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Our technology helps reduce operational costs

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Jacob Jose, CEO & Managing Director, Methods India and DemcoTECH, discusses customised, cutting-edge bulk material handling solutions, and the relevance of modern technology for making cement transport sustainable.

IIn the dynamic world of bulk material handling, innovation and customisation are key to meeting the evolving demands of the cement industry. In this insightful interview, we explore the expertise of Methods India and DemcoTECH, an Indo-South African joint venture, as they share how their advanced are helping cement manufacturers optimise operations and achieve sustainability goals.

Tell us more about your organisation and the work that you do?
We represent Methods India and DemcoTECH, an Indo-South African joint venture that has been in collaboration for nearly five years. Methods India itself has been a key player in the bulk material handling industry for almost 45 years. Our primary focus is on providing cutting-edge solutions for bulk material handling, particularly for industries that require robust and efficient conveying systems.
We provide comprehensive bulk material handling solutions that cater to the specific needs of cement plants, from raw material extraction to final product handling. Our technology, particularly with DemcoTECH, has gained widespread recognition for its efficiency and durability, helping cement manufacturers streamline their operations and reduce downtime. Our solutions, such as pipe conveyors, downhill conveyors, and cross-country conveyors, have played a significant role in enhancing the efficiency of material transportation within cement plants.

Where do your turnkey solutions apply in the cement production process?
Our expertise lies in conveying systems, and we have successfully implemented our technology-driven solutions across various stages of cement production. Our solutions are particularly beneficial in raw material handling, kiln feeding, clinker cooling, and final product packaging.
With our advanced pipe conveyors, downhill conveyors, and cross-country conveyors, we have revolutionised the way cement plants transport raw materials. Our technology helps reduce operational costs, minimise environmental impact, and improve energy efficiency. Over the years, we have observed a positive impact in the industry, particularly with the growing adoption of pipe conveyors and cross-country conveyors, which have proven to be more efficient and environmentally friendly alternatives to traditional transport methods.

How does technology and innovation enhance your offerings to the cement industry?
In today’s industrial landscape, technology plays a crucial role in ensuring optimisation, efficiency and cost-effectiveness. Every cement manufacturer aims to optimise operations—whether in terms of cost, delivery timelines, or operational efficiency. Technology enables us to deliver innovative solutions that meet these evolving demands.
Our approach is centered on continuous innovation, ensuring that we integrate the latest advancements in digital monitoring, predictive maintenance, and automated systems. At DemcoTECH, we have dedicated significant resources to developing state-of-the-art solutions that not only enhance performance but also reduce maintenance requirements and operational disruptions. By incorporating data analytics and real-time monitoring, we help cement plants predict potential breakdowns and maintain seamless operations.

Bulk material handling involves significant wear and tear. How do you manage these challenges?
Wear and tear is one of the most critical challenges in bulk material handling. To address this, we focus on efficient and durable design principles that ensure long-term reliability. Our approach begins with a thorough understanding of the factors that affect the lifespan of components, including operating conditions, material composition, and mechanical stresses.
By working closely with our clients, we tailor our solutions to match their specific operational challenges. Our expertise allows us to recommend the right materials, equipment, and maintenance strategies to mitigate wear and tear. For example, our conveyor systems are designed to withstand high-stress environments, ensuring that they maintain peak performance over extended periods. Additionally, we integrate advanced condition monitoring systems that help operators detect early signs of wear and take preventive measures before failures occur.

How do you incorporate sustainability into your operations?
Sustainability is a fundamental aspect of modern industrial operations, and we take a holistic approach to ensuring that our solutions contribute to environmental conservation and operational efficiency.
From the client’s perspective, sustainability is about applying the right technology to the right solution. By carefully evaluating each client’s specific needs, we ensure that the solutions we provide are efficient, optimised, and environmentally responsible. Our energy-efficient conveyors significantly reduce fuel consumption, lower emissions, and enhance resource utilisation.
Moreover, we prioritise material efficiency, using high-quality, durable components that extend equipment lifespan and minimise waste generation. By promoting automated and optimised material handling, we help cement manufacturers reduce their carbon footprint, align with global sustainability initiatives, and meet regulatory requirements more effectively.

What are some of the key challenges you face in your operations?
One of the biggest challenges we face is that bulk material handling systems are highly customised. Unlike standardised products, each conveying system is bespoke, designed specifically for the unique requirements of a cement plant. This means that a significant amount of time is spent on engineering and design before a project can even begin. By the time the engineering phase is completed, project timelines have already been stretched, making it a challenge to deliver on schedule.
Another major challenge is cost fluctuations. The cement industry is volatile, and price variations can make it difficult to maintain cost predictability for both manufacturers and suppliers. Striking a balance between affordability and quality is a continuous challenge, as clients seek cost-effective solutions without compromising on efficiency and durability.
Despite these challenges, we continue to innovate and adapt, ensuring that we deliver high-quality, efficient solutions that align with the evolving needs of the industry.

How do you approach customisation?
Customisation is at the heart of what we do. Every project begins with a clean slate, where we conduct detailed engineering assessments and create customised layouts based on the client’s requirements.
One of the major advantages of our joint venture is that we bring together a combined 65 years of industry experience. Additionally, we have built one of the largest project data banks in the world, having successfully completed over 3,000 projects globally. This extensive database allows us to analyse past projects, identify best practices, and apply proven solutions to new challenges.
By leveraging this vast experience, we can offer the most effective, tailored solutions to cement plants, ensuring that they receive efficient, cost-effective, and high-performing systems. Our ability to customise and adapt is one of our strongest competitive advantages, and it is what sets us apart in the 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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