From automation to dust control, cutting-edge material handling systems are revolutionising cement production. ICR delves into how innovation is enhancing efficiency, safety, and sustainability in the cement industry.

Material handling systems play a crucial role in the cement industry, ensuring the efficient and safe movement of raw materials and finished products throughout the production process. These systems encompass various equipment and technologies designed to transport, store, and manage materials, including limestone, clay, gypsum and clinker.
The importance of effective material handling in cement production cannot be overstated. First, it significantly impacts operational efficiency by minimising downtime and optimising workflows. A well-designed material handling system reduces the likelihood of blockages and equipment failures, which can lead to costly interruptions. For instance, automated systems can enhance the speed and precision of material transfers, allowing for smoother operations and faster production cycles.
Moreover, effective material handling contributes to safety in the workplace. By automating tasks that involve heavy lifting or handling hazardous materials, the risk of accidents and injuries is considerably lowered. Implementing advanced technologies such as conveyors, air cannons, and dust control systems not only enhances safety but also supports environmental compliance by minimising dust emissions and waste generation.
Furthermore, material handling systems facilitate better inventory management and resource utilisation. By accurately controlling the flow of materials, plants can maintain optimal stock levels, reducing excess inventory and the associated carrying costs. This leads to improved profitability and sustainability as resources are utilised more efficiently.
Material handling systems are integral to the cement production process, driving efficiency, safety, and sustainability. As the industry continues to evolve, investing in innovative material handling technologies will be essential for cement manufacturers seeking to enhance their competitive edge and meet growing market demands.

Dust and emissions control methods
In the cement industry, managing dust and emissions during material transfer is critical for complying with environmental regulations and ensuring a sustainable operational framework. Excessive dust not only poses health risks to workers but also contributes to environmental degradation. Therefore, cement manufacturers are increasingly adopting effective dust control methods and emission reduction technologies throughout the material handling process.

• Enclosed conveyors: Utilising enclosed or covered conveyor systems significantly reduces dust emissions during the transport of raw materials. These systems minimise the exposure of materials to ambient air, effectively containing dust and preventing it from dispersing into the atmosphere.
• Dust suppression systems: Implementing dust suppression systems, such as water sprays or misting systems, helps to control airborne particulates during material transfer. By applying water to the material surface, these systems reduce the amount of dust generated during loading and unloading operations.
• Baghouse filters: For processes that generate fine dust, baghouse filters are an effective solution. These air pollution control devices capture particulate matter from exhaust gases, ensuring that emissions meet regulatory standards. By using fabric filters to trap dust particles, baghouses significantly improve air quality.
• Air cannons and vibrators: Air cannons, such as Martin® Typhoon Air Cannons, can be employed to dislodge material buildup in transfer points. This technology helps to minimise the need for manual cleaning, reducing the likelihood of dust generation during material handling.
• Sealed transfer points: Sealing transfer points where materials are loaded and unloaded prevents dust from escaping into the environment. Implementing hoppers and chutes with proper sealing mechanisms ensures that dust remains contained during material transfer.
• Real-time monitoring: Installing continuous emissions monitoring systems (CEMS) provides real-time data on dust and emission levels. This allows operators to promptly address any issues and adjust processes as needed to comply with environmental regulations.
• Employee training: Educating employees on best practices for material handling and dust control is vital. Proper training ensures that staff understand the importance of minimising dust emissions and can implement appropriate measures effectively.

By incorporating these methods into their operations, cement manufacturers can significantly reduce dust and emissions during material transfer, ensuring compliance with environmental regulations while promoting a healthier workplace and contributing to sustainable practices. As regulations continue to evolve, ongoing investment in innovative dust control technologies will be essential for the cement industry to meet both environmental and operational goals.

