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Optimising Cement Grinding

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Kanika Mathur explores the role of grinding aids in enhancing the efficiency and sustainability of cement production by reducing energy consumption, improving particle size distribution, and extending equipment life.

The grinding process is a crucial step in cement production, directly impacting the final quality and efficiency of cement manufacturing. With growing demands for energy efficiency, cost optimisation, and sustainable production, cement manufacturers are continuously seeking ways to improve grinding operations. Grinding aids, introduced into the process, have emerged as an essential component in achieving these objectives by enhancing the efficiency of
grinding mills and improving the performance of cement. This article explores the significance of the grinding process, the challenges faced in cement grinding, and the role of grinding aids in optimising cement manufacturing.

The Importance of the Grinding Process in Cement Manufacturing
Grinding is a fundamental process in cement production, where clinker, gypsum, and other additives are ground into fine powder to create the final product. The fineness of cement particles influences the hydration reaction, strength development, and overall durability of the cement. The efficiency of the grinding process directly affects the energy consumption, production costs, and environmental impact of cement plants.
The grinding process primarily takes place in ball mills, vertical roller mills (VRMs), and roller presses. Each of these grinding technologies has its advantages and limitations, influencing factors such as energy consumption, operational efficiency, and product quality. In recent years, there has been a shift towards more energy-efficient grinding systems, such as VRMs and roller presses, which offer better control over particle size distribution and reduce specific energy consumption.

Grinding Technologies
The grinding process is a critical component of cement manufacturing, influencing energy consumption, production efficiency, and product quality. Traditional ball mills, vertical roller mills (VRMs), and roller presses are the primary grinding technologies used in the industry. While ball mills have been widely used, they are energy-intensive and require frequent maintenance. VRMs and roller presses, on the other hand, offer better energy efficiency and control over particle size distribution, making them attractive alternatives. The shift toward advanced grinding systems has helped cement manufacturers reduce operational costs and improve sustainability.
However, cement grinding presents several challenges, including high energy consumption, inconsistencies in particle size distribution, and equipment wear. Grinding consumes nearly 60 to 70 per cent of a cement plant’s total electricity, making it one of the most energy-intensive processes. Additionally, friction during grinding generates heat, leading to agglomeration and efficiency losses. Optimising grinding operations requires careful control of raw materials, mill performance, and energy inputs to ensure sustainable and cost-effective production.
Ashok Dembla, Director, KhD Humboldt says, “The use of alternative fuels and raw materials (AFR) is continuously evolving within the cement industry. As a machinery supplier, we are adapting to these changes by providing advanced solutions for handling and processing AFR. One of our most significant innovations is the PyroRotor, an equipment designed specifically for feeding up to 85 per cent of alternative fuels into the pyroclone, which is far beyond what conventional methods can achieve. This has greatly enhanced our ability to replace traditional fuels with more sustainable alternatives.”
“In addition, we have developed solutions to address nitrogen oxide (NOx) emissions, a critical environmental concern. Our NOx reduction equipment significantly minimises NOx generation during the production process, helping plants meet stringent regulatory requirements” he adds.
Grinding aids play a vital role in enhancing grinding efficiency by reducing agglomeration, improving dispersion, and minimising energy consumption. Chemical additives such as amine-based compounds, glycols, and organic acids help improve cement properties by ensuring better flowability, reducing coating on mill internals, and extending equipment life. These additives also enhance cement hydration, leading to stronger and more durable concrete. As cement manufacturers seek ways to reduce costs and carbon footprints, grinding aids have become an essential tool in improving overall plant performance.
Looking ahead, the future of grinding in the cement industry will be shaped by advancements in eco-friendly grinding aids, digital process optimisation, and AI-driven automation. Research into bio-based and waste-derived additives is gaining traction, as companies aim to align with global sustainability goals. Additionally, integrating digital technologies into grinding operations will allow real-time monitoring and process control, further enhancing efficiency. By embracing these innovations, the cement industry can achieve greater sustainability, reduce emissions, and enhance profitability while maintaining high-quality production standards.

