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Economy & Market

There is a push towards eco-friendly packaging

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Riddhish Pandey, Associate General Manager (Packing Plant), Wonder Cement, shares with Kanika Mathur insights into the latest bagging and packaging technologies.

In this insightful interview, we get to understand the cutting-edge advancements in cement
bagging, packaging, and palletising, through the processes at Wonder Cement, as the company focusses on efficiency, sustainability and customer-driven innovations.

How do advancements in bagging and packaging technologies improve efficiency in cement distribution?
Auto truck loader operations for handling cement bags play a critical role in ensuring that cement reaches customers quickly and in optimal condition. Advancements in bagging and packaging technologies have significantly enhanced the efficiency of cement distribution by automating processes that were once manual. Automated bagging systems, for example, allow for faster and more precise filling of cement bags, reducing the need for manual labour, which not only makes operations safer but also improves the consistency of bag weights. Innovations such as high-speed packaging machines have further boosted throughput by minimising downtime, leading to an increase in overall production capacity. Moreover, efficient packaging practices reduce the risk of damage during transportation, ensuring that cement reaches customers without compromise.
A notable advancement in modern packaging systems is the integration of advanced Roto packers with in-line bag weight correction mechanisms. These systems automatically adjust bag weights within a defined range, significantly reducing the need for manual intervention. The use of check weighers plays a vital role in this process, as they ensure that bag weights remain consistent and accurate. This not only reduces downtime associated with manual corrections but also enhances the overall efficiency and reliability of the packaging process.

What innovations in packaging materials are being adopted to enhance the durability of cement bags?
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.

How does automation in bagging and palletising impact production and cost optimisation?
Automation in bagging and palletising has led to significant improvements in production speed and cost optimisation within the cement industry. Automated systems reduce reliance on manual labor, which not only lowers operational costs but also minimises the chances of human error. These systems are designed to run continuously without downtime, thus increasing production output and ensuring a more efficient workflow.
Automated palletising, in particular, plays a crucial role by ensuring the precise stacking of cement bags. This reduces the risk of product damage during handling and transportation, as the bags are organised in a manner that maximises their stability. Additionally, improved stacking helps optimise space utilisation, which leads to more efficient storage and reduces transportation costs. Moreover, the introduction of the ‘First Come, First Out’ (FIFO) system for truck loading helps minimise Turnaround Time (TAT) by ensuring that older stock is loaded and dispatched first. This further enhances operational efficiency by reducing delays and improving the logistics process, ensuring a quicker, more streamlined delivery to customers. These automation-driven improvements contribute to both faster production cycles and cost savings, making cement distribution more effective overall.
We are using the VFD system in the packer to reduce power capacity of packing plant operation to reduce per ton cost.

What measures do you take to ensure sustainable and eco-friendly packaging solutions?
Sustainable packaging solutions are becoming a key focus in the cement industry, driven by the growing need to reduce environmental impact. One of the main strategies involves adopting eco-friendly materials, such as biodegradable bags and recycled plastic products. This shift not only helps reduce the reliance on traditional plastics but also aligns with broader environmental goals.
Reducing the use of single-use plastics is another crucial step in this process. By implementing systems for reusing and recycling cement bags, companies can significantly cut down on waste, minimising their environmental footprint. A well-designed recycling programme for cement bags, where feasible, can contribute to reducing the demand for new raw materials and ensure that packaging materials are used to their full potential. Additionally, optimising packaging design to minimise material usage, without compromising on the strength or quality of the bags, can further reduce waste. Lightweight yet durable packaging helps lower environmental impact while maintaining the integrity of the product.
Exploring alternative materials like paper bags with high-strength properties is another promising direction. These paper bags are both recyclable and biodegradable, offering a more sustainable option compared to conventional plastic bags. With the right innovations and materials, cement packaging can become more environmentally friendly, helping to reduce overall waste and promote sustainability within the industry.