Innovations in material handling
In the cement industry, efficient material handling is crucial for smooth production and operational excellence. Over the years, innovations in equipment like air cannons, conveyors, feeders, and advanced chute designs have significantly enhanced the performance and reliability of material transfer systems, improved productivity and reduced downtime.
Marco Campanari, CEO, CICSA Group, says, “Our R&D department is always active, continuously driving innovation throughout the year. Specifically, we have developed advanced techniques to refine our welding technology, focusing on the butt-flash welding technology with more effective process control. Additionally, we have perfected sophisticated heat treatments, particularly in advanced case hardening processes. These innovations significantly increase the durability and extend the lifespan of our chains.”
Air cannons: Air cannons, such as the Martin® Typhoon Air Cannons, have revolutionised material flow management by preventing blockages and material build-ups in storage vessels, silos, and chutes. These devices release powerful bursts of compressed air to clear obstructions, reducing the need for manual interventions like poking or hammering. This not only enhances material flow but also improves worker safety and plant efficiency by minimising downtime.
Conveyors: Modern conveyors have become more advanced, with enclosed or covered designs that minimise dust emissions and improve material containment. Belt and screw conveyors are now equipped with energy-efficient motors and are designed to handle larger capacities while maintaining smooth material transfer, reducing spillage and wear. Enclosed conveyors, such as pipe conveyors, are particularly effective in reducing environmental impact by containing dust during transportation.
Feeders: Innovations in feeding systems, such as gravimetric and volumetric feeders, ensure precise and consistent material flow. These feeders are crucial for dosing raw materials into the production process, allowing for better control over material proportions, which directly impacts the quality of the final product. Advanced feeders are now equipped with automation and monitoring capabilities to maintain optimal flow rates, reduce wastage, and ensure uninterrupted production.
Advanced chute designs: Chute blockages have long been a challenge in cement plants, often leading to production stoppages and increased maintenance costs. Modern chute designs incorporate features such as wear-resistant liners, curved profiles and optimally angled surfaces to prevent material sticking and reduce wear. These advanced designs also help in controlling dust and minimising material spillage during transfer, improving the overall efficiency of the material handling process.
“Another key trend fuelling growth in the CE industry is the rising demand for technologically advanced and high-performance machinery. For instance, earth-moving equipment, such as backhoe loaders, are robust machines specifically designed for heavy-duty construction tasks. The latest generation of these machines boasts superior designs, enhanced engine technologies, and innovative features. They are equipped with smart connectivity options, including modern digital instrument clusters and advanced onboard diagnostics,” says, Saroj Chouhan, Fortune Business Insights.
Together, these innovations in material handling equipment have transformed cement plant operations, improving reliability, reducing operational costs, and ensuring compliance with environmental standards. By leveraging technologies like air cannons, efficient conveyors, precision feeders, and optimised chutes, cement manufacturers can achieve higher levels of productivity while minimising downtime and enhancing sustainability.

Role of automation and Industry 4.0
The integration of automation and Industry 4.0 technologies is transforming material handling systems in cement plants, making them more efficient, reliable, and sustainable. Advanced automation systems enable real-time monitoring, precise control and optimisation of material transfer processes, reducing human intervention and minimising operational disruptions.
Automation allows for the seamless operation of conveyors, feeders and crushers, enhancing the precision of material flow while reducing energy consumption and wear. Automated systems can also monitor equipment health, predict maintenance needs, and improve decision-making through data analytics, ensuring uninterrupted material handling.
Industry 4.0 technologies such as IoT sensors, cloud computing and AI-driven analytics provide deep insights into material handling systems. Real-time data on material flow, equipment performance, and energy usage allows plant operators to optimise the entire production chain, minimising bottlenecks and maximising efficiency. Predictive maintenance powered by Industry 4.0 reduces unexpected downtimes by alerting operators to potential issues before they lead to costly stoppages.
Together, automation and Industry 4.0 are revolutionising material handling in cement plants, driving operational efficiency, reducing costs, and improving sustainability through smarter and more data-driven processes.