Challenges in Cement Grinding
Despite advancements in grinding technology, cement manufacturers still face several challenges in optimising the grinding process. Some of the key challenges include:

Energy Consumption: Grinding is an energy-intensive process, accounting for nearly 60 to 70 per cent of the total electricity consumption in a cement plant. The high energy demand for clinker grinding results in increased operational costs and contributes to CO2 emissions. Reducing energy consumption while maintaining cement quality remains a primary goal for manufacturers.
Particle Size Distribution: Achieving the right particle size distribution (PSD) is crucial for cement performance. A well-optimised PSD improves the workability of concrete, enhances strength development, and reduces the risk of segregation. However, variations in raw materials, mill operations, and grinding media can lead to inconsistencies in PSD, affecting the quality of the final product.
Mill Performance and Wear: Grinding equipment is subject to continuous wear and tear due to the abrasive nature of clinker and additives. The efficiency of grinding media, liner design,
and mill internals plays a significant role in optimising mill performance and reducing maintenance costs.
Heat Generation and Agglomeration: During grinding, friction generates heat, which can lead to issues such as agglomeration and coating on grinding media. This reduces the efficiency of the grinding process, requiring additional efforts to control mill temperature and ensure proper dispersion of cement particles.
Dyanesh Wanjale, Managing Director, Gebr. Pfeiffer says, “One of the major challenges we face is the demand for expedited deliveries. While customers often take time to decide on placing orders, once the decision is made, they expect quick deliveries. However, our industry deals with heavy and highly customised machinery that cannot be produced off the shelf. Each piece of equipment is made-to-order based on the client’s unique requirements, which inherently requires time for manufacturing.”
“Another significant challenge comes from competition with Chinese suppliers. While the Indian cement industry traditionally favoured our technology over Chinese alternatives, a few customers have started exploring Chinese vertical roller mills. This is concerning because our German technology offers unmatched quality and longevity. For example, our mills are designed to last over 30 years, providing a long-term solution for customers. In contrast, Chinese equipment often does not offer the same durability or reliability. Despite the cost pressures, we firmly believe that our technology provides superior value in the long run” he adds.

Role of Grinding Aids in Cement Grinding
Grinding aids are chemical additives that are introduced into the grinding process to improve efficiency and performance. These additives work by reducing the surface energy of clinker particles, preventing agglomeration, and enhancing the flowability of the cement powder. Some of the key benefits of grinding aids include:
Enhanced Grinding Efficiency: Grinding aids help in breaking down clinker particles more effectively, reducing the energy required for grinding. This leads to higher mill output, lower specific energy consumption, and improved overall plant performance.
Improved Particle Size Distribution: By minimising agglomeration and promoting dispersion, grinding aids contribute to a more uniform particle size distribution. This results in better cement hydration, improved strength development, and enhanced durability of concrete structures.
Reduction in Coating and Mill Wear: Grinding aids help prevent the accumulation of cement particles on grinding media and mill internals, reducing coating issues. This minimises wear and tear on equipment, leading to lower maintenance costs and extended mill life.
Better Flowability and Handling: Cement produced with grinding aids exhibits improved flow properties, reducing the risk of blockages in silos and conveying systems. This facilitates smoother handling, packaging, and transportation of cement.
“The performance evaluation of grinding aids is crucial in determining their efficiency and overall contribution to cement manufacturing processes. A systematic assessment involves analysing key performance indicators (KPIs) such as energy consumption, mill output, and particle size distribution, while also evaluating their impact on cement hydration, setting time, and compressive strength. These evaluations, carried out both in laboratories and real-world industrial settings, provide critical insights into the effectiveness of grinding aids” says Dr SB Hegde.

Types of Grinding Aids
Grinding aids can be classified into different categories based on their chemical composition
and functionality. The most commonly used grinding aids include:
Amine-Based Grinding Aids: These additives, such as triethanolamine (TEA) and diethanolamine (DEA), enhance the grinding process by reducing surface tension and improving dispersion. They are widely used to improve early strength development and reduce setting time.
Glycol-Based Grinding Aids: Polyethylene glycols (PEG) and ethylene glycols are commonly used to improve mill efficiency and reduce energy consumption. They help in reducing agglomeration and enhancing cement flowability.
Organic Acids and Their Salts: Organic acid-based grinding aids, such as acetic acid and citric acid derivatives, function by modifying surface interactions between clinker particles. They contribute to better particle dispersion and enhanced cement performance.

