Operational excellence in cement is no longer about producing more – it is about producing smarter, cleaner and more reliably, where cost per tonne meets carbon per tonne.

Operational excellence in cement has moved far beyond the old pursuit of ‘more tonne’. The new benchmark is smarter, cleaner, more reliable production, delivered with discipline across process, people and data. In an industry where energy can account for nearly 30 per cent of manufacturing cost, even marginal gains translate into meaningful value. As Dr SB Hegde, Professor, Jain College of Engineering & Technology, Hubli, and Visiting Professor, Pennsylvania State University, USA, puts it, “Operational excellence is no longer about producing more. It is about producing smarter, cleaner, more reliably, and more sustainably.”

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JSW Cement, part of the JSW Group, has begun production at a greenfield integrated cement plant in Nagaur, Rajasthan, marking its first such facility in north India. The company said this move raises its total cement grinding capacity to 24.1 million tonnes per annum (MTPA) and its clinker manufacturing capacity, including the joint venture, to nine point seven four MTPA. JSW Cement is described as one of India’s leading green cement producers and is positioned to expand its national presence.

The Nagaur integrated plant is equipped with a three point three zero MTPA clinkerisation unit and a two point five zero MTPA cement grinding unit, with an additional one point zero zero MTPA grinding unit under construction. The facility has been positioned to serve the high-growth markets of Rajasthan, Haryana, Punjab and the National Capital Region. The plant is intended to support construction and infrastructure demand across these nearby states.

The Nagaur unit was funded through a strategic mix of equity and long-term debt, with 8,000 mn from the fresh issue proceeds of the initial public offering (IPO) allocated specifically towards part-financing of the unit. Company executives indicated that the project was completed within 21 months and that the expansion advances the company towards its mid-term capacity target of 41.85 MTPA and its long-term vision of 60 MTPA. The commissioning was cited as an example of the company’s project execution capabilities.

The plant has been designed as a model of sustainable manufacturing and includes provisions for the co-processing of alternative fuels in the kiln to reduce fossil fuel use. The site features a seven km long overland belt conveyor to transport limestone from the mines, reducing road transport, and will soon include a 16 megawatt (MW) Waste Heat Recovery System to capture and reuse process heat, significantly lowering its carbon footprint. These measures are intended to reduce the environmental impact of transport and to lower the carbon intensity of cement production.

JSW Cement, one of India’s green cement producers, has commenced production at a greenfield integrated plant in Nagaur, Rajasthan, marking the company’s first such facility in north India. The commissioning expands the company’s national footprint and takes total cement grinding capacity to 24.1 mn t per annum and total clinker manufacturing capacity, including a joint venture component, to nine point seven four mn t per annum. The move positions the firm to serve high-growth markets across the region. Management said the project is a strategic step towards a pan-India presence.

The Nagaur plant is equipped with a three point three mn t clinkerisation unit and a two point five mn t cement grinding unit, with an additional one mn t cement grinding unit under construction. The facility is strategically located to cater to demand in Rajasthan, Haryana, Punjab and the National Capital Region. An overland belt conveyor will move limestone and reduce reliance on road transport. Project execution was completed within 21 months, underlining the firm’s construction capabilities.

The investment for the Nagaur unit was financed through a mix of equity and long-term debt and the company allocated Rs eight bn from fresh issue proceeds of its IPO towards part financing of the project. The expansion advances progress towards a mid-term capacity target of 41.85 mn t and a long-term vision of reaching 60 mn t capacity. The commencement of operations in the north is expected to support infrastructure growth and provide customers with high-quality, eco-friendly cement while maintaining sustainability credentials.

The plant has sustainability features including provisions for co-processing of alternative fuels in the kiln and a seven km overland belt conveyor to cut the environmental impact of road transport. The facility will include a 16 MW Waste Heat Recovery System to capture and reuse heat from production and reduce carbon emissions. The operation supports the company’s ambition to be among the world’s most sustainable cement producers.