Utssav Gupta, Director, Supertech Fabrics, discusses how technology and innovation is redefining efficiency and sustainability in the cement industry through advanced material solutions.
Innovative approaches to sustainable material development, pollution control systems, and durability-focused solutions are some of the key aspects that Supertech Fabrics focusses on for the cement industry. In this interaction, we aim to understand the role of advanced textiles, renewable energy, and lifecycle optimisation in addressing
global challenges.
Tell us about Supertech Fabrics.
Supertech Fabrics is a specialty fabrics company where we combine textile engineering, polymer engineering, and an understanding of mechanical applications to develop advanced materials. We see ourselves as material developers working towards innovative solutions. When you approach a problem from a solution-centric perspective, it is crucial to align the bottom-up approach with the top-down approach, ensuring both ends meet effectively.
Our endeavour is to continuously innovate in materials to address modern-world challenges. Textile, as a material, is extremely linear and functional, with a distinct Young’s modulus. Compared to conventional materials, textiles offer numerous advantages, especially in a world facing challenges like geoeconomics, sustainability, and energy consumption. We position ourselves at the heart of these critical global challenges, humbly contributing to their resolution through our innovations.
Tell us about the application of your solution in the cement industry.
The cement industry has undergone significant evolution over the past two decades. The financial dynamics of the industry today are vastly different from what they were in the past. This evolution highlights the increasing importance of new materials. Our solutions are already being applied in areas like conveying systems, pollution control systems, and insulation systems. However, we believe there is still significant potential for development, which can be achieved through active industry interaction. This is where interdisciplinary approaches come into play.
The cement industry itself is continually evolving, and intermediate materials that do not stem from traditional engineering backgrounds have a pivotal role to play. This is where we see ourselves making a significant impact.
How does your product or solution help the cement industry become more efficient and precise in its operations and achieve better production?
In our known areas, such as air pollution systems, our approach to sustainability is twofold. First, we aim to develop materials that are non-fossil fuel-based and not reliant on the petroleum economy. For instance, I am particularly passionate about glass fiber, which is derived from silica.
Second, we focus on extending the lifecycle of materials. For example, if a material needs replacement every two years, extending its lifecycle to three years, and eventually four years, significantly reduces its carbon footprint over time. This approach is a core aspect of sustainability.
Functionally, another critical benefit is minimising material loss. Filtration systems, while environmentally focused, also have an economic impact by preventing the loss of valuable materials during production. By enhancing material strength and collaborating with OEMs, we can extend filtration life and reduce emissions. This not only benefits the environment but also prevents revenue loss for manufacturers.
Our approach is multilateral. Innovation, when viewed holistically, impacts finances, environmental sustainability, and operational efficiency. This interconnected perspective is what we strive to promote.
Tell us about the major innovations in your organisation and how technology, including AI, has helped improve your solutions.
Innovation in our field can be categorised in several ways, but I’ll focus on product innovation. The core of material innovation lies in how we create these materials, which involves understanding the energy costs associated with production.
Globally, energy balance structures are being implemented as part of bottom-up strategies. We need to determine where energy costs can be optimised, such as through renewable energy sources. For example, in emission control systems, power costs are a significant concern.
Our innovation efforts target two primary areas: reducing the power costs associated with emission control and achieving lower emissions levels. My pitch to stakeholders is to consider a one-time investment in renewable energy to address these challenges. With this approach, emissions are reduced, recovery is improved, and everyone benefits.
To achieve these goals, our materials must possess greater mechanical strength. Innovations in material science, coupled with system and operational advancements, allow us to meet these challenges. This holistic, multilateral approach to innovation drives progress in sustainability and efficiency.
What challenges do you face in your product solutions, particularly in the cement industry?
One of the primary challenges is the limited exposure to advanced technologies. India, as the world’s second-largest cement producer, stands at a unique opportunity. Unlike developed nations, where infrastructure constraints can limit advancements, India’s newer plants have immense potential to adopt and benefit from innovative solutions.
However, this also presents a contextual challenge. Science and its applications must address specific, localised needs. Transforming challenges into opportunities requires a collective effort involving stakeholders, systems, and technology providers.
Fossil fuel reliance, the use of alternative fuels, and other futuristic developments are areas that demand preparation and innovation. These challenges, when addressed collaboratively, push boundaries and drive meaningful progress.
Tell us about the sustainability efforts in your organisation.
We have already discussed how our products are developed with sustainability in mind, but let me highlight another important factor: PFAS requirements. Due to high temperatures and severe corrosion in certain applications, the use of fluorine-based chemicals is often unavoidable. However, we are working to minimise the use of such chemicals by developing materials that are more durable. By reducing the lifecycle frequency of replacement, the overall usage of fluorine chemicals decreases over time.
At our production facility, we are committed to achieving zero waste. For instance, our waste bins, which used to be emptied weekly, now remain unemptied for a month due to increased efficiency. Our water discharge is minimal, and we actively transition to renewable energy sources and alternative heating media like gas.
Our machinery is equipped with variable motor drives, ensuring energy consumption aligns precisely with operational requirements. While these initiatives may require significant capital investment upfront, they reflect a mindset-driven commitment to sustainability rather than purely financial motivations. Reducing waste and optimising resource use are achievements that bring satisfaction beyond financial gains.
What’s your view on the net zero mission, and how do you see its journey unfolding?
Achieving net zero emissions is non-negotiable. It must be done. While it may appear as a cost on balance sheets, I see it as an investment.
Net zero efforts demand risk mitigation strategies. There will always be risks, but with creativity and commitment, we can navigate these challenges. The goal is not just a financial or operational milestone; it’s a pledge to ensure a sustainable future. Once we make that commitment, everything else falls into place.