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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

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

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