Concrete
The Science and Application of Grinding Aids
Published
7 months agoon
By
admin
Dr SB Hegde discusses the importance of grinding aids as essential chemical additives that enhance cement grinding efficiency, reduce energy consumption and improve overall cement quality in the concluding part of his article.
Grinding aids represent a critical segment of the cement additives market, driven by their ability to enhance grinding efficiency, reduce energy consumption, and improve cement quality. The market dynamics of grinding aids vary significantly across regions, influenced by economic growth, cement production capacities and regulatory environments.
Global market size and growth projections
The global grinding aids market was valued at approximately US $ 1.2 billion in 2023 and is expected to grow at a CAGR of 5.5 per cent from 2023 to 2030, reaching nearly US $ 1.8 billion by 2030.
This growth is fueled by the increasing focus on energy efficiency and sustainable cement production practices worldwide.
Rapid urbanisation and infrastructure development, especially in emerging economies, are major growth drivers. Cement producers are increasingly adopting grinding aids to address rising energy costs, reduce carbon footprints, and improve production efficiencies. For instance, grinding aids have been shown to lower energy consumption by up to 25 per cent, making them a cost-effective solution for plants facing energy price volatility.
Regional trends: Developed vs. developing markets
- Developed markets: Europe and North America represent mature markets for grinding aids. Europe, driven by stringent environmental regulations such as the EU Emissions Trading System (EU ETS), has witnessed a steady rise in the adoption of low-VOC and eco-friendly grinding aids. Leading players in these markets emphasise sustainability and compliance with regulatory frameworks, contributing to steady demand.
In North America, the focus is on productivity enhancements in large-scale cement plants, with grinding aids used to achieve finer cement grades and support blended cement production. - Developing markets: Emerging economies in Asia-Pacific, the Middle East, and Africa exhibit the fastest growth in grinding aid adoption. The Asia-Pacific region accounted for over 40 per cent of global grinding aid consumption in 2023, with countries like India, China, and Vietnam leading the way. The rapid urbanisation, rising construction activity, and increasing cement production capacities in these regions are
driving demand.
In Africa, grinding aids are gaining traction as manufacturers focus on optimising production costs in an environment of fluctuating raw material and energy prices.
Market size and adoption rate in India
India, the world’s second-largest cement producer, offers a significant growth opportunity for grinding aids. In 2023, the grinding aids market in India was valued at US$ 150 million, with a projected growth rate of over seven per cent CAGR through 2030. The adoption rate remains relatively low at smaller plants, which prioritise cost-saving over efficiency gains. However, leading manufacturers and integrated cement plants are increasingly embracing grinding aids, particularly for blended cement production.
Blended cements, such as Portland Pozzolana Cement (PPC) and Portland Slag Cement (PSC), account for more than 70 per cent of the Indian cement market. Grinding aids tailored for fly ash and slag-blended cements are in high demand, with some products delivering up to a 15 per cent increase in mill throughput and improved early strength development.
Emerging trends
- Eco-friendly formulations: The growing demand for sustainable grinding aids has prompted companies to develop low-VOC and biodegradable alternatives.
- Customised solutions: Grinding aid formulations are increasingly tailored to address specific raw material challenges and production processes, such as VRMs or high-SCM cement blends.
- Digitalisation: Smart dosing systems integrated with real-time mill monitoring are enabling optimised grinding aid usage, ensuring consistent performance across diverse production conditions.
Bridging the Trust Gap
For cement plant operators, the quality and performance of grinding aids often appear as a ‘black box.’ The lack of transparency in the formulation and quality checks of these additives has historically limited trust and widespread adoption. Grinding aid manufacturers must address this issue by fostering transparency and providing detailed insights into the testing and validation of their products. This would not only instill confidence but also strengthen collaboration with cement companies.
Grinding aid producers should provide robust documentation outlining the physical and chemical characteristics of their formulations, supported by consistent performance data from laboratory tests, industrial-scale trials, and third-party validations. This transparency is essential to demystify grinding aids’ performance and demonstrate their effectiveness across diverse operational conditions.
Emerging innovations in grinding aid chemistry
The path forward for grinding aid manufacturers lies in innovation. Recent research highlights the potential of hybrid formulations combining traditional amines and glycols with advanced polymeric additives like polycarboxylate ethers (PCEs). These hybrid products can address specific challenges such as improving grindability in blended cements containing fly ash or slag, where traditional additives often underperform. Nano-engineering of grinding aids, incorporating nanoparticles for optimised dispersion and enhanced hydration kinetics, represents another promising avenue.