Advanced Process Control and AI in Grinding Optimisation
The integration of Advanced Process Control (APC) and Artificial Intelligence (AI) in cement grinding has revolutionised the industry by enhancing efficiency, reducing energy consumption, and improving product quality. APC systems use real-time data from sensors to automatically adjust operating parameters, such as mill speed, grinding media distribution, and material flow, ensuring optimal performance. AI-driven predictive analytics further refine this process by identifying patterns and trends, allowing for proactive adjustments that minimise downtime and maximise throughput.
Rajeev Manchanda, Director, Christian Pfieffer says, “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” he adds.
One of the key benefits of AI in grinding optimisation is its ability to handle complex variables that affect grinding efficiency, such as raw material variability, feed rate fluctuations, and mill conditions. Machine learning algorithms continuously analyse historical and real-time data to make intelligent decisions, reducing human intervention and improving accuracy. This results in lower specific energy consumption, better particle size distribution, and increased cement strength.

The Future of Grinding Aids and Sustainable Cement Production
With increasing emphasis on sustainability and reducing the environmental impact of cement production, the development of eco-friendly grinding aids is gaining attention. Researchers are exploring bio-based and waste-derived additives that can improve grinding efficiency while minimising the carbon footprint of cement manufacturing. Additionally, advancements in digitalisation and AI-driven process control
systems are expected to further optimise grinding operations, leading to smarter and more sustainable cement production.

Conclusion
The grinding process plays a crucial role in cement manufacturing, influencing energy consumption, production efficiency, and final product quality. While challenges such as energy demand, particle size distribution, and mill performance persist, the use of grinding aids has proven to be an effective strategy in overcoming these obstacles. By enhancing grinding efficiency, improving cement properties, and reducing operational costs, grinding aids contribute significantly to the sustainability and competitiveness of the cement industry. As technology advances, further innovations in grinding aids and process optimisation will continue to shape the future of cement grinding, ensuring a more sustainable and efficient production process.

Economy & Market

The Road Ahead Begins Here

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The future of India’s roads took centrestage at RAHSTA Expo 2026, where policymakers, contractors and industry leaders came together under one roof. The event blended thought leadership, technology showcase and industry recognition into a single powerful platform.

India’s roads and highways community gathered in full strength at the Jio World Convention Centre, Mumbai, for the 16th edition of the RAHSTA Expo (Roads and Highways Sustainable Technologies & Advancement). Over two action-packed days, the event brought together policymakers, contractors, consultants, developers, equipment manufacturers, material suppliers, technology providers and investors to deliberate on the future of India’s ,infrastructure while showcasing the latest innovations driving the sector.

The event culminated in the prestigious RAHSTA Awards, where Shri. Ajay Tamta, Union Minister of State for Road Transport & Highways, felicitated organisations and professionals for their outstanding contributions to road construction, engineering, safety, sustainability and technology. With leading contractors, senior government officials, industry veterans and technology providers under one roof, the event reaffirmed RAHSTA’s position as one of India’s most influential platforms for the roads, highways, bridges and tunnels ecosystem.

Organised by FIRST Construction Council in association with ASAPP Info Global Group, RAHSTA has steadily evolved beyond an exhibition into a platform where policy, technology, engineering and business converge to address the opportunities and challenges shaping India’s next generation of transport infrastructure.

Beyond expansion, towards value

The conference opened with a thought-provoking address by Pratap Padode, Founder and Editor-in-Chief, Construction World, who observed that India’s highways sector has reached an important inflection point. Introducing this year’s theme – ‘From Expansion to Value: The Next Phase of India’s Highways’ – he noted that while the country has successfully expanded its road network over the past two decades, the industry’s priorities are now shifting towards building infrastructure that delivers greater lifecycle value, durability, safety and operational efficiency. With funding pressures, asset monetisation and evolving project models changing the sector’s dynamics, he said the focus must now move beyond kilometres constructed to the quality and long-term performance of every asset.

