Economy & Market

Stepping Up Sustainability

Published

1 year ago

November 23, 2024

Roshna

Supplementary Cementitious Materials (SCMs) offer a sustainable way to reduce cement usage, enhance concrete durability and lower the environmental impact of construction. ICR discusses integrating industrial byproducts like fly ash and slag as SCMs support resource conservation, cost savings, and long-lasting infrastructure.

The construction industry is at a pivotal juncture, facing increasing pressure to adopt sustainable practices amidst growing environmental concerns. As a major contributor to global greenhouse gas emissions, the industry recognises the urgent need for innovative solutions to minimise its ecological footprint. One such solution is the use of Supplementary Cementitious Materials (SCMs), which have emerged as vital components in the quest for sustainable concrete production. SCMs not only reduce the reliance on Portland cement—one of the most significant contributors to carbon emissions in construction—but also enhance the performance and durability of concrete.
According to a research report published by Spherical Insights & Consulting, the Global Supplementary Cementitious Materials Market Size is Expected to Grow from USD 25.40 Billion in 2023 to USD 47.70 Billion by 2033, at a CAGR of 6.50 per cent during the forecast period 2023-2033. Asia Pacific is estimated to hold the largest share of the supplementary cementitious materials market over the forecast period.
The market for supplementary cementitious materials is experiencing rapid growth, driven by factors such as rapid/fast-paced urbanisation and infrastructure development in emerging economies like China, India, Malaysia, and Singapore. Supportive policies and regulations, coupled with rising demand for durable concrete with lower penetrability, are key drivers impelling the surge in demand for supplementary cementitious materials.

Understanding SCMs
SCMs are materials that can be used to replace a portion of Portland cement in concrete. They react with calcium hydroxide to form additional cementitious compounds, thereby enhancing the concrete’s properties. SCMs include a variety of materials, such as fly ash, ground granulated blast-furnace slag (GGBS), silica fume and natural pozzolans.

Fly ash: Fly ash is a byproduct from burning pulverised coal in electric power generating plants. It is collected from the flue gases and is commonly used in concrete due to its pozzolanic properties. Fly ash can improve workability, reduce water demand, and enhance long-term strength and durability. Its fine particles fill voids within the concrete matrix, resulting in a denser and more impermeable material.
In an authored article by Dr Supradip Das, Vice Chairman, CED 41 (BIS), for NBM&CW, he points out that compared to cement and water, the chemical reaction between fly ash and calcium hydroxide occurs at a slower pace, leading to a delayed setting time in concrete, which promotes enhanced hardening. He explains how this slower hardening, together with the varying properties of fly ash, can present substantial challenges in concrete production. In India, ash ponds currently occupy approximately 65,000 acres, and fly ash production is projected to exceed 235 million tonnes by 2024, he elaborates.
GGBS: This material is obtained by rapidly cooling molten iron slag from a blast furnace with water or steam. GGBS is known for its high strength and durability, particularly in aggressive environments where concrete is exposed to chlorides or sulphates. It not only enhances the concrete’s mechanical properties but also contributes to its resistance to corrosion and shrinkage.
Silica fume: Silica fume is a byproduct of the production of silicon metal or ferrosilicon alloys. It is extremely fine, with a particle size much smaller than that of cement. When added to concrete, silica fume significantly increases strength, reduces permeability, and enhances durability. Its high silica content promotes additional pozzolanic reactions, leading to a denser concrete matrix.
Natural pozzolans: Natural pozzolans, such as volcanic ash and pumice, have been used in construction for centuries. They react with calcium hydroxide in the presence of moisture to form compounds with cementitious properties. These materials are particularly valuable in regions where volcanic ash is abundant, as they are sustainable alternatives that can improve concrete’s performance.

Benefits of Using SCMs
The incorporation of SCMs into concrete mixtures offers numerous benefits that align with sustainable construction practices:

Enhanced durability: Concrete containing SCMs exhibits improved durability characteristics, including increased resistance to sulfate attack, reduced permeability, and enhanced longevity. This durability translates into lower maintenance costs and longer service life for structures.
Reduced carbon footprint: The use of SCMs significantly decreases the amount of Portland cement required in concrete. As cement production is responsible for approximately 8 per cent of global CO2 emissions, reducing its usage through SCMs can lead to substantial reductions in greenhouse gas emissions.
Improved workability: SCMs like fly ash improve the workability of fresh concrete, making it easier to place and finish. This can lead to enhanced productivity on construction sites and reduced labour costs.
Cost-effectiveness: By substituting a portion of cement with SCMs, construction projects can achieve cost savings. Fly ash and GGBS, being industrial byproducts, are often more affordable than Portland cement.
Waste Utilisation: The use of SCMs promotes recycling and waste reduction. By utilising industrial byproducts such as fly ash and slag, the construction industry can contribute to a circular economy.

