Economy & Market

We always keep customers in the forefront

Published

2 years ago

December 24, 2024

Roshna

Jignesh Kundaria, CEO and Director, Fornnax, talks about transforming waste into energy and fostering eco-friendly cement production.

How does Fornnax Technology’s expertise in shredding and recycling equipment contribute in the cement industry?
The average usage of alternative fuels and raw materials in the Indian cement industry currently stands at around 6 to 8 per cent, according to the Cement Manufacturers Association (CMA). This figure indicates a substantial opportunity for improvement within the industry. Increasing the Thermal Substitution Rate (TSR) is essential for reducing dependency on conventional fossil fuels and enhancing environmental sustainability. By efficiently utilising waste materials as alternative fuels, the industry can significantly lower greenhouse gas emissions and promote a greener approach to cement production.
Fornnax Technology’s expertise in developing robust shredding and recycling machinery plays a crucial role in assisting the Indian cement industry to close this gap. By providing innovative solutions for the utilisation of AFR, Fornnax supports the industry’s efforts to increase its TSR. These advancements are pivotal in driving the Indian cement industry towards a greener and more sustainable future.

Could you elaborate on how your products, like primary and secondary shredders, can enhance the overall operational efficiency?
Our SR-MAX primary and R-Max series secondary shredders are specially designed to enhance operational efficiency in municipal solid waste management. These high-performing shredders are tailored to handle mixed and legacy waste which is stored for years in the landfills and it is highly contaminated with inert material and sand, catering to the needs of MSW recyclers and the cement industry, including Refuse Derive Fuel Manufacturers.
The primary SR-MAX series shredders boast revolutionary engineering for producing output sizes ranging from 150-400mm, depending on the knife configuration. This level of flexibility allows for customisation to meet specific requirements. Whereas, The R-Max series shredders are strong enough to deal with the contamination of solid waste meant for producing alternative fuels like RDF/SRF. Depending on the blade and screen configuration, shredders are appropriate for secondary or fine shredding to produce sizes up to 30- 80mm.
The outputs from our shredders have diverse applications. For instance, shredded municipal solid waste can serve as an alternative energy source in cement industries. Material Recovery Facilities (MRFs) utilises pre-shredded material below 400mm suitable for further sorting and separation of recyclables, such as plastics, paper, glass and metals, thereby maximising resource recovery and reducing landfill disposal.
By integrating our shredders into MSW management operations, recyclers can optimise their processes, increase efficiency, and unlock valuable energy resources.

What role does technology play in optimising the recycling of municipal waste materials for use in the cement industry?
The cement industry’s carbon footprint is staggering. It’s been said that if the cement industry were a country, it would rank among the top emitters of carbon dioxide globally. The World Economic Forums’ recent data reveals that cement production worldwide generated a whopping 1.6 billion metric tonnes of CO2 in 2022 – accounting for approximately 8 per cent of global CO2 emissions. To meet global climate targets, it’s crucial that we significantly reduce the carbon intensity of cement manufacturing by reducing the reliance on primary raw materials like fossil fuels and shift towards alternative fuel options and technology is definitely going to play a pivotal role in optimising the recycling of waste materials for use in the cement industry, Fornnax has always been the forefront of this innovation. Our research and development team continuously strives to develop cutting-edge solutions because we firmly believe that innovative recycling technology could provide solutions to the disposal problems of solid wastes in an effective and economical manner.

How Fornnax stands out from its competitors in the cement sector?
Fornnax distinguishes itself from its competitors in the cement sector by offering a comprehensive range of modern engineered and large capacity recycling solutions tailored specifically to the industry’s unique needs. Our deep understanding of the cement industry’s challenges, coupled with our expertise in advanced shredding and recycling technologies, enables us to provide efficient and sustainable solutions. Our state-of-the-art shredding equipment, such as the SR-MAX series are engineered to deliver high performance and low maintenance, ultimately meeting the demand of Refuse Derive Fuel Manufacturers and Municipal Waste Recyclers.
We always keep customers in the forefront, our team works closely with clients to understand their pain points and develop new advanced models that entirely respond to their needs under our specially formulated CBPD (Customer-Based Product Development Process) process. Additionally, our after-sales service network across India ensures prompt and timely resolution from any location. Our customer-first philosophy is rooted in the heart of Fornnax. We believe that every client interaction is an opportunity to build trust, foster innovative solutions, and deliver exceptional experiences that meet expectations.