Dr Brijesh Dixit, Managing Director, Maharashtra State Infrastructure Development Corporation (MSIDC), reminded delegates that successful infrastructure delivery is ultimately a collective effort. Emphasising on collaboration between government, industry and engineering professionals, he remarked, “There is no loser in a winning team, and there is no winner in a losing team,” urging stakeholders to work together to deliver projects with quality, financial sustainability and technological excellence.

Delivering the keynote address, Bidur Kant Jha, Director, New Technologies for Highway Development, Ministry of Road Transport & Highways (MoRTH), outlined the Government’s long-term vision for India’s highway network. Highlighting the country’s 6.26 million km roads network, he spoke about the growing adoption of digital planning tools such as BIM and GIS, bridge health monitoring systems and Integrated Smart Transport Corridors under the Vision 2047 roadmap. He emphasised that while India remains open to global innovations, every new technology must be adapted to Indian conditions before large-scale deployment.

Addressing the gathering during the awards ceremony, Tamta underlined the increasing role of specialised equipment and modern construction technologies in executing complex infrastructure projects across diverse terrains. Referring to challenging tunnel projects in Uttarakhand, he noted how advanced machinery has transformed execution capabilities, while also acknowledging the rapid evolution of Indian contractors into globally competitive infrastructure companies. Recognising excellence through industry awards, he said, motivates organisations to continually raise performance standards and embrace innovation.

Meanwhile, Dr Sanjay Mukherjee, IAS, Metropolitan Commissioner, MMRDA, highlighted that infrastructure development must increasingly focus on integrated urban mobility. Reflecting on Mumbai’s engineering journey – from its historic underground utility network to the Coastal Road and other transformative projects – he underlined that future infrastructure planning must seamlessly integrate roads, metro systems and public transport to create efficient, multimodal cities.

Uttar Pradesh takes centrestage

One of the highlights of the second day was Uttar Pradesh’s comprehensive presentation on its infrastructure-led industrial transformation.

Srihari Pratap Shahi, IAS, Additional CEO, Uttar Pradesh Expressways Industrial Development Authority (UPEIDA), demonstrated how the state’s expanding expressway network is evolving into a catalyst for industrial development through integrated manufacturing and logistics clusters. Expressways, he noted, are no longer merely transport corridors but engines of economic competitiveness.

Building on this narrative, Deeksha Jain, IAS, Additional Chief Executive Officer, Uttar Pradesh State Industrial Development Authority (UPSIDA), showcased the state’s rapidly expanding industrial ecosystem supported by extensive expressway connectivity, dedicated freight corridors, airports, industrial townships and investor-friendly policies. She highlighted Uttar Pradesh’s strong manufacturing growth, expanding industrial land bank, plug-and-play infrastructure and increasing use of digital governance to facilitate investments.

Further underlining the significance of the platform, Deepak Kumar, IAS, Infrastructure & Industrial Development Commissioner, Government of Uttar Pradesh, remarked, “RAHSTA provides an excellent platform for states to showcase our infrastructure progress and investment ecosystem. Uttar Pradesh has transformed significantly over the past decade, backed by more than 34 investor-friendly industrial policies, and platforms like RAHSTA help communicate these developments to industry stakeholders from across the country.”

Ideas that shaped the industry conversation

The two-day conference featured seven panel discussions, each examining a critical dimension of India’s evolving roads and highways sector.

The opening discussion on ‘Financing Roads & Highways in a Capital-Constrained Era’ brought together experts from Cube Highways, NIIF, SBI Capital Markets, Centrum Capital and Bandhan Infra Fund, who examined how the financing landscape is changing. Discussions revolved around asset monetisation, InvITs, institutional investments and new funding structures, with panellists agreeing that better project preparation, transparent governance and predictable returns will be crucial for attracting long-term capital into infrastructure.

Attention then shifted to execution realities during the panel on ‘Contractors’ Perspective: Execution Realities, Risks & the Quality Imperative.’ Representatives from GHV Infra Projects, PNC Infratech, NCC and Maccaferri candidly discussed the challenges of delivering projects amid contractual complexities, land acquisition delays, rising costs and tight timelines. While execution pressures remain significant, the discussion reinforced that better collaboration across the project value chain is essential for achieving both speed and quality.