Energy saving in material handling
Energy-saving solutions are becoming critical in cement plants to improve operational efficiency and reduce costs. One of the most effective methods is the use of energy-efficient motors, which consume less power while delivering the same output as traditional motors. These motors reduce energy losses and have a longer operational life, contributing to both cost savings and sustainability goals. Additionally, variable frequency drives (VFDs) offer significant energy savings by adjusting the speed of motors based on the demand of the material handling process, eliminating unnecessary power consumption during low-demand periods.
Optimising equipment layouts is another crucial strategy to enhance energy efficiency. By streamlining material transfer routes, reducing unnecessary material handling steps, and ensuring shorter conveyor lengths, plants can minimise the energy required for material transport. Well-designed layouts, in conjunction with efficient motors and VFDs, help create a more energy-conscious operation that reduces power usage, lowers operational costs, and contributes to a plant’s environmental objectives.

Challenges in material handling
Material handling in cement plants presents several key challenges that impact both operational efficiency and overall productivity. One major challenge is dealing with abrasive and bulk materials such as limestone, clinker, and raw meal, which can cause significant wear and tear on equipment. This leads to frequent maintenance requirements, unexpected downtimes, and increased operational costs. Additionally, handling these materials efficiently without causing blockages or disruptions during transfer is critical, yet often difficult, due to
the complexity of conveying systems and the heavy loads involved.
Another significant challenge is controlling dust and emissions during material transfer, particularly in light of increasingly stringent environmental regulations. Dust generation not only creates health and safety risks for workers but also contributes to environmental pollution. Effective dust control systems, such as dust suppression technologies and enclosed conveyors, are essential, but implementing these solutions while maintaining high material transfer efficiency can be complex. Balancing operational demands with regulatory compliance and sustainability goals remains a constant challenge for the cement industry.

Future trends in material handling
Emerging technologies are set to revolutionise material handling in the cement industry, offering the potential to enhance efficiency, reduce costs, and improve sustainability. Automation and Industry 4.0 technologies are leading this transformation, enabling real-time monitoring and predictive maintenance through sensors and data analytics. With the integration of Internet of Things (IoT) and AI-driven systems, cement plants can optimise equipment performance, detect issues before they cause downtime, and streamline material flow, all while reducing human intervention and error. These advancements not only increase productivity but also help in energy conservation by ensuring equipment operates at optimal efficiency.
Robotics and advanced material handling equipment like autonomous conveyors, drones for inventory management, and smart feeders are also gaining traction. These technologies reduce the physical burden on workers, minimise the risk of injury, and ensure continuous operations with minimal disruption. Additionally, innovations in sustainable technologies, such as energy-efficient motors, smart grid integration, and eco-friendly materials, further support the industry’s move towards greener operations. Together, these emerging technologies promise to transform material handling systems, making them more reliable, sustainable, and cost-effective in the future.

Conclusion
Material handling plays a pivotal role in the efficiency and sustainability of cement production. As the industry faces growing challenges such as dust control, energy consumption, and environmental regulations, the need for innovative solutions has become more critical than ever. Advanced technologies like air cannons, optimised conveyors and energy-saving equipment have already begun transforming cement plants, addressing these key challenges while improving overall operational efficiency. By integrating automated systems and Industry 4.0 capabilities, cement manufacturers can enhance material handling processes, reduce downtime, and achieve better environmental outcomes.
Looking ahead, the adoption of emerging technologies, including robotics, AI-driven systems and sustainable material handling innovations, will continue to drive the evolution of cement plants. These advancements hold the potential to significantly improve material flow, reduce operational costs and contribute to the industry’s ongoing efforts toward a greener and more efficient future. As cement plants embrace these innovations, they are well-positioned to meet the demands of modern production while maintaining a strong focus on sustainability and operational excellence.

