Concrete
Smart Packaging
Published
9 months agoon
By
admin
The cement industry’s evolution hinges on innovations in bagging, packaging, and palletising—critical processes that ensure product quality, operational efficiency and customer satisfaction. Kanika Mathur delves into the latest trends, challenges and advancements shaping these processes in India’s dynamic cement sector.
The cement industry stands at the crossroads of rapid transformation, driven by demands for higher operational efficiency, reduced costs, and sustainable practices. Among the various processes’ integral to the production and distribution of cement, bagging, packaging, and palletising are crucial for ensuring product quality, customer satisfaction, and logistical effectiveness. These processes not only determine how efficiently the product is delivered to the market but also influence the overall profitability and reputation of cement manufacturers.
In India, where the cement industry is one of the largest in the world, these operations have seen significant advancements over the years. However, challenges such as manual labour dependency, outdated technology, and environmental concerns continue to hinder optimal performance. This article explores the current trends, innovations, and challenges in bagging, packaging, and palletising within the cement industry, highlighting real-world examples and strategies for future growth.
Trends in cement packaging
Packaging has evolved significantly in the cement industry, transitioning from simple manual techniques to highly sophisticated automated systems. Today, the focus is on providing eco-friendly and durable solutions that meet the demands of customers while adhering to environmental standards. Traditional woven polypropylene (WPP) bags have been the industry standard for years, offering a balance between cost and functionality. However, the global shift towards sustainability has driven the adoption of biodegradable and recyclable alternatives.
Riddhish Pandey, Associate General Manager (Packing Plant), Wonder Cement, says, “The adoption of multi-layered packaging materials, such as woven polypropylene (WPP) bags, has significantly improved the durability and strength of cement packaging. WPP bags offer enhanced resistance to moisture, tearing, and wear and tear, which is crucial during handling, transportation, and storage. These bags are particularly effective in protecting the cement from environmental factors that could compromise its quality. In addition to WPP bags, some companies are exploring the use of biodegradable or recycled materials as a sustainable alternative. These materials provide a balance between durability and environmental responsibility, helping to reduce the overall environmental impact of cement packaging without sacrificing product integrity.”
“Moreover, adding protective coatings and lamination to packaging has further strengthened the cement bags’ ability to withstand external pressures. These additional layers help maintain the integrity of the cement by providing an extra shield against moisture, dust, and other contaminants, ensuring the product remains in optimal condition during both storage and transit. This combination of advanced materials and protective measures enhances the overall quality of cement distribution, benefiting both the environment and customers” he adds.
In India, UltraTech Cement has been at the forefront of this change. The company introduced recyclable packaging for select products, showcasing its commitment to reducing its environmental footprint. This initiative has set a benchmark for other manufacturers, encouraging them to explore sustainable packaging options. Automated packaging lines, which ensure precision and consistency, are also becoming increasingly popular, allowing companies to reduce wastage and enhance efficiency.
Automation in bagging and packaging
Automation has revolutionised bagging and packaging processes in the cement industry, offering unparalleled benefits in terms of speed, accuracy, and reliability. Automated bagging machines are capable of handling large volumes with minimal human intervention, ensuring consistent bag weight, precise sealing, and reduced spillage.
Companies such as Wonder Cement have adopted state-of-the-art automated bagging systems that integrate features like real-time monitoring and self-calibration. These systems not only minimise downtime but also enable operators to monitor performance remotely, ensuring that the packaging process aligns seamlessly with production schedules. The result is an optimised workflow that enhances overall plant efficiency and meets customer demands promptly.
Gaurav Gautam, Business Unit Head, Beumer Group, says, “The bagging, packaging, and palletising area is crucial in cement plants as this is where revenue generation happens for our customers. Unfortunately, this area often lacks the same efficiency focus as other sections and continues to employ significant manpower. It is also less human-friendly, as workers still handle 50 kg bags under challenging conditions. We are committed to automating these processes and working alongside our customers to identify and resolve challenges. However, introducing automation requires a supportive ecosystem. Innovative equipment alone isn’t enough if the ecosystem isn’t prepared.”
“We approach this as a partnership with our customers, where we understand their problems—whether it’s space issues or challenges with manual loading. While full automation will take time, we have made significant progress. Several of our customers, such as UltraTech, Holcim and Wonder Cement, have already adopted automation, particularly on the loading side of bagging lines,” he adds.
Additionally, automation reduces the reliance on manual labour, addressing challenges such as worker fatigue, errors, and safety concerns. This shift is particularly significant in India, where labour intensive practices have long dominated the industry. By investing in automated solutions, manufacturers can improve productivity while creating safer working environments for their employees.
Importance of bag quality
The quality of bags used in packaging plays a vital role in ensuring the smooth operation of bagging lines and the durability of the product during transportation and storage. Substandard bags can lead to issues such as spillage, breakage, and moisture infiltration, resulting in financial losses and reduced customer satisfaction.
In the Indian cement industry, woven SDP bags are still widely used. While cost-effective, these bags often lack the durability and sealing capabilities required for optimal performance. High-density polyethylene (HDPE) bags, which offer superior strength and moisture resistance, are emerging as a preferred alternative.
To exemplify, Shree Cement has been experimenting with advanced bag designs that enhance sealing and durability. These improvements not only reduce product loss during transportation but also ensure that the cement reaches customers in pristine condition. By prioritising bag quality, manufacturers can enhance their brand image and build long-term customer loyalty.
Palletising: The shift towards hydbrid models
Palletising represents a significant step forward in the packaging and distribution process. Unlike traditional live operations, where bags are filled and dispatched simultaneously, palletising involves buffering bags onto pallets before loading them onto transport vehicles. This method decouples filling and loading operations, allowing for greater flexibility, reduced bottlenecks, and improved efficiency.
