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Circular economy principles are embedded in our programmes

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Ashok K Gupta, CEO, Dalmia Bharat Foundation, speaks about the significant strides taken in rural empowerment through skill development programmes.

Could you share more about how your DIKSHa initiative has evolved since its inception in 2016, and what specific challenges and successes you have encountered in scaling up this programme?
With the concept of ‘Giving back to Society’ the DIKSHa programme, a flagship CSR initiative of Dalmia Bharat Foundation (DBF), was initiated in 2016 with the vision of providing alternative livelihood opportunities for the community around us. This reflects our shared vision of empowering individuals with valuable skills and enhancing employability. The conceptualisation and design of the programme were driven by a comprehensive analysis of prevailing skill gaps and industry demands for the trained youth in different trades. Our mission is clear: to reach and uplift every young individual within the vicinity of our business operations.
DIKSHa was initiated in partnership with the National Skill Development Corporation (NSDC). The broad roles of Dalmia Bharat Foundation and NSDC were integral to the development and implementation of DIKSHa. DBF took the lead in shaping the programme’s direction by identifying high-demand trades, setting up modern training centres, and ensuring a community-centric approach. This ensured that the programme met the needs of the local population while offering relevant skills. Our strong network of industry partners enabled us to link trainees with organised sector job opportunities. NSDC played an instrumental role by offering insights into skill development, designing the curriculum, and aligning it with national standards, particularly the National Skills Qualifications Framework (NSQF). Regular evaluations ensure continuous improvement in the program’s implementation.
Operating across 20 centers in 10 states, DIKSHa has trained over 16,460 candidates with a commendable placement rate of 73 per cent. With an annual training capacity of 7,200 youths, the programme offers diverse courses across 21 trades, preparing individuals for a range of industries.
Our programme stands out not only for its comprehensive training but also for the extensive post-placement support we provide. Unlike other government programs that offer three months of post-placement assistance, DIKSHa ensures a full year of post placement support to our candidates. This commitment helps our graduates navigate their new roles, overcome challenges and continue to grow in their careers.
Our achievements would not be possible without the invaluable support of our partners. I extend my heartfelt gratitude to our partners such as the National Skill Development Corporation (NSDC), Odisha Skill Development Authority (OSDA), Andhra Pradesh State Skill Development Corporation (APSSDC), NABARD, Bosch, AkzoNobel, Schneider Electric, and many others. Their commitment and collaboration have been instrumental in scaling our efforts and ensuring the highest standards of training and employment opportunities.
Despite these successes, scaling DIKSHa across geographies presented challenges. Maintaining programme quality and consistent implementation of standard operating procedures (SOPs) required a robust framework to monitor and track the progress of our centers. Initially, creating awareness and overcoming community hesitation about the programme’s credibility and job opportunities was tough. Mobilising women beneficiaries also posed challenges, especially given societal norms, but we have addressed these through targeted courses and engagement strategies. Retention of candidates post-training and establishing a unified brand across all DIKSHa centers were additional hurdles we have worked to overcome.

With a notable 63 per cent female enrolment in DIKSHa and a high employment rate for graduates, how does DBF tailor its programmes to ensure that women and youth in rural areas are effectively integrated into the workforce?
Yes, we have an enrolment rate of 63 per cent females in our DIKSHa programme, and we are constantly working to increase it further in the coming years. Not only in enrolment—61 per cent of the trainees (5001) who passed in FY 24 were females, demonstrating our commitment to gender equality and rural empowerment. We have carefully designed tailor-made courses that cater specifically to the interests and needs of women and youth, ensuring these courses also align with market demand at both the local and national levels. This approach has made our programs more attractive to participants while increasing their employability. Trades such as General Duty Assistant (GDA), Sewing Machine Operator, Solar PV Installer, Customer Relationship Manager and Assistant Beauty Therapist are examples of how we match local opportunities with the aspirations of our trainees.
To ensure smooth integration into the workforce, we provide comprehensive support during the job placement process, spanning across districts and regions. Our commitment doesn’t end with placement—DIKSHa offers one year of post-placement support, ensuring that our graduates can settle into their roles. If a candidate chooses to switch jobs at any time, they can rely on our team for assistance in securing new employment, reflecting our dedication to long-term career support. Also, for placements where trainees, especially women trainees need to join outside their home district, DIKSHa team members accompany them to the joining location to ensure a smooth process. This support not only ensures a seamless transition but also boosts the confidence of women trainees as they step into their new roles
In addition to formal employment, DBF facilitates the entrepreneurial aspirations of our trainees, especially women. We support the establishment of micro and small businesses by assisting in securing loans from banks or cooperative societies, further promoting financial independence.
Looking ahead, DBF has plans to open three more training centers by FY 25, increasing our total centers to 23 and our annual training capacity
to 8,000. This expansion will enable us to reach more rural youth and women, continuing to bridge the gap between skill development and employment opportunities.