Day 2 opened with a technically rich discussion on ‘Designing Roads for Sustainability, Durability & Climate Resilience’. Experts from CSIR-CRRI, IIT Bombay, IIT Madras, Zydex Group and SRMB Steel explored advanced pavement technologies, recycled materials, climate-resilient designs and scientific construction practices that can significantly improve durability while lowering lifecycle costs. Sustainability, they agreed, must become an integral part of road design rather than an afterthought.

The subsequent session on ‘Bridges & Tunnels: Complex Engineering, Safety & Future Readiness’ highlighted the growing complexity of India’s infrastructure projects. Panellists discussed advances in structural engineering, digital monitoring, risk management and safety practices that are enabling the successful delivery of increasingly ambitious bridge and tunnel projects across the country.

Technology remained a recurring theme during the discussion on ‘Technology as a Risk-Mitigation Tool for Developers & Investors’. Experts explained how AI, BIM, drones, predictive analytics, digital twins and intelligent monitoring systems are helping improve project planning, minimise execution risks, strengthen quality assurance and enhance asset management throughout the infrastructure lifecycle.

The construction equipment panel brought together leading industry experts to examine how technology, sustainability and digitalisation are redefining construction equipment in an era of rising cost pressures. Discussions centred on enhancing productivity, reducing lifecycle costs and preparing the industry for India’s infrastructure ambitions leading up to 2047.

The conference concluded with an engaging CXO Forum on ‘Rebuilding Confidence in India’s Roads & Highways Sector’, where senior industry leaders emphasised that stronger governance, better project preparation, digitalisation, transparent contracting and closer public-private collaboration will be essential to sustain India’s infrastructure growth over the coming decades.

Technology and recognition under one roof

Beyond the conference halls, RAHSTA Expo reflected the technological transformation underway across India’s road infrastructure ecosystem. Leading equipment manufacturers, technology companies and material suppliers showcased advanced construction equipment, intelligent digital platforms, pavement technologies, structural materials and productivity-enhancing solutions designed to improve project efficiency and asset performance. The exhibition created valuable opportunities for contractors, consultants, government agencies and project developers to evaluate new technologies while interacting directly with solution providers.

The event also served as a celebration of excellence through the RAHSTA Awards 2026, which recognised outstanding achievements across road construction, contracting, materials, equipment, technology, safety, sustainability and infrastructure development. Presented by Minister Tamta, the awards honoured organisations that are setting new benchmarks for quality, innovation and execution across India’s roads sector.

RAHSTA Expo 2026 also received extensive support from across the infrastructure ecosystem. Alongside leading corporate sponsors, the event was backed by industry bodies including the Builders Association of India (BAI), Construction Equipment Rental Association (CERA), Consulting Engineers Association of India (CEAI), International Road Federation (IRF), CSIR-CRRI, CILT India, All India Transporters Welfare Association, Hydraulic Trailer Owners Association (HTOA), Gujarat Contractors Association, Bitumen Forum, Fluid Power Society of India, Indian Institute of Material Management, Ministry of Ports, Shipping and Waterways, Gati Shakti Vishwavidyalaya and Mumbai First, reflecting the industry’s collective commitment to advancing India’s road infrastructure.

As the curtains came down on the two-day event, one message resonated throughout the conference: India’s highways story is entering a new chapter. While expansion will continue, the future will increasingly be defined by smarter planning, stronger partnerships, digital transformation, sustainable engineering and long-term value creation. By bringing together the entire infrastructure value chain on a single platform, RAHSTA Expo 2026 once again demonstrated why it has become one of the country’s most influential forums for shaping the future of roads, highways, bridges and tunnels.

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Economy & Market

Fornnax Names Lukas Baur as Authorised Service Partner to Bolster EU Operations

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Strapline: Fornnax Technology has appointed NOBA Maschinenservice’s Lukas Baur as its authorised service partner for the European Union, strengthening its commitment to delivering fast, reliable, and localised after-sales support across the region.

Fornnax Technology, a leading manufacturer of industrial shredding solutions, has announced the appointment of Mr. Lukas Baur of NOBA Maschinenservice as its authorised service partner for the European Union. The partnership, formalised under the authorisation of Fornnax CEO Mr. Jignesh Kundaria, reinforces the company’s commitment to providing dependable, localised service support to its expanding customer base across Europe.