Vimal Joshi, Assistant General Manager – Quality Control, Wonder Cement, says, “SCMs like fly ash, slag and silica fume significantly enhance the durability and strength of concrete, particularly under diverse environmental conditions. Fly ash improves workability and extends the setting time, making it ideal for mass concrete projects and hot climates. The fine particles fill voids in the cement matrix, reducing permeability and enhancing resistance to sulphate and chloride attack, thus increasing durability. Slag, with its slow hydration properties, improves long-term strength and is particularly effective in reducing thermal cracking in massive concrete structures. It also enhances resistance to aggressive chemicals, making it suitable for marine environments and industrial applications.”
“Silica fume, known for its ultrafine particles, increases the density of concrete, boosting both compressive strength and durability, especially in harsh environments. By incorporating SCMs, we create concrete that is more resilient to environmental stressors, ensuring longer-lasting structures with reduced maintenance needs” he adds.

Sustainable construction
Sustainable construction practices are increasingly prioritised due to their environmental, social and economic impact. SCMs play a pivotal role in this paradigm shift. By integrating SCMs into concrete production, the construction industry can achieve:

Reduced resource consumption: By minimising the reliance on virgin materials, SCMs contribute to the conservation of natural resources. This is particularly important in regions where natural aggregates and raw materials are scarce.
Promotion of circular economy: The use of byproducts like fly ash and slag exemplifies a circular economy approach, where waste materials are repurposed for new applications. This not only reduces landfill waste but also promotes sustainable sourcing practices.
Alignment with green building certifications: Many green building rating systems, such as LEED (Leadership in Energy and Environmental Design), encourage the use of SCMs. By incorporating these materials, projects can earn credits for sustainability, making them more appealing to environmentally conscious clients.

Tushar Khandhadia, General Manager – Production, Udaipur Cement Works, says, “SCMs provide an environmentally friendly alternative to traditional Portland cement by reducing the amount of clinker required to produce cement. Clinker is the main ingredient in Portland cement and is produced by heating limestone and other raw materials to high temperatures, which releases significant GHG emissions. Thus, by using SCMs, less clinker is required, thereby reducing GHG emissions, energy use and the environmental impact of cement production. Some SCMs such as fly ash and slag are by-products of other industrial processes, meaning that their use in cement production reduces waste and enhances resource efficiency. Moreover, the use of SCMs can enhance the properties of concrete, thereby increasing its durability and service life which helps to further reduce the overall embodied carbon of the structure.”

“In short, the use of SCMs contributes to reducing the carbon footprint of cement production by improving the efficiency of resource utilisation and reducing greenhouse gas (GHG) emissions during the production process. This has led to an increased demand for SCMs in the construction industry, as environmental concerns and sustainable development goals have become more prominent factors in the selection of building materials,” he adds.

Performance Characteristics of SCMs
The performance characteristics of concrete are significantly enhanced when SCMs are incorporated. Key attributes include:

Increased Compressive Strength: Studies have demonstrated that concrete containing SCMs, particularly silica fume and GGBS, can achieve higher compressive strengths compared to conventional concrete mixtures. This is crucial for high-performance applications, such as high-rise buildings and infrastructure.

Dr SB Hegde, Professor, Jain College of Engineering and Technology, Hubli, and Visiting Professor, Pennsylvania State University, USA states, “The raw mix plays a vital role in clinker formation. A high liquid phase due to improper ratios of silica, alumina, and iron oxide can lead to excessive melting. Controlling the silica modulus (SM: 2.3-2.7) and alumina modulus (AM: 1.3-1.8) ensures a more stable clinker and reduces the risk of red river formation. If the raw mix is improperly proportioned, red river formation becomes more likely due to high fluxing compounds that melt at lower temperatures. The occurrence of red river has numerous negative impacts on both clinker quality and kiln performance.”

Reduced permeability: SCMs improve the density of the concrete matrix, leading to reduced permeability. This characteristic is vital for structures exposed to harsh environmental conditions, as it minimises water ingress and subsequent damage.
Altered hydration kinetics: The presence of SCMs can influence the hydration process of cement, often resulting in a slower but more sustained release of heat. This is beneficial in mass concrete applications where heat buildup can lead to cracking.
Long-term strength development: Concrete containing SCMs typically exhibits improved long-term strength characteristics. While initial strength development may be slower, the overall strength continues to increase over time as the pozzolanic reactions progress.