In the context of Dalmia Bharat’s broader sustainability goals, how does DBF contribute to the circular economy through its skill development programmes?
The Foundation aligns closely with Dalmia Bharat’s broader sustainability goals. Circular economy principles are embedded in our programmes. Through these initiatives, we not only enhance the employability of rural youth but also promote environmental sustainability by focusing on resource efficiency, waste reduction, and the use of renewable energy sources. Our programmes, such as those that train individuals in green jobs like solar PV installation, are designed to address the dual challenge of unemployment and environmental degradation.
By offering skills in organic farming and water conservation techniques, we encourage sustainable agricultural practices, leading to improved crop yields and reduced dependence on chemical inputs. These efforts contribute to environmental sustainability while providing rural communities with the tools to flourish economically, creating a model of inclusive and sustainable development. Moreover, we also support circular economy initiatives by facilitating the use of biomass as alternative fuel through projects like bamboo cultivation, municipal waste collection, and the use of agricultural waste as fuel, significantly contributing to the reduction of carbon footprints in rural areas.
The DIKSHa programme has been a game-changer for contributing to the circular economy. A recent Social Return on Investment (SROI) study conducted by KPMG India for the DIKSHa programme revealed an impressive SROI value of 7.5. This means that for every rupee invested, the programme generates 7.5 rupees in socio-economic value. The programme trains youth and women in trades such as industrial sewing machine operators, domestic electricians, assistant beauty therapists, general duty assistants and customer relationship managers, equipping them with industry-relevant skills. The programme enhances employability, improves livelihoods, and promotes financial stability, leading to inclusive growth.
In addition to skill development, DBF is actively involved in environmental sustainability through its water and soil conservation programmes. A study by the Confederation of Indian Industry (CII) on over 6,000 water conservation structures highlighted the impact of these initiatives, achieving another SROI value of 7.5. These programmes focus on organic farming, water conservation techniques, and the promotion of climate resilient practices.
This not only reduces waste and encourages
recycling but also empowers rural communities economically, creating a model of inclusive and sustainable development.
These initiatives help DBF build resilient and self-reliant communities while contributing to India’s sustainable development goals.

As India progresses towards its ‘Viksit Bharat’ vision, what role do you see DBF playing in shaping the future of rural development and employment?
As India advances towards its ‘Viksit Bharat’ vision, Dalmia Bharat Foundation (DBF) is committed to playing a pivotal role in shaping the future of rural development and employment. Our focus has always been on empowering rural communities by building sustainable livelihoods, enhancing skill development, and promoting social and economic inclusion. DBF envisions being a key driver in ensuring that rural India contributes significantly to the country’s overall growth story.
To support this vision, we plan to scale up our existing programmes like DIKSHa and Gram Parivartan. DIKSHa, which has already trained over 16,460 candidates, will expand further with three additional centers in FY 25, increasing our annual training capacity to 8,000. This will allow us to offer skill development in more sectors, particularly in green and future-ready jobs, aligning with national priorities. We are also exploring partnerships to introduce digital skilling, which will equip rural youth with skills for the tech-driven economy.
Under Gram Parivartan, we aim to deepen our impact across the 20 locations covering more than 84,000 households where we currently operate. With the success of our livelihood intervention model, which integrates agriculture, horticulture, micro-enterprises and social capital, we plan to cover more households by introducing innovative income-generating activities such as agri-tech solutions and climate-resilient farming techniques. We also see the potential in expanding micro-enterprises, particularly for women and landless households, to build resilient rural economies.
In terms of new initiatives, we are exploring opportunities to enhance our efforts in renewable energy training and water conservation, ensuring that rural communities not only have access to sustainable resources but also the skills to manage them. The vision is to create a rural green economy where sustainable practices, such as solar energy, rainwater harvesting, and organic farming, become the backbone of livelihood activities.
Furthermore, DBF plans to strengthen its public-private partnerships, aligning our programs with various government schemes and global development goals. Through collaboration, innovation, and firm focus on rural empowerment, DBF is poised to be a critical contributor to India’s “Viksit Bharat” vision, ensuring that no rural community is left behind in the nation’s journey toward progress.

– Kanika Mathur

Concrete

The primary high-power applications are fans and mills

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Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.

As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.

How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.

What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.

Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.

Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.

How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.

What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.

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We conduct regular internal energy audits

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Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.

In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.

How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.

What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.

How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.

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Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport

The airport is set to become Asia’s largest air connectivity hub.

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Enlight Metals has supplied 3,200 metric tonne of steel for the newly inaugurated Navi Mumbai International Airport, marking a major contribution to one of India’s largest infrastructure projects and reinforcing the company’s commitment to supporting national development.

The Navi Mumbai International Airport, developed under a Public-Private Partnership led by the Adani Group, was inaugurated today by Prime Minister Narendra Modi. The airport is set to become Asia’s largest air connectivity hub, enhancing regional connectivity, boosting economic growth, and expanding trade opportunities. Prime Minister Modi described the project as a “glimpse of Viksit Bharat,” highlighting its transformative impact on infrastructure and development in the region.

“The supply of 3,200 metric tonne of steel for this key project aligns with our focus on supporting critical infrastructure development through reliable and timely metal sourcing. Enlight Metals is committed to enhancing transparency and efficiency in the steel supply chain, contributing to projects integral to India’s growth objectives,” said Vedant Goel, Director, Enlight Metals.

Enlight Metals has implemented technology-driven solutions to strengthen supply chain efficiency, ensuring consistent availability of construction materials for large-scale projects nationwide. Its contribution to the Navi Mumbai International Airport underscores the company’s growing role in supporting India’s infrastructure development initiatives.

This milestone reflects Enlight Metals’ ongoing engagement in delivering quality materials and timely services for major national projects, further cementing its position as a reliable partner in India’s infrastructure sector

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