How do you address challenges related to the transportation and handling of cement pallets?
To effectively address challenges related to transportation and handling, we ensure that our cement pallets are stacked optimally and securely, minimising the risk of damage during transit. Our palletising process uses specialised materials and techniques to ensure that the bags remain stable and well-positioned throughout transportation. This approach reduces the likelihood of shifting or collapsing, which can lead to product damage or inefficiencies in space utilisation. Additionally, we implement comprehensive training programs for workers, focusing on the proper handling of cement bags. These training initiatives equip employees with the necessary skills to safely load and unload the bags, further minimising the risk of damage during these crucial stages. By emphasising safe and efficient handling, we improve both the quality and reliability of our cement delivery process, ensuring that customers receive their orders in optimal condition.
This combination of optimised palletising, secure stacking, and trained workforce helps streamline the entire logistics process, contributing to reduced damage rates and enhanced operational efficiency.

What role does digitalisation play in optimising bagging and palletising operations?
Digitalisation plays a pivotal role in optimising bagging and palletising operations by integrating advanced tracking and monitoring systems. These systems leverage sensors and automated technologies to gather real-time data on critical factors such as machine performance, product weight, and packaging integrity. This data-driven approach allows for immediate adjustments to the process, ensuring consistent product quality and reducing the likelihood of errors or inconsistencies.
One of the key benefits of digitalisation is the implementation of predictive maintenance. By continuously monitoring equipment conditions, digital systems can anticipate potential failures before they occur, reducing downtime and keeping production running smoothly. This proactive approach helps maximise the lifespan of machinery and ensures that operations are not interrupted by unexpected breakdowns. Additionally, digitalisation enhances inventory management by providing real-time insights into stock levels, enabling companies to optimise their production schedules. This leads to more efficient, just-in-time production and delivery, ensuring that the right amount of cement is produced and dispatched without overstocking or shortages. Overall, the integration of digital systems boosts efficiency, reduces operational costs, and improves the reliability of the bagging and palletising process.

How are customer demands influencing trends in cement packaging design and functionality?
Customer demands are playing an increasingly influential role in shaping packaging designs, with a clear focus on convenience, durability, and sustainability. Modern consumers are looking for packaging that enhances usability, such as bags with ergonomic designs that are easy to carry, and resealable options that allow for more flexibility in storage. These features cater to the growing demand for practical, user-friendly solutions, especially for residential or small-scale use.
Alongside convenience, there is a significant push towards eco-friendly packaging. Customers are now more conscious of environmental issues, leading to a preference for packaging made from sustainable materials, such as biodegradable or recyclable options. This demand reflects the broader trend toward sustainability in various industries, including cement packaging, as consumers seek ways to reduce their environmental footprint. Additionally, the trend toward smaller, more compact bags is gaining traction. Many customers now prefer to purchase cement in smaller quantities, especially for residential or projects. This change in consumer behavior requires packaging solutions that are not only convenient but also tailored to individual needs.
Finally, customers expect a high level of consistency in packaging quality. Cement packaging must not only be functional but also provide reliable protection during storage and transit. The durability of the packaging is essential to ensure that the cement reaches customers without damage, maintaining its integrity and usability.
By responding to these customer demands, companies can enhance customer satisfaction while contributing to sustainability and efficiency in the cement packaging process.

What strategies do you implement to minimise waste and improve recyclability in cement packaging?
Prioritising waste reduction through the use of recyclable packaging materials is a crucial step in making cement packaging more sustainable. By working closely with suppliers, we can ensure that the materials used for packaging are eco-friendly, recyclable, or reusable at the end of their life cycle. This collaboration helps us source packaging solutions that align with our environmental goals, reducing waste and conserving resources.
In addition to using recyclable materials, we can focus on optimising packaging sizes and material usage during production. By designing packaging that is efficient and tailored to customer needs, we can minimise excess materials, thus reducing waste and improving resource efficiency. Streamlining packaging design not only lowers costs but also supports sustainability by ensuring that materials are used as effectively as possible.
To further support a circular economy, we can actively raise awareness among customers about the importance of proper disposal and recycling of cement packaging. Providing clear instructions on how to recycle or reuse packaging materials can empower customers to contribute to the circular economy, where materials are kept in use for as long as possible, reducing the need for new resources and minimising environmental impact.
Through these combined efforts, we can help foster a more sustainable approach to cement packaging, making a positive impact on both the environment and the community.

Concrete

Nuvoco Vistas, CleanMax Partner for Wind-Solar Hybrid Project in Rajasthan

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The project – comprising 20 MW of wind and 26.4 MWdc of solar capacity – will support Nuvoco’s cement operations with cleaner power while strengthening its renewable energy and decarbonisation strategy.