Guidelines and Standards
The effective use of SCMs in concrete is governed by various guidelines and standards. In India, the Bureau of Indian Standards (BIS) has established specific specifications for the use of fly ash and GGBS in concrete.

IS 456:2000: This Indian Standard provides general guidelines for the use of SCMs in concrete and outlines performance requirements to ensure the quality of construction materials. Adherence to these standards is crucial for maintaining the integrity and performance of concrete.
IS 1489 (Part 1 and Part 2): These standards specifically address the use of fly ash and GGBS, providing criteria for their quality, chemical composition, and performance in concrete.

Following these guidelines ensures that SCMs contribute positively to concrete performance, supporting the construction of durable and sustainable structures.

Challenges in SCM Adoption
Despite their numerous advantages, several challenges hinder the widespread adoption of SCMs in India:

Quality variability: The quality of SCMs can vary significantly depending on their source and production methods. This variability can lead to inconsistencies in concrete performance, necessitating rigorous quality control measures.
Regulatory barriers: A lack of comprehensive regulations and standards for SCMs can impede their acceptance and use in construction projects. Greater clarity and uniformity in regulations would facilitate broader adoption.
Compatibility issues: Different types of cement and SCMs may not always be compatible, leading to challenges in mix design. It is essential to conduct thorough testing to ensure that the chosen SCMs integrate well with the cement used in a specific project.

Shreesh A Khadilkar, Consultant and Advisor, and Former Director Quality and Product Development, ACC says, “Clinkers with good reactivity are observed to show 1 Day strengths in lab ground cements of 30 to 35 MPa. Higher values being observed when clinker alkali sulphates are high (especially with Petcoke as fuel), the achieved Blaine’s and quantity of nibs removed from the lab ground cement, in the fixed grinding time is also indicative of clinker grindability. Judicious raw mix optimisation with existing or alternative corrective materials (with the fuel mix used by the plant) can be attempted so as to have a clinker with improved reactivity/hydraulic potential. In a running plant the approach has to be by attempting small gradual changes to clinker composition and assessing the impact of the changes, on kiln performance and clinker quantity.”
Awareness and training: There is a need for increased awareness and training among construction professionals regarding the benefits and proper use of SCMs. Educating stakeholders can drive their acceptance and utilisation.

Successful Applications of SCMs
Several projects across India have successfully demonstrated the benefits of using SCMs, showcasing their effectiveness in enhancing concrete performance while reducing environmental impact:

Delhi Metro Rail Corporation (DMRC): In the construction of the DMRC, high volumes of fly ash were used to produce concrete. This decision resulted in substantial cost savings, improved workability, and reduced environmental impact. The use of SCMs also contributed to the project’s overall sustainability goals.
Narmada River Valley Project: In this project, GGBS was incorporated into the concrete mix, enhancing the durability and longevity of structures exposed to the water-saturated environment. The use of GGBS ensured that the concrete could withstand the harsh conditions prevalent in the region, reducing maintenance needs and extending the service life of the structures.

These case studies illustrate the practical benefits of using SCMs in large-scale construction projects, reinforcing their viability as sustainable alternatives.

Future Trends in SCM Use
As the Indian cement industry evolves, several trends are expected to shape the future of SCM utilisation:

Innovations in materials: Research into new SCMs, such as bio-based materials and advanced pozzolans, is on the rise. These innovations may expand the range of materials available for sustainable concrete production, providing more options for construction professionals.
Increased awareness: Growing awareness among construction professionals about the benefits of SCMs is likely to drive their adoption. Workshops, seminars, and training programs can play a crucial role in educating stakeholders about proper mix design and applications.
Government support: Policymakers can promote the use of SCMs by offering incentives for sustainable construction practices. This can include subsidies, tax breaks, or recognition for projects that utilise SCMs, encouraging broader acceptance.
Technological advancements: Advances in technology may facilitate better quality control, enabling more consistent production of SCMs and improving their integration into concrete mixtures.

Conclusion
SCMs represent a vital component in the transition toward more sustainable concrete production. By incorporating these materials, the Indian cement industry can significantly reduce its carbon footprint, enhance concrete performance, and contribute to a circular economy. While challenges remain, the benefits of SCMs far outweigh the drawbacks, making them an essential element in the future of sustainable construction. As awareness grows
and innovations emerge, SCMs are poised to play an even more significant role in shaping a greener built environment.