– Kanika Mathur

Sustainable mining is shaping the cement industry’s path to environmental responsibility and paving the way for a greener future. However, it is an uphill task – one that requires technology, on-ground support and forward-thinking leadership. ICR looks at how companies are seeking to balance production demands with environmental responsibility.

Cement production relies heavily on the extraction of raw materials like limestone, clay, and gypsum, making the mining process a key component of the supply chain. However, traditional mining methods often result in significant environmental degradation, including habitat destruction, deforestation, and water contamination.
To address these issues, the cement industry is adopting sustainable mining practices that minimise environmental impact while ensuring resource efficiency. Techniques such as precision mining, water conservation, land reclamation, and the use of renewable energy in operations are being widely implemented. These practices not only help reduce the carbon footprint but also support biodiversity and ecosystem restoration in mining areas.
Pukhraj Sethiya, India Managing Director, and Jyotirmoy Saha, Senior Consultant, ReVal Consulting, say, “Mine planning is a complex job and requires extensive critical thinking along with technical competency. With a core focus on sustainability and resource recovery maximisation, our mine plans are built in ways that ensure long term gains for our esteemed clients. We deploy first principle thinking and create numerous design iterations which helps us in curating a comparative picture of the different ways of operating a particular mine. This involves defining the mine pit boundary first which is of prime importance to ensure optimum land requirement and utilisation.”
Sustainable mining is vital for the cement industry as it ensures the long-term availability of raw materials while aligning with global environmental goals. By embracing these practices, cement manufacturers can reduce waste, conserve natural resources, and contribute to a more sustainable production cycle, ultimately leading to enhanced cost efficiency and regulatory compliance in an increasingly eco-conscious market.

Impact of traditional mining
Traditional mining practices, often employed in the extraction of raw materials for cement production, pose significant environmental challenges. Conventional mining methods, such as open-pit mining, can lead to large-scale habitat destruction, deforestation, and soil erosion. The removal of vegetation and the disruption of natural landscapes often result in the loss of biodiversity and long-term ecological degradation.
One of the primary concerns is the pollution of water bodies due to the release of harmful chemicals and sediments, which can affect aquatic ecosystems and local communities relying on these resources. Air pollution, caused by dust emissions and the release of greenhouse gases from mining operations, contributes to climate change and affects the health of nearby populations. Land degradation and the generation of large quantities of waste materials also present significant environmental challenges.
Rajendra Bora, AVP – Mines, Wonder Cement, says, “Balancing raw material extraction with ecosystem preservation is one of our core priorities at Wonder Cement Ltd. We adopt a holistic approach to mining, integrating stringent environmental impact assessments before beginning operations. This allows us to plan our extraction activities in ways that minimise disruption to local ecosystems. For example, we have implemented controlled blasting techniques and utilised buffer zones to protect wildlife and vegetation. We have also restored abandoned quarries into eco-friendly landscapes that support local biodiversity. Use of Surface Miner helps in preserving the natural ecosystem during raw material extraction.”
“Wonder Cement is committed to reducing its reliance on natural resources through the use of alternative raw materials. We have adopted the use of industrial by-products such as fly ash, slag, and other recycled materials to supplement raw material requirements in cement production. These alternative materials not only reduce the need for mining but also contribute to the circular economy by diverting waste from landfills. This approach underscores our commitment to resource efficiency and sustainability” he adds.
Key challenges in addressing these issues include the need for sustainable resource management, the high costs of implementing environmentally friendly technologies, and balancing economic pressures with ecological preservation. Additionally, restoring ecosystems post-mining can be complex and time-consuming, requiring extensive rehabilitation efforts.
The cement industry must navigate these challenges by adopting more sustainable mining techniques and implementing stricter environmental regulations to mitigate the ecological impact of mining activities while ensuring the long-term viability of raw material extraction.