Mumbai, September 29, 2026

Nuvoco Vistas Corp Ltd, part of Nirma Group and one of India’s leading cement companies, has partnered with Clean Max Enviro Energy Solutions Limited (CleanMax), a renewable energy solutions provider for the commercial and industrial (C&I) sector, to develop a 46.4 MW wind-solar hybrid renewable energy project in Rajasthan.

The project will support Nuvoco’s cement operations with cleaner power while strengthening its renewable energy and decarbonisation strategy. It is expected to increase the share of renewable energy in Nuvoco’s power mix, reducing fossil fuel consumption and associated emissions.

Developed by CleanMax, an Independent Power Producer (IPP), at Bhikamkhore, Rajasthan, the project will comprise 20 MW of wind capacity and 26.4 MWdc of solar capacity, along with a 2-MWh Battery Energy Storage System (BESS). Power generated from the facility will be supplied to Nuvoco through the State Transmission Utility (STU) Open Access network.

The hybrid project is expected to generate approximately 100 million units (MU) of renewable electricity annually and help avoid around 1,25,485 tonnes of CO₂ emissions every year across Scope 1 and Scope 2 emissions.

The initiative supports Nuvoco’s ongoing efforts to reduce the carbon intensity of its manufacturing operations through renewable energy adoption, Waste Heat Recovery Systems (WHRS), energy-efficiency measures and increased use of alternative fuels. It also aligns with the company’s DIRE (Digitalisation, Innovation and Renewables) agenda, which focuses on climate action, renewable energy transition, water stewardship, circularity and biodiversity conservation across its manufacturing ecosystem.

Commenting on the initiative, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said, “This marks an important step in advancing Nuvoco’s journey towards more sustainable and resilient operations. Our collaboration with CleanMax will increase the share of renewable energy across our Rajasthan operations, strengthening our energy mix while improving long-term cost efficiency and reducing our dependence on conventional power sources. Initiatives such as these reinforce our commitment to operational excellence and responsible growth, while supporting our vision of Building a Safer, Smarter and Sustainable World.”

Kuldeep Jain, Founder and Managing Director, CleanMax, said, “Cement plants run continuously, so the power behind them has to be dependable for decades, not years. We’re seeing manufacturing industries view clean energy as an integral part of their core operations and long-term strategy. Our partnership with Nuvoco reflects that shift, and we’re pleased to support its decarbonisation journey. This wind-solar hybrid project is designed to deliver long-term cost certainty while supporting the Company’s transition to cleaner power.”

Nuvoco has been advancing its sustainability initiatives through renewable energy, operational efficiency and technology-driven solutions. The company operates across Cement, Ready-Mix Concrete (RMX) and Modern Building Materials (MBM) segments, with a presence across East, North and West India.

The company began operations in 2014 with a greenfield cement plant in Nimbol, Rajasthan, and later acquired Lafarge India Limited, which entered India in 1999, along with Emami Cement Ltd in 2020 and Vadraj Cement Limited in April 2025. With planned expansion initiatives, including a new grinding mill at the Arasmeta Cement Plant and multiple debottlenecking projects, Nuvoco aims to achieve a cement capacity of 35 MMTPA.

The company reported total income of Rs 113.62 billion in FY 2025-26, reflecting its continued growth trajectory. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem brands, while its RMX business offers products under Concreto, Artiste, InstaMix, X-Con and Ecodure brands. Nuvoco also provides construction solutions under its Zero M range of modern building materials.

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Concrete

UltraTech Cement achieves 100% green energy milestone at Chhattisgarh plant

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UltraTech Cement’s Kukurdih Works becomes its first integrated unit to meet 100 per cent electricity needs through green energy every month.

Raipur (Chhattisgarh)

UltraTech Cement Limited, the world’s largest cement company outside China, has achieved a significant decarbonisation milestone, with its Kukurdih Cement Works integrated unit in Chhattisgarh meeting 100 per cent of its electricity requirement through green energy every month since April 2026.

Commissioned in 2024, Kukurdih Cement Works has an installed grey cement capacity of 3.3 million tonnes per annum. The unit achieved this milestone through a combination of renewable power sourcing and Waste Heat Recovery Systems (WHRS), which now collectively meet its entire electricity demand while ensuring operational reliability.