– Kanika Mathur

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SEW-EURODRIVE India Opens Drive Technology Centre in Chennai

Published

2 weeks ago

March 25, 2026

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The new facility strengthens SEW-EURODRIVE India’s manufacturing, assembly and service capabilities

SEW-EURODRIVE India has inaugurated a new Drive Technology Centre (DTC) in Chennai, marking a significant expansion of its manufacturing and service infrastructure in South India. The facility is positioned to enhance the company’s responsiveness and long-term support capabilities for customers across southern and eastern regions of the country.

Built across 12.27 acres, the facility includes a 21,350-square-metre assembly and service setup designed to support future industrial growth, evolving application requirements and capacity expansion. The centre reflects the company’s long-term strategy in India, combining global engineering practices with local manufacturing and service capabilities.

The new facility has been developed in line with green building standards and incorporates sustainable features such as natural daylight utilisation, solar power generation and rainwater harvesting systems. The company has also implemented energy-efficient construction and advanced climate control systems that help reduce shopfloor temperatures by up to 3°C, improving production stability, product quality and working conditions.

A key highlight of the centre is the 15,000-square-metre assembly shop, which features digitisation-ready assembly cells based on a single-piece flow manufacturing concept. The facility also houses SEW-EURODRIVE India’s first semi-automated painting booth, aimed at ensuring uniform surface finish and improving production throughput.

With the commissioning of the Chennai Drive Technology Centre, SEW-EURODRIVE India continues to strengthen its manufacturing footprint and reinforces its long-term commitment to supporting industrial growth and automation development in India.

Concrete

Material Flow Efficiency

Published

3 weeks ago

March 18, 2026

admin

We explore how material handling systems are becoming strategic assets in cement plants, enabling efficient movement of raw materials, clinker and finished cement. Advanced conveying, automation and digital technologies are improving plant productivity while supporting energy efficiency and sustainability goals.

Material handling systems form the operational backbone of cement plants, enabling the efficient movement of raw materials, clinker and finished cement across complex production networks. With India’s cement industry producing over 391 million tonnes of cement in FY2024 and possessing an installed capacity of around 668 mtpa, according to the CRISIL Research Industry Report, 2025, efficient material logistics have become critical to maintaining plant productivity and cost competitiveness. At the same time, cement production is highly energy intensive and contributes around 7 per cent to
8 per cent of global CO2 emissions, making efficient material flow and logistics optimisation essential for reducing operational inefficiencies and emissions states the International Energy Agency Cement Technology Roadmap, 2023. As plants scale capacity and integrate digital technologies, modern material handling systems, ranging from automated conveyors to intelligent stockyards, are increasingly recognised as strategic assets that influence plant stability, energy efficiency and environmental performance.

Strategic role of material handling
Material handling is no longer viewed as a secondary utility within cement plants; it is now recognised as a strategic system that directly influences production efficiency and process stability.
Cement manufacturing involves the continuous movement of large volumes of limestone, clay, additives, clinker and finished cement across multiple production stages. Even minor disruptions in conveying systems or storage infrastructure can lead to kiln feed fluctuations, production delays and significant financial losses. According to Indian Cement Industry Operational Benchmarking Study, 2024, unplanned downtime in large integrated cement plants can cost between Rs.15–20 lakh per hour, highlighting the economic importance of reliable material handling systems.
Modern cement plants are therefore investing in advanced mechanical handling systems designed for high throughput and operational reliability. Large integrated plants can process over 10,000 tonnes per day of clinker, requiring highly efficient conveying systems and automated stockyards to maintain continuous material flow, suggests the International Cement Review Industry Analysis, 2024. Efficient material handling also reduces spillage, minimises dust emissions and improves workplace safety. As cement plants become larger and more technologically advanced, the role of material handling is evolving from simple transport infrastructure to a critical operational system that supports both productivity and sustainability.

From quarry to plant
The transport of raw materials from quarry to processing plant represents one of the most energy-intensive stages of cement production. Traditionally, limestone and other raw materials were transported using diesel-powered trucks, which resulted in high fuel consumption, dust generation and increased operational costs. However, modern plants are increasingly adopting long-distance belt conveyors and pipe conveyors as a more efficient alternative. These systems allow continuous material transport over distances of 10–15 kilometres, significantly reducing fuel consumption and operating costs while improving environmental performance, states the FLSmidth Cement Industry Technology Report, 2024.
Milind Khangan, Marketing Manager, Vertex Market Research & Consulting, says, “Efficient and enclosed handling of fine materials such as cement, fly ash and slag requires modern pneumatic conveying systems. By optimising the air-to-material ratio, these systems can reduce energy consumption by 10 per cent to 15 per cent while ensuring smooth material flow. Closed-loop conveying further minimises dust loading and improves the performance of bag filters, supporting cleaner plant operations. In addition, flow-regulated conveying lines help prevent clogging and maintain reliable dispatch performance. Overall, automation in pneumatic conveying delivers immediate operational benefits, including improved equipment uptime, lower energy use, reduced material spillage and more stable kiln and mill performance.”
Pipe conveyor systems are particularly gaining traction because they provide a completely enclosed transport system that prevents material spillage and dust emissions. According to global cement engineering studies, conveyor-based transport can reduce energy consumption by up to 30 per cent compared to truck haulage, while also improving operational reliability. Several cement plants in India have already implemented such systems to stabilise quarry-to-plant logistics while reducing carbon emissions associated with diesel transport.

