chinnakomerla village in Mylavaram Mandal in Kadapa district. The project carries an investment of Rs 31 billion (bn) and is slated for completion by the third quarter of the financial year 2028. The expansion is intended to boost industrial growth and employment generation across the Rayalaseema region.

Once commissioned, the Kadapa facility will become Dalmia Bharat’s largest integrated cement manufacturing ecosystem in southern India, creating over 1,000 direct and indirect jobs and opening new business avenues for regional micro, small and medium enterprises and transport operators. Lokesh said the expansion signalled growing corporate confidence in the state and reflected the practical ease of doing business that secured repeat investment.

He placed the project within the government’s wider economic targets and recalled the Yuvagalam padayatra commitment to generate two million (mn) jobs within five years, noting that the state would cultivate talent while industry created opportunities. Lokesh highlighted Andhra Pradesh’s competitive pursuit of major manufacturing accounts, mentioning past successes and a personal initiative to engage global investors when persuading them to anchor expansion in the state.

The plant will leverage Kadapa’s abundant limestone reserves to scale production and sustainability. Clinker capacity is planned to rise from two point five million tonnes per annum (mn tpa) to six point one mn tpa, while overall cement output will increase from three point six mn tpa to nine point six mn tpa. The unit is designed to operate on over eighty per cent renewable energy and deploy waste heat recovery, zero liquid discharge, water recycling and advanced AI systems to optimise efficiency. Industries Minister TG Bharat, BC Welfare Minister S. Savitha and Jammalamadugu MLA C. Adinarayana Reddy attended the ceremony.