Since April 2026, nearly one-third of UltraTech’s 76 manufacturing units in India have maintained green energy utilisation above 50 per cent of their electricity requirements. Five units, including Kukurdih, have exceeded 95 per cent green energy utilisation. The company is also progressively deploying Battery Energy Storage Systems (BESS) across its network to enable deeper renewable energy integration.

As part of its decarbonisation strategy, UltraTech has not invested in additional captive thermal power capacity for greenfield projects or brownfield expansions at its integrated units for over a decade.

As of Q1FY27, the company’s captive green energy capacity stood at 1,897 MW, comprising 1,463 MW of renewable energy capacity from solar, wind and hybrid sources, along with 434 MW of WHRS capacity. Under its RE100 commitment, UltraTech aims to increase the share of green power in its total energy mix to 85 per cent by 2030 and achieve 100 per cent by 2050.

UltraTech Cement Ltd, the cement flagship company of the Aditya Birla Group, is a $10-billion building solutions company and the largest cement producer globally by sales volume outside China. The company has a total grey cement capacity of 210.1 MTPA and white cement/putty capacity of 3.5 MTPA. It is a signatory to the GCCA Climate Ambition 2050 and has committed to the Net Zero Concrete roadmap announced by GCCA.

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Economy & Market

From First Mile to Last Mile

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Praveen Vashistha, Founder, Gxpress Solutions, speaks about building a holistic logistics network that encompasses latest technology and current challenges faced by logistics service providers.

Logistics may seem to only entail transporting a package from one location to another. However, there is more to this term than just that. Logistics refers to the entire process of controlling all movement, transfers and decisions in the correct way at the right time and cost and with the desired level of visibility.

People nowadays want to receive more than just the delivery. They want quick, efficient, reliable and transparent logistics service. On the other hand, companies are facing higher operating costs, broken supply chains, congested cities, changing habits of consumers and growing complexity of logistics services. In this situation, a full logistics package is gaining importance not only as a competitive advantage but also as a necessity for a successful business.

The main challenge lies in uniting the first mile, the middle mile and the last mile into one seamless process.

The journey begins before the package moves

First-mile logistics may be the least recognised part of the logistics chain, but they have a crucial influence on all that follows.

This stage starts from the moment the shipment leaves the manufacturer, supplier, farm, warehouse or distribution centre. Depending on the industry, first-mile logistics may involve grouping shipments from multiple suppliers, compiling paperwork and checking the inventory before sending the shipments to a central hub.

Flaws in first-mile logistics produce effects later down the supply chain. Delays in cargo pickup can affect warehouse operations; improper packaging can damage goods in transit; and incorrect inventory information may cause stockholding or unnecessary replenishments.

This is why building a reliable network involves simplifying the operations done at the beginning of the supply chain.

Companies require accurate demand forecasts, supplier visibility, standard procedures, and software to capture information from the moment a shipment enters the supply chain. Route planning and fleet management are also important at this stage, especially as it may involve contacting multiple suppliers.

The main goal is simply to make the first mile predictable.

The middle mile: Where scale meets complexity

When products leave the original site, they travel through the ‘middle mile,’ which connects fulfilment centres, warehouses, sorting centres, and regional distribution points. In this phase, logistics networks begin operating on a large scale. A shipment can pass through several facilities before reaching the final destination. Each additional transfer entails the risk of delay or damage and information losses. Accordingly, the ideal solution is not to minimise the number of transfers but rather to optimise them. The use of hub-and-spoke networks, regional distribution centres, and strategically placed distribution centres can help companies shorten transportation routes and optimise distribution costs. Besides, data can be used to determine the optimal placement of inventories.

For instance, a retailer may find that it takes more time and is more expensive to deliver goods to customers if everything is stored in a central warehouse. Meanwhile, regional distribution helps meet the customer’s needs quicker and more efficiently.

The last mile is where the customer judges you

When it comes to the logistics experience, the customer experience comes down to the delivery. While the last mile might comprise a small part of the entire journey in actual distance, it could also entail expensive and difficult processes. Delivery runs through densely populated cities, through traffic jams, through unsuccessful delivery attempts, and through changing consumer preferences and narrowed time frames.