Stockyard management and homogenisation
Stockyards play a critical role in maintaining raw material consistency and stabilising kiln feed quality. Modern cement plants use advanced stacker and reclaimer systems to ensure efficient storage and blending of raw materials before they enter the grinding and pyroprocessing stages. Automated stacking methods such as chevron or windrow stacking enable uniform distribution of materials, while bridge-type or portal reclaimers ensure consistent extraction during kiln feed preparation. These systems are essential for maintaining stable chemical composition of raw meal, which directly influences kiln efficiency and clinker quality. The Cement Plant Operations Handbook, 2024 indicates that advanced homogenisation systems can reduce raw mix variability by up to 50 per cent, significantly improving kiln stability and energy efficiency. Integrated stockyard management systems also incorporate sensors for monitoring bulk density, moisture levels and stockpile volumes, enabling real-time control over material blending processes.

Clinker and cement conveying technologies
Once clinker is produced in the kiln, it must be efficiently transported to storage silos and subsequently to grinding and packing units. Modern cement plants rely on high-capacity belt conveyors, bucket elevators and pneumatic conveying systems to manage this stage of material flow. Steel-cord belt bucket elevators are now capable of lifting materials to heights exceeding 120 metres with capacities reaching 1,500 tonnes per hour, making them suitable for large-scale clinker production lines, states the European Cement Engineering Association Technical Paper, 2023.
For fine materials such as cement, fly ash and slag, pneumatic conveying systems provide a reliable and dust-free solution. These systems transport powdered materials using controlled airflow, ensuring enclosed and contamination-free movement between grinding units, silos and packing stations. Optimised pneumatic systems can reduce energy consumption by 10 per cent to 15 per cent compared to older conveying technologies, while also improving plant cleanliness and environmental compliance, according to the Global Cement Technology Review, 2024.

Automation and digitalisation
Digitalisation is transforming material handling systems by introducing real-time monitoring, predictive maintenance and automated control. Advanced sensors and Industrial Internet of Things (IIoT) platforms enable plant operators to track conveyor health, stockpile levels and equipment performance in real time. Predictive maintenance systems analyse vibration patterns, temperature fluctuations and equipment load data to detect potential failures before they occur. According to McKinsey’s Industry 4.0 Manufacturing Report, 2023, for heavy industries, digital monitoring and predictive maintenance technologies can reduce equipment downtime by up to 30 per cent and increase productivity by 10 per cent to 15 per cent. Digital control centres also integrate data from conveyors, stacker reclaimers and dispatch systems, enabling centralised management of material flows from quarry to dispatch.

Handling of AFR
The growing adoption of Alternative Fuels and Raw Materials (AFR) has introduced new challenges and opportunities for material handling systems in cement plants. AFR materials such as refuse-derived fuel (RDF), biomass and industrial waste often have irregular particle sizes, variable moisture content and lower bulk density compared to conventional fuels. As a result, specialised storage, dosing and feeding systems are required to ensure consistent kiln combustion. According to the Cement Sector Decarbonisation Roadmap published by NITI Aayog in 2026, increasing the use of AFR could enable India’s cement sector to achieve thermal substitution rates of around 20 per cent in the coming decades. To support this transition, plants are investing in automated receiving stations, shredding units, drying systems and precision dosing equipment to stabilise AFR supply and combustion performance.

Energy efficiency and dust control
Material handling systems also play a crucial role in improving plant energy efficiency and environmental performance. Modern conveyor systems equipped with variable speed drives and energy-efficient motors can significantly reduce electricity consumption. Permanent magnet motors used in conveyor drives can deliver 8 per cent to 12 per cent energy savings compared to conventional induction motors, improving overall plant energy efficiency according to the IEA Industrial Energy Efficiency Study, 2023. Dust control is another major concern in cement plants, particularly during material transfer and storage operations. Enclosed conveyors, dust extraction systems and advanced bag filters are widely used to minimise particulate emissions and improve workplace safety.