Emerging technologies in eco-friendly mining
The mining industry is witnessing a transformative shift towards eco-friendly practices through the adoption of emerging technologies like artificial intelligence (AI), automation, and data analytics. These innovations are revolutionising resource extraction, helping reduce the environmental footprint while enhancing efficiency in cement production.
AI-powered systems can predict equipment failures, optimise mining routes, and improve energy efficiency by analysing vast amounts of operational data. Automation, such as autonomous vehicles and robotic drills, minimises human intervention in hazardous environments and reduces energy consumption. These technologies also contribute to precision mining, where resource extraction is optimised to avoid wastage, lowering emissions and reducing land degradation.
Dr Ing. Metodi Zlatev, Head of the Sales and Project Department, Haver & Boecker Niagara, says, “Industry 4.0 and innovative technologies are revolutionising cement mining operations by making them more sustainable and efficient. Our Quatro 4.0 system allows operations to manage their system in an optimal way. It automatically, effortlessly and securely provides data that can signal potential maintenance issues while enabling deep insights into machine productivity, scrap rates and more. This proactive approach allows operations to reduce downtime and costs, optimise their processes and contribute to the environment.”
“Furthermore, our Pulse condition monitoring system, equipped with advanced sensors installed on critical machinery, provides 24/7 monitoring capabilities. This continuous surveillance ensures that any deviations or potential issues are detected early, allowing for timely interventions. The accompanying mobile app provides instant access to this data, facilitating quick decision-making and further reducing unexpected downtime. By integrating such advanced systems, cement companies can achieve their goals of operational excellence and environmental stewardship,” he adds.
Data analytics plays a crucial role in monitoring environmental impact, helping mining companies track emissions, water usage, and biodiversity changes in real-time. This data-driven approach enables better decision-making and supports compliance with environmental regulations.
By integrating AI, automation, and data analytics, eco-friendly mining technologies are improving resource efficiency, reducing operational costs, and minimising the ecological impact of mining operations. For the cement industry, these innovations offer a pathway towards more sustainable raw material sourcing, aligning with global decarbonisation goals.

Role of explosives in mining
Explosives play a critical role in mining operations, particularly in extracting raw materials for industries like cement production. Traditional explosives, such as ammonium nitrate fuel oil (ANFO), are widely used to break rock formations and access valuable minerals. While effective, the use of such explosives raises concerns about environmental impacts, including air pollution, ground vibrations and habitat disruption.
In the context of sustainable mining, there is a growing focus on using eco-friendly explosives and blasting techniques that minimise environmental harm. Emulsion-based explosives, for example, offer a safer, more efficient alternative with lower toxicity levels and reduced emissions. Innovations in precision blasting, supported by data analytics and real-time monitoring, also contribute to more controlled and targeted explosions, reducing waste and energy consumption.
Shubham Choudhari, Chief Technology Officer, SBL Energy, says, “At SBL Energy, we leverage advanced technology to improve resource recovery during blasting. Our precision blasting techniques ensure optimal rock fragmentation, minimising the need for re-blasting and ensuring that a higher proportion of extracted material is of high quality and ready for processing.”
Sustainable explosives practices align with broader goals of reducing carbon emissions and preserving ecosystems around mining areas. By incorporating these advancements, the cement industry can continue to meet its raw material demands while maintaining a commitment to environmental stewardship.

Reducing carbon footprint
Reducing the carbon footprint of mining operations has become a priority as the cement industry aims to align with global sustainability goals. A significant shift towards the adoption of renewable energy sources for powering mining equipment is helping to achieve this. Traditionally, mining operations have relied heavily on fossil fuels, leading to high carbon emissions. However, by integrating solar, wind, and other renewable energy solutions, mining companies can reduce their dependence on carbon-intensive power sources. Solar-powered mining equipment, wind farms, and hybrid energy systems are increasingly being deployed to lower emissions and enhance energy efficiency.
Furthermore, electrification of heavy machinery, such as electric trucks and loaders, is contributing to a decrease in the use of diesel, significantly cutting operational emissions. These renewable-powered technologies not only reduce greenhouse gas emissions but also bring long-term cost savings by lowering fuel expenses and enhancing operational resilience against energy price fluctuations.
For the cement industry, adopting renewable energy in mining operations is crucial in minimising environmental impact, supporting the industry’s decarbonisation journey, and contributing to global efforts to combat climate change.

