Economy & Market

Net zero efforts demand risk mitigation strategies

Published

2 years ago

January 15, 2025

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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.

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Economy & Market

Leonard Unveils Dual-Head Robotic Arm for Hazardous Industrial Demolition

Published

2 days ago

October 30, 2026

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Leonard unveils Descender Duo, a dual-head robotic demolition arm designed to improve industrial safety and reduce shutdown time by up to 50 per cent.

Industrial robotics and refractory services specialist Leonard has launched Descender Duo, a dual-head robotic demolition arm designed to improve safety, accelerate maintenance and reduce shutdown times in hazardous industrial environments. The system made its debut at Lisahally Power Station in Northern Ireland, removing 25 tonnes of slag material within hours.

Developed for the cement, metals, waste-to-energy and petrochemical industries, Descender Duo enables remote-controlled refractory demolition, anchor cutting and welding, and refractory spraying inside boilers, calciners and silos. Its vertical-access design eliminates the need for personnel to enter confined, high-risk spaces during these operations.

Weighing less than two tonnes, the pre-assembled system requires an access opening of just 1.2 m². Supported by an external overhead hoist, it uses electrically operated hydraulic stabilising legs to secure itself inside vessels. The robotic arm offers 360-degree rotation and is suited to vessels approximately 9 m in diameter, with its operating reach extendable through strategically positioned access points.

Equipped with two independently controlled robotic heads, Descender Duo can perform identical or different tasks simultaneously, including refractory demolition, anchor cutting and spraying. Its remote-control system incorporates live camera feeds, allowing operators to monitor operations without entering hazardous environments.

According to Leonard, the technology can deliver time savings of up to 50 per cent compared with manual methods. Its ability to operate at temperatures exceeding 100°C allows maintenance to begin as early as 24 hours after burner shutdown. An all-electric power supply further supports cleaner and more cost-efficient operations.

First Deployment Demonstrates Shutdown Efficiency

The system was first deployed at Burmeister & Wain Scandinavian Contractor’s (BWSC) Lisahally Power Station in Londonderry, Northern Ireland. The facility generates electricity from grade C waste wood, supplying approximately 40,000 homes and businesses.

Leonard and BWSC collaborated to develop a customised solution for the plant’s 26-metre furnace, where extensive external pipework created significant access challenges.

Mark Leonard, Managing Director, Leonard, said, “It required new thinking and rather than step away from the problem we were committed to solving it for the customer, with the customer. We’re relentless in our approach to tackling complex challenges, head-on. We took our years of cement plant experience, coupled with our working knowledge of the BWSC plant, and designed, engineered and tested a completely new vertical solution within just seven weeks from that initial conversation with the customer. That solution was the Descender Duo as we know it today.”

Traditionally, the furnace required a cooling period of up to 36 hours before preparatory work could begin, followed by manual slag removal using rope-access personnel. With Descender Duo, work commenced just 24 hours after shutdown, reducing downtime by up to one day.

The deployment removed 25 tonnes of slag within hours, eliminated the need for at least six workers to enter the hazardous furnace interior and saved 26 hours in the shutdown programme.

“The effectiveness exceeded expectation,” said Martin Doran, Plant Manager at Lisahally Power Station.

“When the Descender Duo concept was first discussed, we had to spend some time with the team from Leonard looking at how it was going to be moved into the furnace. Every site is different and that presented its own challenges, but nothing that the team couldn’t overcome. Once it was installed we were hugely impressed by its efficiency.”

Expanding Industrial Robotics Applications

Descender Duo joins Leonard’s existing portfolio of robotic maintenance solutions, including the Axis horizontal-access arm, Nano confined-space access arm, Charger cement mill media recharging system and Calibre cement mill media grading system.

Headquartered in Northern Ireland, Leonard provides robotic refractory demolition, installation, inspection and industrial maintenance services across the cement, metals, energy, biomass, glass and civil engineering sectors.

Formerly known as G Leonard, the company has more than 35 years of industry experience and operates across Europe, North America, the Middle East, Africa and Asia-Pacific.

The latest innovation reinforces Leonard’s focus on replacing hazardous manual processes with robotic systems that improve workforce safety, enhance operational efficiency and minimise industrial downtime.

Concrete

Martin Engineering Appoints Ashwini Khunte as India General Manager

Published

2 days ago

October 30, 2026

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Martin Engineering names Ashwini Khunte India General Manager to strengthen operations and drive growth across key bulk material handling sectors.