While many Indian cement plants are still in the early stages of adopting palletising, pioneers like Ambuja Cement are leading the way. The company has introduced hybrid models that combine manual and automated processes, ensuring a smoother transition from traditional methods to fully automated systems. These palletising solutions not only improve loading efficiency but also enhance safety by minimising manual handling of heavy bags.
In global markets, palletising has become the norm, with European and American manufacturers leveraging advanced robotics and software to optimise operations. As the Indian cement industry continues to modernise, the adoption of palletising is expected to gain momentum, bringing significant benefits in terms of speed, accuracy, and safety.
Dust-free and moisture-controlled packaging environments
Creating a dust-free and moisture-controlled environment is essential for preserving cement quality and ensuring the health and safety of workers. Dust generated during the packaging process can lead to product loss, environmental pollution, and respiratory issues for employees. Similarly, exposure to moisture can cause cement to harden prematurely, rendering it unusable.
To address these challenges, modern cement plants are investing in advanced dust collection systems, moisture barriers, and air-tight packaging technologies. Automated loading machines, for example, are designed to operate close to truck beds, minimising fugitive dust and ensuring precise bag placement.
Digital transformation in bagging and packaging
The integration of digital tools into bagging and packaging processes is revolutionising the cement industry. From predictive maintenance to real-time monitoring, digital technologies enable manufacturers to optimise operations, reduce downtime, and enhance overall equipment effectiveness.
IoT-based solutions are particularly transformative, allowing plant managers to collect and analyse data on machine performance, production rates, and maintenance needs. For instance, Dalmia Cement has introduced digital tools that provide actionable insights into its bagging and packaging operations. These systems help identify potential issues before they escalate, ensuring that equipment remains operational and production schedules
are maintained.
Sustainability quotient
Sustainability has become a critical focus area for the cement industry, with packaging practices playing a key role in achieving environmental goals. By transitioning to biodegradable materials, reducing plastic use, and adopting energy-efficient machinery, manufacturers can minimise their environmental impact while meeting regulatory requirements.
Dalmia Cement’s exploration of biodegradable packaging is a notable example of this commitment. By aligning packaging practices with sustainability objectives, the company not only reduces its carbon footprint but also strengthens its reputation as an environmentally responsible organisation.
Challenges and opportunities in India
Despite significant advancements, the Indian cement industry continues to face challenges in bagging, packaging, and palletising. Infrastructure limitations, workforce training gaps, and the high cost of adopting advanced technologies are major barriers. Additionally, the reliance on traditional bags and manual operations in many plants limits efficiency and increases operational risks.
However, these challenges also present opportunities for innovation and growth. By investing in automation, embracing digital tools, and prioritising sustainability, Indian cement manufacturers can enhance their competitive edge and contribute to the industry’s overall development.
Conclusion
Bagging, packaging, and palletising are not just operational processes—they are strategic enablers that shape the future of the cement industry. By adopting advanced technologies, improving bag quality, and transitioning to hybrid and automated models, Indian cement manufacturers can overcome existing challenges and unlock new opportunities. As the industry embraces innovation, sustainability, and ecosystem readiness, it is well-positioned to achieve long-term success in an increasingly competitive global market.
Concrete
The primary high-power applications are fans and mills
Published
2 days agoon
October 10, 2025By
admin
Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.
As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.
How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.
What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.
Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.
Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.
How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.
What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.
Concrete
We conduct regular internal energy audits
Published
2 days agoon
October 10, 2025By
admin
Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.
In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.
How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.
What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.
What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.
What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.
How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.
What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.
Concrete
Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport
The airport is set to become Asia’s largest air connectivity hub.
Published
2 days agoon
October 10, 2025By
admin
Enlight Metals has supplied 3,200 metric tonne of steel for the newly inaugurated Navi Mumbai International Airport, marking a major contribution to one of India’s largest infrastructure projects and reinforcing the company’s commitment to supporting national development.
The Navi Mumbai International Airport, developed under a Public-Private Partnership led by the Adani Group, was inaugurated today by Prime Minister Narendra Modi. The airport is set to become Asia’s largest air connectivity hub, enhancing regional connectivity, boosting economic growth, and expanding trade opportunities. Prime Minister Modi described the project as a “glimpse of Viksit Bharat,” highlighting its transformative impact on infrastructure and development in the region.
“The supply of 3,200 metric tonne of steel for this key project aligns with our focus on supporting critical infrastructure development through reliable and timely metal sourcing. Enlight Metals is committed to enhancing transparency and efficiency in the steel supply chain, contributing to projects integral to India’s growth objectives,” said Vedant Goel, Director, Enlight Metals.
Enlight Metals has implemented technology-driven solutions to strengthen supply chain efficiency, ensuring consistent availability of construction materials for large-scale projects nationwide. Its contribution to the Navi Mumbai International Airport underscores the company’s growing role in supporting India’s infrastructure development initiatives.
This milestone reflects Enlight Metals’ ongoing engagement in delivering quality materials and timely services for major national projects, further cementing its position as a reliable partner in India’s infrastructure sector

The primary high-power applications are fans and mills

We conduct regular internal energy audits

Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport

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The primary high-power applications are fans and mills

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Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport

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