Rahul Rajgor, Managing Director, Fives Combustion Systems, discusses their focus on innovation, energy efficiency and sustainability, emphasising the role of customer collaboration in developing tailored solutions.

Tell us about the innovations and solutions you are providing to the cement industry?
At our company, innovation is not just a concept—it is the cornerstone of our operations. We see ourselves as pioneers within the cement industry, and this mindset extends across all sectors we serve. We truly believe that the best innovations come directly from our customers. Their needs and feedback drive the improvements and new ideas we bring to market. Every year, we make it a priority to introduce fresh innovations, not only within the cement industry but across other industries as well. Our approach to innovation is deeply rooted in collaboration with customers, which we consider partners, and this partnership is essential to our success. We are always ready to take on challenges and tackle the most complex issues in the industry.

How are your solutions aimed at improving energy efficiency in the cement industry?
Energy efficiency and sustainability are at the core of our philosophy. We understand that reducing energy consumption is essential for the future of our planet, and it is something we focus on in every solution we offer. The systems we design are energy-efficient by nature, and we do everything we can to ensure that each system is optimised for maximum performance. Through extensive in-house calculations and analysis, we continually improve our technologies to meet and exceed energy-efficiency standards. Our commitment to the energy sector has been long-standing, and as pioneers in this field, we specialise in providing highly efficient burners and combustion solutions that are specifically designed to reduce CO2 emissions. By doing so, we help cement plants significantly lower their carbon footprints and contribute to global sustainability efforts.

Could you share some of the sustainability or decarbonisation initiatives that your organisation has implemented?
Sustainability is a key priority for us, and we have been actively engaged in decarbonisation efforts for many years. We launched our sustainability program five years ago, with a clear focus on reducing the environmental impact of our operations. Over time, we have become leaders in this space, particularly with the advent of hydrogen technology. We were one of the pioneers in the hydrogen sector, not only in developing hydrogen combustion solutions but also in the liquefaction of hydrogen for use in various industrial applications. In fact, we were the first company in India to sell a hydrogen burner, which was used for a 52-megawatt boiler application. Beyond hydrogen, we are also focused on finding alternative solid fuels for cement manufacturing. We are currently working on developing hybrid technologies that combine hydrogen, alternative solid fuels, and fossil fuels. This combination is crucial for reducing the carbon footprint in the cement industry. We are continuously investing in research and development to create innovative solutions that can accelerate the global shift toward decarbonisation.

How do you tailor your innovative solutions to meet the unique needs of the cement industry?
One of the fundamental aspects of our innovation process is our close partnership with customers. Innovation does not exist in a vacuum—it is driven by the real needs and challenges faced by our customers. We firmly believe that innovation often arises from even the smallest ideas proposed by users. We make it a point to listen carefully to our customers, as their feedback is invaluable. For instance, one of the key innovations we developed—a custom-made burner—was created in collaboration with our customer Holcim Europe. We tailored this burner specifically to meet their needs, which illustrates how we approach innovation: our solutions are not one-size-fits-all. We provide bespoke solutions that are customised to each customer’s specific requirements, making sure that every solution we offer is the best possible fit for the individual circumstances of the customer. This is a significant differentiator for us in a market where many competitors offer generic solutions.

You mentioned a burner developed with the help of your customers. Could you tell us more about it?
Yes, we have developed several advanced technologies in collaboration with Holcim Europe, one of our key partners. A perfect example of this is the custom-built burner we designed together. It was created specifically to meet the unique requirements of Holcim’s operations, ensuring that it delivered optimal performance for their systems. This burner, like all of our innovations, is a result of close collaboration between our engineering teams and the customer. It serves as a reminder that the best solutions often come from understanding the specific needs of the customer and working together to design a tailored solution that achieves the desired results.

Given the level of innovation, what challenges do you face, particularly in the Indian market?
In the Indian market, one of the biggest challenges we face relates to the shortage of sorted waste for use as Alternative Solid Fuel (ASF) or Refuse-Derived Fuel (RDF). While we have some of the best technology available for utilising ASF, the issue lies in the lack of a comprehensive waste-sorting infrastructure. In developed nations, waste segregation is well-established, but in India, we are still behind in this regard. For example, industries and communities have yet to fully embrace the importance of sorting waste, which is essential for ASF to be viable as a sustainable fuel alternative. Without proper waste segregation, the potential of ASF remains untapped. To address this, we need to educate not just the industry, but society as a whole, about the importance of waste sorting. This is an area where we see a significant opportunity to improve.

How do you envision the journey toward achieving net-zero emissions, and what role will the cement industry play in it?
The journey toward net-zero emissions is undoubtedly one of the most critical challenges for the cement industry, and the role of combustion solutions is key. The cement industry relies heavily on combustion processes, so as a provider of combustion technologies, we play an integral part in helping the industry meet its net-zero targets. We are heavily involved in research and development to ensure that we are contributing to reducing emissions.
However, it is important to recognise that achieving net-zero emissions by 2070 is a formidable challenge, especially in a country like India, where the cement industry still depends on fossil fuels. The widespread adoption of hydrogen, natural gas and alternative solid fuels will help us significantly reduce the carbon footprint of the cement industry.
While the journey is long, we are confident that, through continuous innovation and collaboration, we will make meaningful progress toward achieving net-zero emissions.

– Kanika Mathur