Pune

Martin Engineering, a global provider of bulk material handling solutions, has appointed Ashwini Khunte as General Manager of its India business, strengthening its leadership as the company expands its presence across the country’s cement, mining, steel, power and infrastructure sectors.

Khunte brings more than a decade of experience with Martin Engineering, having joined its Indian operations in 2013 as a Design Engineer, shortly after the company established its presence in the country in 2012.

A mechanical engineer by qualification, she spent her initial five years developing bulk material handling solutions in collaboration with the company’s operations team. During this period, she gained extensive experience addressing operational challenges in the steel, cement and coal industries. She subsequently moved into project engineering, managing major engineering, procurement and construction (EPC) and original equipment manufacturer (OEM) projects from initial enquiry to commissioning. Her responsibilities later expanded to overseeing Martin Engineering’s conveyor product portfolio in India, involving customer engagement, technical presentations and site visits across heavy industries.

In 2024, Khunte was promoted to Head of Sales & Marketing for the company’s Europe, Middle East, Africa and India (EMEAI) region. The position broadened her international market exposure and strengthened her strategic and commercial leadership capabilities.

Commenting on her appointment, Ashwini Khunte, General Manager, Martin Engineering India, said: “India represents a tremendous opportunity for Martin Engineering. The country’s continued investment in cement, mining, steel, power and infrastructure is creating increasing demand for safer, cleaner and more productive bulk material handling, and that’s exactly what we do. My priority will be to build on the strong foundations already established in India, while continuing to develop our people, strengthen customer relationships and bring practical solutions to the challenges faced by our industry.”

Robert Whetstone, Area Vice President – EMEAI, Martin Engineering, highlighted Khunte’s technical expertise, market understanding and leadership experience.

“Ashwini brings an exceptional combination of technical understanding, customer knowledge and commercial leadership. She has grown as Martin Engineering has grown, and has consistently demonstrated outstanding capability to transform her expertise into practical solutions. Her knowledge of the Indian market, together with her international experience, makes her ideally suited to lead our India business through its next stage of growth for years to come.”

Since establishing its Indian business in 2012, Martin Engineering has expanded its local workforce, manufacturing capabilities and dealership network. The company supplies conveyor products, transfer point solutions, material flow aids, training and technical support to bulk material handling industries. Khunte’s appointment positions the company to further strengthen customer relationships and expand its solutions portfolio in India’s growing industrial and infrastructure markets.

Concrete

Fornnax Wins AIRIA’s Special Export Award for Rubber Machinery in 2025-26

Published

2 weeks ago

October 19, 2026

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Fornnax Technology Pvt. Ltd. has been honoured with the Special Export Award – Rubber Machinery for 2025–26 by the All-India Rubber Industries Association (AIRIA), in recognition of its highest exports of tyre recycling plants to the European region.

With more than a decade of experience in India’s tyre recycling industry, Fornnax has contributed to the development of advanced recycling technologies and infrastructure. The company currently holds a 90% market share in India’s domestic tyre recycling sector, while exports account for 30% of its business, spanning markets such as Europe, Australia and the GCC.

The award marks another milestone for Fornnax, whose tyre recycling lines and advanced shredding technologies are supporting the growth of the circular economy in India and international markets.

Commenting on the recognition, Mr. Jignesh Kundaria, Founder and Director of Fornnax, said:

“This honour from AIRIA is a reflection of an incredible journey we have undertaken over the years. When we started Fornnax, there was no established recycling industry in India to follow. We chose to build for the future instead. Today, when you see India’s tyre recycling sector, it has already transformed into a dynamic, high-growth industry and we are extremely proud to have played our part in building it.”

Unlike standalone equipment suppliers, Fornnax focuses on developing complete, high-capacity recycling infrastructure. Its integrated systems combine multiple stages of shredding and size reduction to enable efficient, continuous operations. This system-level engineering approach helps recycling operators improve throughput, equipment reliability and operational consistency.

The recognition reinforces Fornnax’s commitment to developing engineering technologies that contribute to a more efficient and circular recycling ecosystem.

Looking ahead, the company aims to expand its international presence while continuing to develop advanced shredding and recycling solutions to address the growing volumes and evolving requirements of the global recycling industry.

For more information, visit: www.fornnax.com