Future trends in material handling
The future of material handling in cement plants will be shaped by automation, digitalisation and sustainability considerations. Emerging technologies such as AI-driven logistics optimisation, autonomous mobile equipment and digital twins are expected to further improve plant efficiency and operational visibility. Digital twin models allow engineers to simulate material flow patterns, optimise stockyard operations and predict equipment performance under different operating conditions. According to the International Energy Agency Digitalisation and Energy Report, 2024, the adoption of advanced digital technologies could improve industrial energy efficiency by up to 20 per cent in heavy industries such as cement manufacturing. As cement plants expand capacity and adopt low-carbon technologies, intelligent material handling systems will play a critical role in maintaining productivity and reducing environmental impact.

Conclusion
Material handling systems have evolved from basic transport infrastructure into strategic operational systems that directly influence plant efficiency, reliability and sustainability. From quarry transport and automated stockyards to digital dispatch platforms and advanced conveying technologies, modern material handling solutions enable cement plants to manage large production volumes while maintaining process stability.
As India’s cement industry continues to expand to meet infrastructure and urban development demands, investments in advanced material handling technologies will become increasingly important. By integrating automation, digital monitoring and energy-efficient systems, cement manufacturers can improve operational performance while supporting the industry’s long-term sustainability and decarbonisation goals.

Kanika Mathur

Concrete

Modernise to Optimise

Published

3 weeks ago

March 18, 2026

admin

Cement plant modernisation is reshaping the industry through upgrades in
kilns, energy systems, digitalisation, AFR integration and advanced material
handling. We explore these technologies that improve efficiency, reduce
emissions, strengthen competitiveness, while preparing the industry for India’s
next phase of infrastructure growth.

India’s cement industry, the world’s second-largest, is undergoing a rapid transformation driven by infrastructure demand, decarbonisation targets and technological advancement. The sector’s installed capacity stood at approximately 668 million tonnes per annum (mtpa) in FY2025 and is projected to reach 915–925 mtap by 2030, supported by large-scale capacity expansions and infrastructure investment cycles, suggests CRISIL Intelligence Industry Report, 2025. At the same time, cement production remains highly energy intensive and contributes about 6 per cent to 7 per cent of India’s total greenhouse gas emissions, making efficiency improvements and modernisation critical for long-term sustainability as stated in CareEdge ESG Research, 2025. As a result, cement manufacturers are investing in advanced kiln technologies, digital monitoring systems, waste heat recovery, alternative fuels, and modern material handling infrastructure to enhance productivity while aligning with global decarbonisation pathways.

Need for modernisation
The need for plant modernisation is closely linked to the sector’s rapid capacity expansion and rising operational complexity. India’s installed cement capacity has grown significantly in the last decade and is expected to exceed 900 mtpa by 2030, driven by demand from housing, infrastructure and urban development projects, as per the CRISIL Intelligence Industry Report, 2025. However, increasing scale also places pressure on energy efficiency, logistics, and production stability. The report also suggests that the cement plants must upgrade equipment and processes to operate at higher utilisation rates, which are projected to reach 75 per cent to 77 per cent by the end of the decade, compared to around 72 per cent to 74 per cent in FY2026.
Environmental imperatives are another major driver of modernisation. Cement manufacturing is responsible for a significant share of industrial emissions because clinker production requires high-temperature processes that depend heavily on fossil fuels. According to CareEdge ESG research, the cement sector contributes 6–7 per cent of India’s total greenhouse gas emissions, with approximately 97 per cent of emissions arising from direct fuel combustion and process emissions in kilns. Consequently, plant modernisation initiatives now focus not only on productivity improvements but also on reducing emissions intensity, energy consumption, and reliance on conventional fuels.
“One of the most impactful upgrades implemented at Shree Cement in the last five years has been the adoption of advanced data management platforms that provide real-time visibility across major process areas. This digital advancement has strengthened plant automation by enabling faster and more accurate responses to process variations while improving the reliability of control loops. Real-time dashboards, integrated analytics and automated alerts now support quicker, data-driven decision-making, helping optimise kiln and mill performance, improve energy control and detect deviations early. By consolidating data from multiple systems into a unified digital environment, the company has enhanced operational consistency, reduced downtime and improved both productivity and compliance. This shift towards intelligent automation and real-time data management has become a key driver of operational excellence and future-ready plant management,” says Satish Maheshwari, Chief Manufacturing Officer, Shree Cement.