Customers want to have control over their delivery. Delivery means that customers expect to know the exact moment when their order is delivered. They need to receive current updates about their orders and the ability to decide whether they want scheduled deliveries, or whether they want their order to be dropped off at a designated location far from their house.

As a result, last-mile logistics must incorporate both efficiency and experience. The technology may be used to ensure timely and accurate delivery, through such products as route optimisation and real-time delivery tracking.

However, technology is not enough to guarantee success in terms of last-mile delivery. Knowledge of the local area is still an important aspect that contributes to successful delivery.

One network, not three separate operations

First, the common mistake that organisations can make is treating the first mile, the middle, and the last mile separately.

An effective first mile of logistics does not matter much if the shipment waits in a hub for many hours. A perfectly working warehouse does not make a happy customer if the last-mile delivery fails. Therefore, even the fastest last-mile delivery can become an expensive operation if the supply is not well geographically positioned.

The three moments should work together as one whole system.

This implies having a common view on inventory, transport capacities, shipment statuses and demand. The Transportation Management System, Warehouse Management System and order management system should give information to each other instead of acting like separate islands.

That is where real-time information comes into play!

If something happens, such as a vehicle gets delayed, the company has to know that from the start. If not, someone from Customer Service should be informed about the situation.

Visibility is the new infrastructure

Previously, companies had to rely on physical assets, such as warehouses, trucks, and sorting facilities, to create their logistics networks. Today, they have an additional layer of technology providing visibility.

Command-and-control systems now include GPS tracking, Internet of Things devices, bar-coding, RFID, cloud computing, artificial intelligence, and analytics, which allow companies to know what the goods are doing, how well they are doing, and what is going to happen next.

Predictive analytics reveal possible delays. AI-powered forecasting increases availability. Digital dashboards enable the manager to monitor all operations in one place. The efficiency of such technologies is not measured in the amount of information they gather, but rather in their capability of converting data into knowledge.

Logistics managers should be able to answer the following questions: Where is it? When is it supposed to arrive? What causes the delay? What impact does it have? Can it be delivered some other way? How much will it cost?

The sooner the answers are given, the more resilient the logistics system is.

Resilience must be designed into the network

The events of recent years have highlighted the vulnerability of interconnected supply chains. Geopolitical tensions, bad weather, a lack of labour, poorly developed infrastructure and an unexpected spike in demand are some events that can cause problems for logistics systems without prior notice. Thus, companies should create an end-to-end network not just for normal times but also capable of functioning quickly in problematic situations. In order to create such a network, it is necessary to find alternative suppliers, use several means of transportation, create several routes of delivery, and establish inventory. It is also important to use scenario planning to define what to do if the main hub becomes unavailable or any means of transportation is blocked.

Sustainability: Part of the delivery equation

The future of logistics will also be shaped by environmental considerations.

As delivery volumes rise, businesses are under increasing pressure to reduce emissions without compromising service. Better route planning, load optimisation, electric vehicles, alternative fuels, renewable-energy-powered warehouses and consolidated deliveries can all contribute. The most sustainable shipment is often the one that does not require unnecessary movement in the first place.

Better demand forecasting and inventory placement can reduce empty miles and avoid repeated transportation. Consolidating deliveries can improve vehicle utilisation. Reverse logistics can ensure that products, packaging and materials return efficiently instead of becoming waste.

Sustainability, therefore, should not be treated as a separate initiative. It should be incorporated into network design itself.

The future belongs to connected logistics

An end-to-end logistics network ultimately seeks to close existing gaps between various processes.

Every mile of the process should be interconnected with the other miles. Warehouses should be aware of the restraints imposed by transportation. Delivery crews should be able to know at every moment the inventory at their disposal. Clients must have access to this useful information.

Companies that will be successful in this area will not necessarily be the ones with the biggest fleets or the most warehouses. They will simply be the ones that can employ their resources in the most effective manner.

The future of logistics will be represented by an ecosystem consisting of the combination of the physical aspect, digital intelligence, and personnel decisions. Every mile in the process of delivery is important. However, the key advantage here is getting those miles to work together.

For companies, it means having minimal resistance, enhancing their efficiency and improving customer care. For clients, it means simply having the right product delivered at the right time.

About the author: Praveen Vashistha, Founder, Gxpress Solutions,

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