Sustainable water management and biodiversity preservation
Sustainable water management has become a critical focus in mining, especially within the cement industry, where efficient resource utilisation is essential. Mining operations can be water-intensive, but advanced techniques like water recycling, rainwater harvesting, and the treatment of wastewater are helping to mitigate water scarcity issues. Closed-loop water systems, which minimise water withdrawal from local sources, ensure that mining operations remain eco-friendly and sustainable.
Restoration of mining sites post-extraction is another key aspect of responsible mining. Leading practices include land reclamation, afforestation and soil stabilisation efforts that rehabilitate the environment after mining activities cease. These measures ensure that ecosystems are restored, enabling the land to support plant life and wildlife once again.
Efforts to preserve biodiversity around mining areas are equally important. Companies are increasingly conducting biodiversity assessments before starting extraction and implementing strategies to protect local flora and fauna. Creating wildlife corridors, reducing habitat fragmentation, and ensuring minimal disruption to natural ecosystems are becoming standard practices in sustainable mining, reflecting the industry’s commitment to environmental stewardship. These initiatives not only help in reducing the environmental footprint of mining operations but also support long-term ecological balance, aligning with global sustainability goals.

Alternative fuels in mining
The shift towards incorporating alternative fuels in mining machinery is gaining traction as industries, including the cement sector, strive to reduce their carbon footprints and environmental impact. Utilising alternative fuels like biodiesel, hydrogen, and compressed natural gas (CNG) in mining equipment helps reduce the reliance on traditional fossil fuels, which are major contributors to greenhouse gas emissions.
One of the primary benefits of this shift is a significant reduction in CO2 emissions, aligning with global sustainability goals and the industry’s efforts to achieve net-zero targets. Additionally, alternative fuels often offer enhanced energy efficiency and lower operational costs over time, making mining operations more economically sustainable.
Furthermore, using cleaner fuel sources improves air quality in and around mining sites, promoting healthier working environments for employees and minimising the environmental degradation caused by mining activities. As cement production continues to grow, adopting alternative fuels in mining machinery becomes a key strategy for fostering greener, more sustainable mining practices.

Ethical supply chains from mine to cement plant
The cement industry faces increasing scrutiny regarding the ethical implications of its supply chains, particularly in sourcing raw materials from mining operations. Establishing transparent and ethical supply chains is essential not only for compliance with regulatory standards but also for fostering trust among stakeholders, including consumers, investors and local communities.
To achieve this, companies must prioritise traceability at every stage of the supply chain, ensuring that materials are sourced responsibly and sustainably. This includes conducting thorough due diligence on suppliers to verify their environmental and labour practices. Embracing technologies like blockchain can enhance transparency, allowing for real-time tracking of materials from extraction through to processing and delivery at cement plants.
Additionally, engaging with local communities and stakeholders is crucial for addressing social and environmental concerns associated with mining activities. By investing in community development and ensuring fair labour practices, companies can build stronger relationships and support sustainable practices that benefit all parties involved.
Ultimately, creating ethical supply chains not only mitigates risks but also enhances brand reputation and contributes to the overall sustainability of the cement industry. By committing to transparency and ethical sourcing, companies can help pave the way for a more responsible and sustainable future in cement production.

Challenges in cement mining
Cement mining, a critical component of the cement production process, faces numerous challenges that can impact efficiency, sustainability and overall operational success. Understanding these challenges is essential for industry stakeholders aiming to optimise mining operations while adhering to environmental and social standards.