What level of customisation do you provide to ensure the machinery aligns with customers’ distinct visions?
Fornnax Technology is committed to delivering tailored solutions that perfectly align with each customer’s unique vision. We understand that every cement plant has specific requirements and challenges, and we strive to provide customised machinery that addresses these needs precisely. Our team of experienced engineers works closely with our customers to understand their specific requirements, including production capacity, waste type, desired output size, and power constraints. Based on this in-depth understanding, we carefully select the most suitable shredding technology and customise the machine’s design and configuration to meet the specific needs of the customer.
Our customisation options extend beyond just the machine’s design. We also offer a range of additional features and services to enhance the overall performance and efficiency of our machinery. These include:

Collaborative product development: We actively involve our customers in the product development process through workshops and discussions with our experienced engineering team
Customer-centric approach: We prioritise understanding our customers’ needs by conducting regular site visits and surveys. This valuable feedback is essential in shaping our product development strategy.
Incorporating customer insights: We analyse customer input meticulously and incorporate it into the design and testing phases of our equipment.
Customer-driven innovation: Fornnax is dedicated to delivering innovative solutions that meet the evolving needs of our customers. We consistently integrate customer feedback into the final design of our products. As we continue to innovate, customer insights remain the cornerstone of our product development.

What are the key challenges in implementing advanced recycling technologies in cement plants?
As we reflect on the journey towards sustainability in the cement industry, we firmly believe that implementing alternative fuel options is a crucial step forward. However, this transition does come with its set of challenges. One major obstacle is the resistance to change, often stemming from traditional mindsets. Additionally, the remote locations of many cement plants pose logistical challenges that can’t be overlooked.
Keeping up with the ever-evolving environmental regulations is another significant challenge, requiring continuous investment in technology and process upgrades, which can be especially tough for small and medium-scale industries due to the high capital needed. Furthermore, the lack of effective waste segregation and management infrastructure can impede progress. For instance, the inconsistent quality and composition of waste materials can lead to operational challenges and reduced efficiency in cement kilns. Improper waste segregation can also result in contamination, compromising the quality of the final cement product.
Despite these hurdles, Fornnax remains optimistic about the Indian cement sector’s ongoing investment in preprocessing and waste segregation equipment. This shift towards sustainable practices is a major breakthrough not only for the cement industry but also for other sectors looking to adopt greener and more efficient technologies, setting a precedent for a more sustainable future.

Can you highlight any of your recent innovations which are set to reshape the future of the cement industry?
Our recent major launch of the game-changing SR-MAX2500 primary shredder powered by a hydraulic drive motor at IFAT 2024 Mumbai, marks a significant milestone to our commitment to providing cutting-edge waste management solutions. It is specially designed to revolutionise MSW, industrial and other waste categories by efficiently shredding challenging materials into smaller, manageable sizes.
The introduction of the SR-MAX2500 primary shredder is a major breakthrough in reducing the Indian cement industry’s dependence on imported shredders. Our SR-MAX2500 primary shredders have been meticulously engineered to handle the unique challenges posed by Indian waste, which is often highly contaminated and unsegregated.
SR-MAX2500 is set to transform waste management and cement industries in India and globally. Our objective is to equip municipal waste recycling industries with a robust and transforming solution that prioritises sustainability. By doing so, we’re aligning with the honorable Prime Minister’s vision of achieving Net Zero emissions by 2050, and committed to create a green future for our future generations.

