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Our focus has been integrating digital monitoring tools

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Gaurav Gautam, Business Unit Head, Beumer Group, talks about bulk material handling with predictive maintenance, digital transformation and customised sustainable solutions.

Efficient bulk material handling is crucial for the cement industry, where operational efficiency and sustainability go hand in hand. Beumer Group, a global leader in material handling solutions, is redefining industry standards with digital transformation and innovative technologies. In this exclusive interview, Gaurav Gautam, Business Unit Head, Beumer Group, discusses how their cutting-edge solutions optimise equipment effectiveness, enhance predictive maintenance and drive sustainability. From reducing carbon footprints
to improving material transport, he sheds light on the company’s commitment to future-ready operations.

Can you tell us about some of theinnovative products you supply to the cement industry and how they have helped improve operations?
We do not want to remain solely focused on products. Instead, what we are offering is a complete value proposition for our customers. While the product itself is an essential part of our offering, we also emphasise long-term services, product lifecycle cost optimisation, and total cost of ownership.
When we talk about total cost of ownership and full value propositions, a crucial element in this equation is digital transformation. We are introducing digital tools that go beyond reactive problem-solving. Rather than addressing issues after they have already occurred, we are moving towards a predictive approach. This means we are now able to analyse data and forecast potential problems before they arise—whether in the next month or three months down the line. This predictive capability enhances the overall availability and efficiency of our offerings.
Our focus is on optimising overall equipment effectiveness (OEE), which is determined by three key aspects: availability, accuracy, and throughput. These three factors collectively contribute to improving equipment efficiency. Our product portfolio covers both upstream and downstream operations. On the upstream side, we are highly active in long-distance conveying, cross-country conveyors, stacker reclaimers, and yard equipment handling machines. Additionally, we offer solutions for tall elevators and critical applications for kiln feeds and preheaters. On the downstream side, we provide innovative filling, packing, and palletising machines, ensuring seamless processing from start to finish.

Transporting bulk materials, such as raw materials from mines to cement plants, results in significant wear and tear. Similarly, carrying hot clinker from the kiln to the cooling point before it is fully cooled also causes high levels of wear and tear. How do you manage these challenges?
That is an excellent question. We are material handling experts, and our solutions start right from the mining stage. We are heavily involved in providing stockyard machines, large reclaimers and long-distance conveyors, which help optimise material transport. One of the key areas we focus on is shifting from truck-based transport to mechanical conveying solutions. This shift not only improves efficiency but also significantly reduces carbon footprint.
Once within the plant boundaries, we handle various critical applications, including kiln feed
and post-cooling material transport. Over the years, we have continuously improved our equipment,
such as bucket elevators and apron conveyors, to withstand the high wear and tear associated with cement manufacturing.
A major recent focus has been integrating digital monitoring tools into our equipment. These tools include condition monitoring sensors that track temperature variations, vibrations and operational anomalies in real-time. By capturing this data, plant operators can take proactive actions when conditions start deviating from normal parameters. This approach prevents sudden breakdowns and, in the long term, enhances the durability and reliability of the equipment.
Moving forward, digitalisation will play a key role in tackling wear and tear challenges. By increasing the number of data capture points and applying advanced analytics tools, we can gain deeper insights into equipment health and performance, ensuring a more efficient and predictive maintenance strategy.

In this entire process, what do you think is your carbon footprint, and how do you ensure sustainability in your operations?
Sustainability is a broad and complex subject. However, in my view, sustainability efforts must lead to tangible outcomes—both in terms of environmental benefits and business viability. Simply implementing sustainability initiatives for the sake of it will not be effective unless they generate measurable improvements. Sustainability must address two key aspects: its impact on human life and its contribution to business efficiency.
From a financial standpoint, sustainability initiatives should not become a burden by requiring excessive capital investments without generating returns. Instead, they should lead to long-term cost savings and efficiency gains. This is the approach we take with our products and solutions. We define sustainability ratings for our offerings and work with customers to evaluate the total cost of ownership while integrating sustainable practices.
One practical example is our work in long-distance conveying from mines to cement plants. If a cement plant traditionally relies on 100 trucks per day to transport limestone or other raw materials, replacing those with conveyor systems eliminates fossil fuel consumption, resulting in a significant reduction in CO2 emissions. Our conveyor systems are highly energy-efficient, consuming far less power than a fleet of trucks.
Another major focus area is reducing fossil fuel consumption in kilns. The adoption of alternative fuels (AFR) presents a promising solution, but the challenge lies in the processing, pre-processing, and co-processing of AFR. Alternative fuels often have high moisture content and vary widely in composition, making them difficult to handle.
To address these challenges, we are introducing several innovative solutions. These include air-supported conveyors, which eliminate the need for traditional idlers and maintenance-heavy platforms, as well as OptiFeeds, which can handle a broad range of AFR particle sizes and moisture levels. By integrating
these solutions, we aim to make alternative fuel adoption more efficient and practical, thereby contributing to the overall sustainability goals of the cement industry.