• Regulatory compliance: The cement industry is subject to stringent environmental regulations and mining laws. Ensuring compliance with these regulations can be challenging, requiring substantial investment in environmental management systems and processes.
• Environmental impact: Traditional mining practices can lead to significant ecological disruptions, including habitat destruction, soil erosion and water contamination. Balancing the need for raw materials with environmental protection is a complex challenge that requires innovative practices and technologies.
• Resource depletion: As easily accessible reserves are depleted, mining operations must dig deeper or explore less accessible locations, which can increase costs and operational risks. Sustainable resource management and efficient extraction techniques are critical to mitigating this issue.
• Community relations: Cement mining often occurs in close proximity to local communities, which can lead to conflicts over land use, environmental concerns and social impacts. Building and maintaining positive relationships with local stakeholders is essential for the long-term success of mining operations.
• Technological advancements: Keeping pace with rapidly evolving technologies in the mining sector is a challenge. Adopting new technologies, such as automation and data analytics, can enhance efficiency but may require significant investment and training.
• Economic fluctuations: Volatility in the global cement market can affect demand for raw materials and, consequently, mining operations. Companies must develop strategies to adapt to market changes while maintaining operational efficiency.

Addressing these challenges requires a multifaceted approach that integrates sustainable practices, community engagement and technological innovation. By proactively tackling these issues, the cement industry can enhance the resilience and sustainability of its mining operations, ultimately contributing to a more responsible cement production process.

Innovations on the horizon for sustainable mining
As the cement industry increasingly prioritises sustainability, innovative practices and technologies are emerging to transform mining operations. The integration of advanced automation, robotics and AI is optimising resource extraction, reducing operational costs and minimising environmental impact. These technologies enhance decision-making and operational efficiency, allowing companies to improve resource allocation and predict equipment failures, thereby minimising waste.
Moreover, innovations in eco-friendly explosives and the shift towards electric and hybrid mining equipment are significantly reducing the environmental footprint of mining operations. Sustainable explosives minimise vibrations and dust emissions, improving safety and reducing ecological disruption. The adoption of IoT-enabled remote monitoring systems further enhances operational efficiency and safety by allowing real-time tracking and management of mining processes.
The long-term integration of these innovations will not only support the cement industry’s growth trajectory but also help align it with environmental regulations and climate goals. By optimising resource efficiency and reducing waste, the cement industry can meet the increasing global demand for its products while fostering better relationships with local communities and attracting investment in green technologies. Embracing these advancements positions the industry as a leader in sustainable development, paving the way for a more resilient and eco-friendly future.

Conclusion
The future of sustainable mining in the cement industry is bright, driven by innovative technologies and practices that prioritise environmental responsibility. The integration of advanced automation, eco-friendly explosives, and IoT solutions is reshaping mining operations, enhancing efficiency and significantly reducing ecological impacts. As the industry embraces these advancements, it not only meets the growing global demand for cement but also aligns with sustainability goals and environmental regulations. By fostering a commitment to sustainable mining, the cement industry can ensure its long-term growth while contributing to a healthier planet and building stronger relationships with communities, ultimately paving the way for a more resilient and sustainable future.

Some things are changing at FLSmidth Cement, but most remain the same, as the company’s Indian head, Manoj Taneja, explained to Indian Cement Review.

FLSmidth Cement is changing. Over recent years, the company’s pureplay strategy has separated its cement and mining businesses, and the cement business is now undergoing divestment: news that was met by some with uncertainty. However, according to Manoj Taneja, Head of India Cluster and Designated Partner in FLSmidth Cement India LLP, this has all been a “good move” that allows the cement business to “take control of our future”.
Taneja began his professional career as a service engineer at EEL India Ltd, a manufacturer of various material handling and bag packing systems acquired by FLSmidth in 2009. He has led the company’s Indian operations since 2022. “It is an exciting time at FLSmidth Cement. With pureplay and the divestment, we can now chart our own course. The most obvious example of this in our Indian business is consolidating our manufacturing footprint into a single facility near our corporate headquarters in Chennai. This allows us to focus exclusively on our cement clients, improving efficiency and responsiveness, simplifying logistics, and centralising our expertise into a single point of excellence. Chennai also offers good access to the rest of the country, making it easier for clients to visit our factory for inspections and performance testing.”
The corporate headquarters is also moving as the company seeks offices that better match its needs. “As we continue to embrace a flexible post-COVID working model, finding a workspace that supports this shift and provides our employees with a favourable working environment is essential,” Taneja explained. “We are staying in Chennai, however, and currently undertaking a site selection process that aims to limit the inconvenience caused to employees.”