Kiln and pyroprocessing upgradation
The kiln remains the technological heart of cement manufacturing, and modernisation efforts often begin with upgrades to pyroprocessing systems. Many older plants in India operate with four- or five-stage preheaters, while modern plants increasingly adopt six-stage preheater and pre-calciner systems that significantly improve heat efficiency and clinker output. These systems enhance heat transfer, reduce fuel consumption, and stabilise kiln operations under high throughput conditions.
Professor Procyon Mukherjee suggests, “Cement manufacturing is, at its core, a thermal process. The rotary kiln and calciner together account for energy consumption and emissions. The theoretical thermal requirement for clinker production is around 1700–1800 MJ per tonne, yet real-world plants often operate far above this benchmark due to inefficiencies in combustion, heat recovery and material flow. Modernisation, therefore, must begin with the
kiln system, and not peripheral automation or
isolated upgrades. The shift from wet to dry process kilns, combined with multi-stage preheaters and precalciners, has already delivered step-change improvements, making dry kilns nearly 50 per cent more energy efficient.”
Recent investment programmes across the industry have included kiln cooler upgrades, advanced burners, and improved refractory materials designed to increase operational reliability and reduce specific heat consumption. Such upgrades are essential because cement production remains highly energy intensive, and continuous efficiency improvements are required to meet global decarbonisation targets. According to the International Energy Agency (IEA) Cement Tracking Report, 2023, the cement sector must achieve annual emissions intensity reductions of around 4 per cent through 2030 to align with global net-zero scenarios.

Energy efficiency and WHRS
Energy efficiency remains one of the most important areas of modernisation in cement manufacturing, given the sector’s heavy reliance on thermal and electrical energy. Modern plants deploy advanced process controls, efficient grinding systems, and improved combustion technologies to reduce specific energy consumption. The adoption of energy-efficient technologies is particularly important in India, where energy costs account for a large share of production expenses. As demand grows and plants expand capacity, improving energy performance becomes essential to maintain competitiveness.
Waste Heat Recovery Systems (WHRS) have emerged as a key solution for improving plant energy efficiency. During cement production, large volumes of high-temperature gases are released from kilns and coolers. WHRS technology captures this waste heat and converts it into electricity, thereby reducing reliance on external power sources. According to energy benchmarking studies for the Indian cement industry, installed waste heat recovery capacity in the sector has reached approximately 840 MW, with an additional potential of around 500 MW states the Green Business Centre, Energy Benchmarking Report, 2023. Several leading producers have already implemented large WHRS installations; for example, UltraTech Cement has deployed systems with around 121 MW of waste heat recovery capacity, reducing carbon emissions by nearly 0.5 million tonnes annually according to the Energy Alternatives India Case Study, 2024.

Integration of AFR
The integration of Alternative Fuels and Raw Materials (AFR) is another critical dimension of cement plant modernisation. AFR refers to the use of industrial waste, biomass, refuse-derived fuel (RDF), and other non-fossil materials as substitutes for conventional fuels such as coal and petcoke. Increasing the use of AFR helps reduce fossil fuel consumption while simultaneously addressing waste management challenges. According to the NITI Aayog Decarbonisation Roadmap, 2026, scaling the use of RDF and other alternative fuels could enable the sector to achieve thermal substitution rates of around 20 per cent in the coming decades.
However, integrating AFR requires significant plant modifications and operational adjustments. Waste-derived fuels often have inconsistent calorific values, higher moisture content, and heterogeneous physical properties compared to traditional fuels. As a result, modern plants invest in advanced fuel preparation systems, dedicated feeding equipment, and automated dosing technologies to ensure stable kiln operation. These upgrades allow plants to maintain consistent clinker quality while increasing the share of alternative fuels in their energy mix.

Digitalisation and smart plant operations
Digitalisation is rapidly transforming cement plant operations by enabling data-driven decision-making and predictive maintenance. Industry 4.0 technologies such as IoT sensors, artificial intelligence (AI), and advanced analytics are now used to monitor equipment performance, optimise process parameters, and anticipate maintenance requirements. These digital tools enable plant operators to detect early signs of equipment failure, minimise unplanned downtime, and improve operational efficiency. Predictive maintenance systems, for example, analyse vibration, temperature, and acoustic signals from rotating equipment to identify potential faults
before they escalate into major breakdowns. Digital twins and integrated control systems further allow operators to simulate plant performance under different scenarios and optimise production strategies. Such technologies are becoming increasingly important as cement plants operate at larger scales and higher levels of process complexity.
Maheshwari also adds, “Plant modernisation is also increasingly central to the global competitiveness of Indian cement manufacturers. As cost pressures rise across energy, logistics and regulatory compliance, modern plants offer the structural efficiency required to operate reliably and competitively over the long term. Technologies such as AI-driven Advanced Process Control (APC) integrated with real-time data systems are emerging as essential investments for the future. These platforms use predictive algorithms, machine learning and live process inputs to optimise kiln, mill and utility operations with greater precision than traditional control systems. By continuously analysing variations in feed chemistry, temperature profiles, energy demand and equipment behaviour, APC enables stable operations, lower specific energy consumption, reduced emissions and improved product consistency. As regulatory expectations tighten and plants pursue higher efficiency with lower carbon intensity, AI-enabled APC will play a crucial role in strengthening automation, enhancing decision-making and ensuring long-term operational resilience.”

