Rajeev Manchanda, Director, Christian Pfieffer, talks about pioneering sustainable solutions in cement manufacturing with Kanika Mathur.

For over 70 years, CPG Group has been at the forefront of innovation in the cement industry, delivering customised, high-quality solutions for manufacturers worldwide. With a strong focus on technology, efficiency and sustainability, the company continues to revolutionise cement production. In this interview, we explore how CPG Group’s expertise, strategic collaborations and eco-friendly initiatives are shaping the future of the industry.

How does your company collaborate with the cement industry?
Our company, CPG Group, has been a prominent name in the cement industry for the last 70 years. We are known for manufacturing complete cement plants, including clinkerisation units, cement mills, raw mills, and pyro systems, among other components. Our operations are backed by four workshops where we produce approximately 80 per cent of the required machinery in-house. This enables us to maintain high standards of quality and precision, ensuring that the equipment meets the specific demands of the cement industry. Over the decades, we have built strong relationships with cement manufacturers, delivering solutions tailored to their needs and contributing to the industry’s growth and sustainability.

Do you customise your machinery based on the cement manufacturers’ requirements?
Absolutely. All our designs and manufacturing processes are tailored to the specific requirements of our clients. We do not rely on pre-designed equipment. Instead, we analyse the client’s needs, assess their operational challenges, and then design machinery to address those requirements effectively. Customisation is a cornerstone of our approach, as every cement manufacturer operates under unique conditions. By aligning our solutions with their specific goals and constraints, we ensure that our clients achieve optimal performance, efficiency, and cost-effectiveness.

How is technology helping improve your operations, and how is it helping the cement industry enhance theirs?
Technology plays a vital role in both our operations and those of the cement industry. We have established several collaborations with leading European companies to provide cutting-edge technology and services. These partnerships allow us to offer energy-efficient and environmentally friendly solutions to our clients. For example, we work closely with Semprotect to optimise the calorific value of clinkerisation plants, which significantly reduces coal consumption. By saving coal, we not only cut costs but also contribute to environmental preservation.
All our equipment is designed with the primary objectives of saving energy, minimising coal usage, and increasing production efficiency. Our approach involves replacing outdated systems with modern, optimised ones, which have consistently delivered substantial benefits to our clients. These improvements are aligned with our commitment to reducing the industry’s carbon footprint while enhancing operational efficiency.

Can you share an example where your company upgraded a system for a client and delivered significant results?
Recently, we upgraded a part of a cooler that was originally supplied by another vendor. By making specific modifications to the system, we managed to save 15 kilocalories per kilogram of clinker. This improvement directly reduced coal consumption, resulting in significant cost savings for the client. Additionally, it contributed to a reduction in environmental impact.
There are many such instances where we have enhanced production efficiency, reduced power consumption, and minimised coal usage for our clients. These projects underscore our expertise in delivering customised solutions that address the unique challenges faced by cement manufacturers. Such interventions not only benefit our clients financially but also align with broader environmental sustainability goals.

What is your perspective on sustainability in your operations and within the cement industry?
To me, sustainability means ensuring that systems and operations can run profitably over the long term. For our company, sustainability involves designing systems that help clients reduce production costs while improving efficiency and environmental performance. When businesses adopt such practices, they naturally achieve more sustainable operations.
Sustainability creates a win-win scenario: it benefits our clients by improving their profitability, it supports the environment by reducing emissions and resource consumption, and it strengthens the industry by promoting long-term viability. Our work in optimising energy usage, reducing coal consumption, and increasing production efficiency exemplifies this balanced approach to sustainability. It’s a comprehensive effort that positively impacts all stakeholders, including the country and the global environment.

What is your view on the net-zero mission, and how is your company contributing to it?
The net-zero mission is an ambitious but essential goal for the cement industry and beyond. At CPG Group, we are doing our part by focusing on reducing coal consumption, optimising power usage, and minimising pollution in cement production. For example, in our designs, we aim to significantly reduce the emission of pollutants. While earlier systems emitted 100 milligrams of particulate matter per cubic meter, we have progressively reduced this to 50 milligrams and now maintain levels as low as 10 milligrams.
Our efforts also extend to designing equipment and processes that minimise the environmental impact of cement production. Cement manufacturing is inherently a polluting process, but by incorporating innovative technologies, we aim to mitigate its effects. Achieving net zero will require joint efforts from all stakeholders, including manufacturers, suppliers, governments, and society at large.
It is a challenging journey that requires time, resources, and collaboration. While our contribution may seem small in the grand scheme of things, we believe that every step counts. By continuously improving our systems and designs, we are moving closer to a more sustainable future for the industry.