A name you can rely on
Some things, however, remain constant. “We are still delivering the same industry-leading equipment and services as we have always done,” according to Taneja. Nowhere is this more obvious than the record-setting new clinker line at Shree Cement Ltd’s Nawalgahr plant in Rajasthan. Inaugurated in December 2023 with a guaranteed capacity of 11,500 tph, the plant is averaging daily clinker production of 13,695 tonnes. The line features a four-string preheater with low-NOX calciner, a 6m dia. x 88m long kiln, and the largest Cross Bar® Cooler ever delivered, with a grate area of over 325m2.
Shree Cement Ltd also recently signed their first group-level PlantLine™ service agreement in India, covering all current and future FLSmidth Cement automation solutions across seven plants. “PlantLine agreements aim to maintain the operational excellence of digital and automation solutions through a comprehensive, customisable range of services,” explained Tanega. “The Shree Cement agreement puts us just shy of 300 PlantLine agreements globally and shows the increasing significance of services that help improve and maintain plant performance.”
“One of the main benefits of our services is access to specialist (and potentially hard-to-acquire) skills and experience,” continued Taneja. “Our global network offers 24/7 access to support from a world-leading team of experts in all aspects of the cement-making process, plant, equipment, and automation systems, wherever you are in the world.”

Renewed focus on cement
Another outcome of the company’s pureplay transition is “keeping our cement clients front and centre of our activities; there is no competition with mining,” emphasised Taneja. “For example, here, in India, we recently ran nine client-focused webinars on diverse topics, all on the theme of enhancing equipment reliability. These sessions received an overwhelming response, attracting over 100 participants each, from all levels of client organisations, which indicates the widespread interest and engagement in the topics discussed.”
Webinars are a “great way to exchange and foster closer collaboration between us and our clients,” Taneja added. “However, we also understand the importance of face-to-face meetings and will attend several upcoming in-person conferences.”
This includes the upcoming 18th NCB International Conference and Exhibition in New Delhi, where FLSmidth Cement will present papers on various topics, including a paper on alternative fuels. “We are particularly excited about the impending commercial launch of our new FUELFLEX® Pyrolyzer, which uses hot meal from the lower preheater cyclones to dry and pyrolyze hard-to-burn refuse-derived fuels or biomass,” said Taneja. This innovative new equipment enables cement plants to achieve up to 100% fossil fuel replacement in the calciner, cutting CO2 emissions, diverting waste from landfills, and reducing fuel costs.
Other topics to be presented include a paper on the digital cement plant and another on supplementary cementitious materials, focusing on calcined clay. “We see growing interest in technologies that reduce the carbon intensity of cement,” explained Taneja. “Part of our core mission is to help the cement industry address and reduce its environmental impact. We are also fortunate to have some of the industry’s true sustainability leaders here in India, opening the way for collaborative innovation to solve these most pressing issues.”

A past to build the future on
“Change is a fact of life,” concluded Taneja. “This is particularly true in a dynamic and changing market such as the Indian cement industry. However, there are some things you can rely on throughout all the changes. One of those cornerstones is FLSmidth Cement. We remain committed to supplying equipment, services, and solutions that
improve the cement industry – just as we have always done.”

(Communication by the management of the company)