Strengthening Service Through Proven Expertise

With over two decades of experience in servicing, maintaining, and overhauling industrial shredders, Mr. Baur brings extensive technical expertise to the partnership. His capabilities span welding, hardfacing, shaft and knife rebuilding, complex assembly, hydraulics, and complete electrical engineering services, delivered in collaboration with a trusted partner company based in Halle/Saale.

Operating from Worbis, Germany, Mr. Baur is strategically positioned to provide emergency support across the European Union within 24 hours, covering an operational radius of approximately 1,000 kilometres.

Supporting this capability is a well-equipped service infrastructure comprising 12 Mercedes Sprinter service vans, a team of 24 skilled technicians, specialised bearing-change tools, a fully equipped hydraulic workshop, and a 1,000-square-metre facility with a five-ton crane track. Together, these resources position his team to manage the complete spectrum of Fornnax’s European service requirements efficiently and reliably.

Partnership Driven by Industry Insight

Having spent years servicing Eldan, Lindner, and Vecoplan shredders across the European recycling industry, Mr. Baur’s decision to collaborate with Fornnax is rooted in his understanding of market needs and customer expectations. His experience has provided valuable insight into what recycling plant operators require—not only from their machinery but also from the service teams supporting them.

According to Mr. Baur, Fornnax’s reputation for robust machine construction, superior wear protection, and maintenance-friendly design made the partnership a natural fit.

The collaboration comes at a time when Europe’s tyre recycling industry is facing mounting challenges, including rising cost pressures, shrinking margins, delayed investments, and a shortage of skilled labour. Mr. Baur believes these conditions reinforce the need for technically strong service partners capable of delivering rapid, dependable support.

Commenting on the partnership, he said, “Fornnax, with its exceptional price-performance ratio and superior quality, has the potential to become a market leader in Europe. We would like to be their service partner in this journey.”

Comprehensive Support Across the Equipment Lifecycle

As Fornnax’s authorised service partner, Mr. Baur will oversee the complete lifecycle support of the company’s equipment throughout the European Union. His responsibilities will include installation, commissioning, preventive maintenance, emergency repairs, and spare parts support across mechanical, hydraulic, and electrical systems.

Looking ahead, he also plans to develop a centralised spare parts distribution hub for European customers, particularly if Fornnax establishes a warehouse facility in Worbis to facilitate faster deliveries. To further strengthen service coverage, Mr. Baur intends to expand operations by adding two to three additional service teams and vehicles each year, progressively increasing capacity across the continent.

A Shared Commitment to Customer Excellence

Highlighting the strategic importance of the partnership, Mr. Jignesh Kundaria, Director and CEO of Fornnax, said:

“We strongly believe that by continuously improving our service quality and customer satisfaction index, we can build long-term relationships with our customers. Higher customer satisfaction leads to greater trust, which significantly increases repeat orders and ultimately drives sustained growth in our sales revenue.”

This customer-first philosophy underpins Fornnax’s strategy of building a dedicated European service partner network instead of relying solely on remote support. With Mr. Baur joining this network, customers across the European Union will benefit from faster response times, expert technical assistance, and dedicated on-ground support from a partner with extensive experience in high-throughput shredding operations.

Mr. Baur’s appointment also reflects Fornnax’s broader ambition to establish itself as the preferred shredding solutions provider for the European recycling industry, marking another important milestone in the company’s international growth strategy.

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Concrete

Nuvoco Vistas launches Limla cement plant, expands Gujarat footprint

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Nuvoco Vistas opens a 2 MMTPA grinding unit at Limla, entering Gujarat and advancing its target of 35 MMTPA capacity by FY 2028.

Surat (Gujarat)

Nuvoco Vistas Corporation Ltd, a part of Nirma Group and one of India’s leading building materials company, has inaugurated the Limla Cement Plant in Surat (Gujarat), one of Vadraj Cement Limited’s (VCL) principal manufacturing facilities. The commissioning represents a key milestone in Nuvoco’s acquisition and restoration of VCL, while supporting the company’s expansion across the Western Indian cement market.