What is Fornnax Technology’s vision for the future of sustainable recycling solutions, and what innovative strategies are needed to achieve this vision within the cement industry?
As we look to the future, Fornnax is committed to revolutionising the cement industry through sustainable recycling solutions. Driven by the increasing demand for eco-friendly waste management and growing environmental awareness, we’re optimistic about the prospects ahead. Our strategic vision focuses on innovation, customer-centricity, and targeted growth. To achieve this goal, we’re expanding our operations to Eastern Europe, Australia, GCC and other leading countries, investing heavily in research and development, and strengthening key partnerships to address the evolving needs of our clients.
Our recent acquisition of a 23-acre land parcel in Ahmedabad, Gujarat, highlights our dedication to scaling up operations and meeting the growing demand for sustainable solutions. This expansion will enable us to produce high-capacity machinery tailored to various recycling applications, including MSW, tyre, cable, e-waste, and metal processing. By adopting advanced technologies and sustainable practices, we’re poised to play a pivotal role in shaping the future of sustainable recycling within the cement industry and beyond.

– Kanika Mathur

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Wonder Cement appoints Mahesh Singh as VP Corporate Brand Communication

Published

3 days ago

October 9, 2026

admin

Singh brings 20+ years of brand and marketing experience, and will lead integrated corporate brand communication initiatives at Wonder Cement

New Delhi

Wonder Cement, a leading cement manufacturer, has appointed Mahesh Singh as Vice President – Corporate Brand Communication. In his new role, he will oversee corporate brand strategy and communication, including digital and performance marketing, public relations, trade, events, exhibitions, sports and experiential marketing.

Singh brings over two decades of experience across marketing and communications, with roles spanning the automotive industry, agencies and entrepreneurship. He spent more than a decade with Honda Motorcycle & Scooter India, working across integrated communication, media, digital, retail and consumer engagement. His stint also included helping build the company’s digital marketing capabilities.

He moved to dentsu X India as Vice President – Strategy & Planning, working across categories such as automotive, auto components, electric vehicles, FMCG, consumer electronics, BFSI, apparel and brand consulting. His responsibilities included media and marketing strategy, product launches, content, performance marketing and consumer activations.

Singh subsequently took an entrepreneurial route with Radiant Brands before joining Shriram Ltd (SPR Autotech) as Head – Marketing & Communications. There, his remit included brand and corporate strategy, communications, PR and ORM, retail identity, loyalty programmes and events.

At Wonder Cement, Singh will be responsible for bringing together the company’s corporate brand communication initiatives across digital, performance marketing, PR, trade, sports and experiential platforms. The role will focus on creating an integrated approach to communication across consumers, trade partners and other key stakeholders.

The appointment brings to Wonder Cement a marketer whose career has spanned the brand, agency and entrepreneurial sides of the communications ecosystem.

Wonder Cement, part of the RK Group, is a cement manufacturer with roots in Rajasthan and a focus on quality, trust and transparency. The company has grown to six manufacturing plants, and a cement capacity of 21.5 MTPA. With more than 2,000 employees and a network of over 5,000 dealers, its operations span manufacturing, distribution and customer engagement, with a focus on consistent product quality and efficient execution.

Concrete

JSW Cement commissions additional 1 MTPA grinding unit at Nagaur

Published

4 days ago

October 8, 2026

admin

With this commissioning, JSW Cement’s total cement grinding capacity has increased to 25.10 MTPA,
Mumbai

JSW Cement, one of India’s leading green cement producers and part of the diversified JSW Group, today announced the successful commissioning of an additional 1.00 MTPA cement grinding unit at Nagaur, Rajasthan. The commissioning marks another significant milestone in the Company’s growth strategy.

With this commissioning, JSW Cement’s total cement grinding capacity has increased to 25.10 MTPA, while its total clinker manufacturing capacity, including clinker capacity at its joint venture, JSW Cement FZC, stands at 9.74 MTPA.

JSW Cement had commenced operations in North India in March 2026 with the Nagaur Integrated Plant, comprising a 3.30 MTPA clinkerisation unit and 2.50 MTPA cement grinding unit. With the commissioning of the additional 1.00 MTPA cement grinding unit, the plant’s total cement grinding capacity has increased to 3.50 MTPA, enhancing the company’s ability to cater to the growing cement demand across Rajasthan, Haryana, Punjab and the National Capital Region (NCR). The expansion has been funded through a strategic mix of equity and long-term debt.