Modern material handling and logistics
Material handling systems play a critical role in ensuring smooth plant operations and efficient logistics. Modern cement plants rely on advanced conveying systems, automated stockyards, and digital dispatch platforms to manage the movement of raw materials, clinker, and finished cement. Long-distance belt conveyors and pipe conveyors are increasingly replacing truck-based transport between quarries and plants, reducing fuel consumption, dust emissions, and operational costs. Automated stacker-reclaimers ensure consistent blending of raw materials,
which improves kiln stability and clinker quality. Meanwhile, advanced packing and dispatch systems equipped with high-speed rotary packers and robotic palletisers enhance throughput and reduce manual labour. These technologies allow cement plants to optimise logistics efficiency while supporting higher production capacities.

Emission control and environmental compliance
Environmental compliance has become a central focus of cement plant modernisation as regulators and investors place greater emphasis on sustainability performance. Modern plants deploy advanced emission control technologies such as high-efficiency bag filters, electrostatic precipitators, and selective non-catalytic reduction systems to reduce particulate matter and nitrogen oxide emissions.
Sine Bogh Skaarup, Vice President, Head of Green Innovation and R&D, Fuller Technologies says, “One of our key focus areas is decarbonisation. We help cement producers reduce CO2 and overall carbon emissions. We offer alternative fuel solutions and calcined clay technologies to enable the production of LC3 cement, which play a significant role in decarbonising the cement industry. By combining alternative fuels and calcined clay solutions, CO2 emissions can be reduced by up to 50 per cent, making this a highly impactful approach for sustainable cement production.”
Continuous emission monitoring systems are increasingly used to track environmental performance in real time and ensure compliance with regulatory standards. In addition to air pollution control, cement companies are also investing in water recycling systems, renewable energy integration, and carbon reduction initiatives. These measures are essential for aligning the sector with national climate goals and improving the environmental footprint of
cement manufacturing.

Economic benefits and future outlook
Beyond environmental and operational advantages, cement plant modernisation also delivers significant economic benefits. Energy efficiency improvements, digital process optimisation, and advanced material handling systems reduce operating costs and improve asset utilisation. Waste heat recovery and alternative fuels help lower fuel expenditure and reduce exposure to volatile fossil fuel markets. As the industry expands capacity to meet growing demand, modernised plants are better positioned to achieve higher productivity and maintain profitability. The long-term outlook for the sector remains positive, with India expected to continue large-scale infrastructure investments in roads, housing, railways, and urban development.
Milan R Trivedi, Vice President – Projects, Prod & QC, MR, Shree Digvijay Cement, says, “The main focus in case of modernisation projects drives through the investment decision, which is mainly based on IRR and impact on overall efficiency improvement, cost optimisation and improvement in reliability. However, there are certain modernisation, which has high impact on environmental impact, statutory requirements, etc. has higher priority irrespective of ROI or payback period.”
“The energy efficiency and reliability investment projects generally provide fast return on investment whereas strategic, digitalisation and environmental investment projects provide long term and compounded benefits. Typical modernisation investment projects are decided with IRR of about > 20 per cent, payback period of typically 2-3 years for fast-track projects,” he adds.
In this context, modernisation will remain a key strategic priority for cement manufacturers seeking to maintain competitiveness in an increasingly sustainability-focused market.

Conclusion
The modernisation of cement plants is no longer a purely technical upgrade but a strategic transformation that reshapes how the industry operates. As India’s cement sector expands capacity toward the next growth cycle, improvements in energy efficiency, digitalisation, alternative fuels and advanced logistics will determine the competitiveness of individual plants. Modern technologies allow producers to operate at higher productivity levels while simultaneously reducing energy consumption and emissions intensity.
Looking ahead, the pace of technological adoption will play a decisive role in shaping the future of
the cement industry. Companies that successfully integrate modern equipment, digital systems, and sustainable production practices will be better positioned to meet rising infrastructure demand while aligning with global climate commitments. In this evolving landscape, plant modernisation stands as the cornerstone of both operational excellence and environmental responsibility.