Vadraj Cement Limited is a subsidiary of Nuvoco Vistas Corporation Limited and has installed cement capacity of 6 MMTPA across its assets. The Limla inauguration therefore represents the first operational step in the acquired platform’s wider revival, while the Kutch facilities provide clinker supply, mineral security and coastal logistics support for the western business.

Nuvoco completed its acquisition of Vadraj Cement Limited, then under the Corporate Insolvency Resolution Process, after paying a consideration of Rs 1,800 crore in June 2025. VCL’s asset portfolio comprises a clinker unit at Kutch and a grinding unit at Limla in Surat. It also includes high-quality captive limestone reserves and a captive jetty at Kutch, supporting more efficient logistics. Following the takeover, Nuvoco began an extensive programme of restoration, refurbishment and expansion at both locations, leading to the commissioning of the Limla plant.

The Limla Cement Plant is expected to support a phased increase in sales volumes across Gujarat. It will also help Nuvoco supply neighbouring markets in Western Maharashtra and release cement capacity from its northern plants, which can consequently be redirected towards markets in North India. The plant will manufacture a full portfolio comprising Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. It will additionally produce the complete Nuvoco Duraguard range, including the premium Nuvoco Duraguard Microfibre product. The acquisition is also expected to generate operational synergies with Nuvoco’s existing plants at Nimbol and Chittorgarh in Rajasthan, improving logistics optimisation and market reach across important regional markets.

The grinding unit at the Limla Cement Plant was completed ahead of schedule, with 2 MMTPA of capacity now inaugurated to expand Nuvoco’s operating scale and customer reach. After Vadraj Cement’s assets become fully operational, plants in North and West India are expected to account for nearly 40 per cent of Nuvoco’s total cement capacity. This will broaden the company’s manufacturing network, strengthen access to high-growth markets and support its plan to increase consolidated cement capacity to 35 MMTPA by FY 2028, reinforcing its longer-term growth strategy.

Commenting on the development, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said: “The inauguration of the Limla Grinding Unit in Surat is an important milestone in Nuvoco’s growth journey and demonstrates our commitment to disciplined, value-accretive expansion. Gujarat is strategically significant for Nuvoco, with substantial opportunities arising from infrastructure investment, industrial growth, rapid urbanisation and continuing demand from the housing and construction sectors. The facility strengthens our regional footprint, improves operational flexibility and increases our ability to serve customers across northern and western markets with greater reliability and efficiency.”

He added: “Through the Vadraj acquisition, we have refurbished and restarted a strategically important asset, returning it to operations in record time through strong execution and collaboration between teams. The achievement demonstrates our ability to create value from acquired assets, fulfil our commitments and retain the confidence of stakeholders. It also highlights the strength of our project delivery capabilities and our continued focus on building sustainable, profitable growth over the long term.”

Nuvoco Vistas Corporation Limited is a building materials company whose vision is to build a safer, smarter and more sustainable world. It is among the leading players in East India and has a significant presence across North and West India. Nuvoco began operations in 2014 with a greenfield cement plant at Nimbol, Rajasthan. It later acquired Lafarge India Limited, which had entered India in 1999, followed by Emami Cement Limited in 2020 and Vadraj Cement Limited in April 2025. The company has also announced an expansion in eastern India through a new grinding mill at the Arasmeta Cement Plant, supported by several debottlenecking programmes involving equipment upgrades, process improvements and internal capacity initiatives. These developments place Nuvoco on track to achieve total cement capacity of approximately 35 MMTPA. The company reported total income of Rs 11,362 crore in FY 2025-26, reflecting its continuing growth trajectory.

Nuvoco operates a diversified portfolio across three segments: Cement, Ready-Mix Concrete and Modern Building Materials. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem, covering Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. Its pan-India RMX business provides value-added products under Concreto for performance concrete, Artiste for decorative concrete, InstaMix for ready-to-use bagged concrete, X-Con covering M20 to M60 grades, and Ecodure for specialised green concrete. Nuvoco has supplied materials to projects including the Mumbai-Ahmedabad Bullet Train, Birsa Munda Hockey Stadium in Rourkela, Aquatic Gallery at Science City in Ahmedabad, and metro railway projects in Delhi, Jaipur, Noida and Mumbai.

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