Concrete

India Sets Up First Carbon Capture Testbeds for Cement Industry

Five CCU testbeds launched to decarbonise cement production

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The Department of Science and Technology (DST) recently unveiled a pioneering national initiative: five Carbon Capture and Utilisation (CCU) testbeds in the cement sector, forming a first-of-its-kind research and innovation cluster to combat industrial carbon emissions.
This is a significant step towards India’s Climate Action for fostering National Determined Contributions (NDCs) targets and to achieve net zero decarbonisation pathways for Industry Transition., towards the Government’s goal to achieve a carbon-neutral economy by 2070.
Carbon Capture Utilisation (CCU) holds significant importance in hard-to-abate sectors like Cement, Steel, Power, Oil &Natural Gas, Chemicals & Fertilizers in reducing emissions by capturing carbon dioxide from industrial processes and converting it to value add products such as synthetic fuels, Urea, Soda, Ash, chemicals, food grade CO2 or concrete aggregates. CCU provides a feasible pathway for these tough to decarbonise industries to lower their carbon footprint and move towards achieving Net Zero Goals while continuing their operations efficiently. DST has taken major strides in fostering R&D in the CCUS domain.
Concrete is vital for India’s economy and the Cement industry being one of the main hard-to-abate sectors, is committed to align with the national decarbonisation commitments. New technologies to decarbonise emission intensity of the cement sector would play a key role in achieving of national net zero targets.
Recognizing the critical need for decarbonising the Cement sector, the Energy and Sustainable Technology (CEST) Division of Department launched a unique call for mobilising Academia-Industry Consortia proposals for deployment of Carbon Capture Utilisation (CCU) in Cement Sector. This Special call envisaged to develop and deploy innovative CCU Test bed in Cement Sector with thrust on Developing CO2 capture + CO2 Utilisation integrated unit in an Industrial set up through an innovative Public Private Partnership (PPP) funding model.
As a unique initiative and one of its first kind in India, DST has approved setting up of five CCU testbeds for translational R&D, to be set up in Academia-Industry collaboration under this significant initiative of DST in PPP mode, engaging with premier research laboratories as knowledge partners and top Cement companies as the industry partner.
On the occasion of National Technology Day celebrations, on May 11, 2025 the 5 CCU Cement Test beds were announced and grants had been handed over to the Test bed teams by the Chief Guest, Union Minister of State (Independent Charge) for Science and Technology; Earth Sciences and Minister of State for PMO, Department of Atomic Energy, Department of Space, Personnel, Public Grievances and Pensions, Dr Jitendra Singh in the presence of Secretary DST Prof. Abhay Karandikar.
The five testbeds are not just academic experiments — they are collaborative industrial pilot projects bringing together India’s top research institutions and leading cement manufacturers under a unique Public-Private Partnership (PPP) model. Each testbed addresses a different facet of CCU, from cutting-edge catalysis to vacuum-based gas separation.
The outcomes of this innovative initiative will not only showcase the pathways of decarbonisation towards Net zero goals through CCU route in cement sector, but should also be a critical confidence building measure for potential stakeholders to uptake the deployed CCU technology for further scale up and commercialisation.
It is envisioned that through continuous research and innovation under these test beds in developing innovative catalysts, materials, electrolyser technology, reactors, and electronics, the cost of Green Cement via the deployed CCU technology in Cement Sector may considerably be made more sustainable.
Secretary DBT Dr Rajesh Gokhale, Dr Ajai Choudhary, Co-Founder HCL, Dr. Rajesh Pathak, Secretary, TDB, Dr Anita Gupta Head CEST, DST and Dr Neelima Alam, Associate Head, DST were also present at the programme organized at Dr Ambedkar International Centre, New Delhi.

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Concrete

JK Lakshmi Adopts EVs to Cut Emissions in Logistics

Electric vehicles deployed between JK Puram and Kalol units

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JK Lakshmi Cement, a key player in the Indian cement industry, has announced the deployment of electric vehicles (EVs) in its logistics operations. This move, made in partnership with SwitchLabs Automobiles, will see EVs transporting goods between the JK Puram Plant in Sirohi, Rajasthan, and the Kalol Grinding Unit in Gujarat.
The announcement follows a successful pilot project that showcased measurable reductions in carbon emissions while maintaining efficiency. Building on this, the company is scaling up EV integration to enhance sustainability across its supply chain.
“Sustainability is integral to our vision at JK Lakshmi Cement. Our collaboration with SwitchLabs Automobiles reflects our continued focus on driving innovation in our logistics operations while taking responsibility for our environmental footprint. This initiative positions us as a leader in transforming the cement sector’s logistics landscape,” said Arun Shukla, President & Director, JK Lakshmi Cement.
This deployment marks a significant step in aligning with India’s push for greener transport infrastructure. By embracing clean mobility, JK Lakshmi Cement is setting an example for the industry, demonstrating that environmental responsibility can go hand in hand with operational efficiency.
The company continues to embed sustainability into its operations as part of a broader goal to reduce its carbon footprint. This initiative adds to its vision of building a more sustainable and eco-friendly future.
JK Lakshmi Cement, part of the 135-year-old JK Organisation, began operations in 1982 and has grown to become a recognised name in Indian cement. With a presence across Northern, Western, and Eastern India, the company has a cement capacity of 16.5 MTPA, with a target to reach 30 MT by 2030. Its product range includes ready-mix concrete, gypsum plaster, wall putty, and autoclaved aerated fly ash blocks.

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Concrete

Holcim UK drives sustainable construction

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Holcim UK has released a report titled ‘Making Sustainable Construction a Reality,’ outlining its five-fold commitment to a greener future. The company aims to focus on decarbonisation, circular economy principles, smarter building methods, community engagement, and integrating nature. Based on a survey of 2,000 people, only 41 per cent felt urban spaces in the UK are sustainably built. A significant majority (82 per cent) advocated for more green spaces, 69 per cent called for government leadership in sustainability, and 54 per cent saw businesses as key players. Additionally, 80 per cent of respondents stressed the need for greater transparency from companies regarding their environmental practices.

Image source:holcim

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