During the quarter ended 30th September 2026, JSW Cement has also commissioned the Alternate Fuel Handling System and the Waste Heat Recovery system (WHRS) at the Nagaur Integrated Plant.

Nilesh Narwekar, CEO, JSW Cement, said: “The commissioning of additional 1.00 MTPA grinding capacity at Nagaur is a key strategic priority for us and will accelerate JSW Cement’s expansion into North India. We look forward to servicing the growing needs of the region and contributing to the economic growth of Rajasthan, Haryana, Punjab and the NCR area. I am delighted to share that the company has commissioned this grinding unit within the expected timeline, showcasing our project execution capabilities. Further, the Alternate Fuel Handling System and the Waste Heat Recovery system (WHRS) are expected to substantially reduce our production costs going forward.”

Concrete

UltraTech becomes first Indian cement firm to cross 2 GW green energy

Published

5 days ago

October 7, 2026

admin

UltraTech Cement has crossed 2 GW of captive green energy capacity, with renewables and waste heat recovery meeting 48 per cent of its power needs.

Mumbai

UltraTech Cement Limited has surpassed 2 GW of installed green energy capacity for captive use, becoming the first cement company in India to achieve the milestone. The Aditya Birla Group company commissioned 116.55 MW of wind capacity at its Inter-State Transmission System-connected wind-solar hybrid project in Barmer, Rajasthan, along with 10 MW of Waste Heat Recovery System capacity at Sarlanagar Cement Works in Karnataka.

With these additions, UltraTech’s cumulative installed green energy capacity has reached 2,024 MW. This includes 1,580 MW of renewable energy capacity and 444 MW of waste heat recovery capacity, together meeting around 48 per cent of the company’s current power requirements.

The company said the milestone reflects the progress of its long-term energy transition strategy. In FY27 so far, nearly one-third of UltraTech’s 76 manufacturing units in India have maintained green energy utilisation above 50 per cent of their electricity requirements, while five units have crossed 95 per cent.

K C Jhanwar, Managing Director, UltraTech Cement Limited, said, “Crossing the 2 GW green energy milestone is the result of a strategy we have pursued consistently over the past decade. Cement is an energy-intensive, hard-to-abate sector, and showing that reliability and growth can go hand in hand with a rapid shift to green energy sets a benchmark for the industry. With nearly half of our power needs now met through green energy, we are significantly less exposed to fossil fuel supply constraints and power price volatility. As we scale up renewables, waste heat recovery and battery storage across our operations, we are building an energy foundation for stable, long-term growth.”

UltraTech commissioned 430 MW of green energy capacity in FY26 and continues to expand its renewable energy and waste heat recovery portfolio.

The company is also progressively integrating Battery Energy Storage Systems across its operations to improve renewable energy utilisation and supply reliability.

In 2025, UltraTech operationalised what it described as India’s first on-site hybrid round-the-clock renewable energy project at Sewagram Cement Works in Gujarat. The project combines solar, wind and battery storage.

As part of its decarbonisation strategy, UltraTech said it has not invested in new captive thermal power capacity for either greenfield projects or brownfield expansions at its integrated units for more than a decade.

The company said its expanding green energy portfolio is helping reduce dependence on conventional grid electricity and fossil fuel-based power, while lowering exposure to fluctuations in coal and electricity prices.

UltraTech aims to increase green energy’s share in its total power mix to 85 per cent by 2030. As a member of RE100, it has also committed to meeting 100 per cent of its electricity requirement through renewable sources by 2050.

UltraTech Cement, the cement flagship of the Aditya Birla Group, has a total grey cement capacity of 210.1 MTPA and white cement and putty capacity of 3.5 MTPA. The company is also a signatory to the GCCA Climate Ambition 2050 and has committed to the GCCA Net Zero Concrete roadmap.