Leveraging AI for optimisation
The integration of artificial intelligence (AI) and machine learning tools into grinding aid application systems is reshaping the cement industry. AI-driven systems enable real-time optimisation of grinding aid dosages by analysing mill performance data, such as power consumption, throughput, and particle size distribution. For example, a cement plant in Europe reported a 15 per cent reduction in specific energy consumption and a 10 per cent
increase in mill throughput using AI-optimised dosing systems. This innovation reduces operational variability and improves the predictability of grinding aid performance.
Expectations from grinding aid producers
The cement industry demands more than just products; it seeks partnerships with grinding aid manufacturers. Key expectations include:
1. Customised formulations: Tailored products designed for specific raw materials, clinker compositions, and mill configurations to maximise efficiency and performance.
2. Eco-friendly additives: Grinding aids with low volatile organic compound (VOC) emissions and biodegradable ingredients that align with the industry’s sustainability goals.
3. Comprehensive technical support: On-site training and technical services to help plant operators understand grinding aid chemistry, application techniques and performance optimisation strategies.
4. Advanced quality control systems: Transparent testing protocols, including real-time quality assurance of grinding aids delivered to cement plants. Regular reporting of performance consistency through defined KPIs like grindability index and Blaine fineness is essential.
Role of cement companies in promoting grinding aid usage
Cement producers must take an active role in promoting grinding aid adoption. Sharing success stories of energy savings, improved mill performance, and enhanced cement quality can encourage industry-wide adoption. For example, an Indian cement manufacturer recently documented a 20 per cent improvement in 28-day compressive strength and a 10 per cent reduction in energy consumption with glycol-based additives, driving interest among peers.
Moreover, collaborative initiatives between cement producers and grinding aid manufacturers, such as joint research programs and knowledge-sharing forums, could lead to significant advancements in grinding technology. Organisations like the Cement Manufacturers’ Association of India and the World Cement Association can facilitate these partnerships.
Conclusion
Grinding aids play a pivotal role in modern cement manufacturing, offering significant advantages in energy efficiency, mill productivity and cement quality. Despite their transformative potential, adoption remains inconsistent due to challenges like raw material variability, operational concerns and limited trust in product formulations. Transparency and collaboration between grinding aid producers and cement manufacturers are critical to addressing these issues and fostering broader acceptance.
Innovations in grinding aid chemistry, including hybrid formulations and nano-engineered additives, have unlocked new possibilities for enhancing grindability and hydration performance. Meanwhile, advancements in artificial intelligence and data analytics have opened avenues for real-time optimisation, ensuring precise dosing and measurable cost savings. These developments underscore the evolving synergy between technology and grinding aid applications.
Globally, the grinding aid market is poised for growth, with developed regions leading adoption and emerging economies like India offering immense potential driven by infrastructure demands. However, tapping into these opportunities requires grinding aid producers to align with industry expectations. Cement manufacturers expect customised solutions, eco-friendly formulations, technical support and transparent quality assurance processes to build trust and confidence.
The path forward demands a collaborative approach. Grinding aid producers must continue investing in research and innovation while actively engaging with the cement industry to educate stakeholders and demonstrate measurable benefits. Concurrently, the cement industry must champion adoption through case studies, knowledge sharing, and regulatory support. Together, these efforts will ensure grinding aids fulfill their promise of enabling a more efficient, sustainable, and resilient cement manufacturing sector.
References
1. Gao, J., Zhang, S., Wang, X., & Ma, B. (2011). “Effect of organic grinding aids on cement properties and the analysis via liquid chromatography-mass spectrometry.” Construction and Building Materials, 25(8), 3600–3605.
2. Amritphale, S. S., Patel, M., & Singh, R. (2017). “Grinding aids: A study on their mechanism of action in cement grinding processes.” Indian Cement Review.
3. Cembureau – The European Cement Association. “Cement grinding optimisation through grinding aids.” Industry Report, 2023.
4. Flatt, R. J., & Schober, I. (2012). “Superplasticisers and the rheology of concrete.” International Journal of Cement Chemistry, 64(4), 91–109.
5. Mejeoumov, G. G. (2007). “Improved cement quality and grinding efficiency by means of closed mill circuit modeling.” PhD Dissertation, Texas A&M University.
6. Global Cement. “Advances in grinding aids: Market trends and new technologies.” Published October 2024.
7. Statista. “Global grinding aids market size and forecast (2023-2030).” Published March 2024.
8. Pal, B. K., & Rath, P. C. (2020). “Influence of grinding aids on particle size distribution, strength, and hydration of cement.” Journal of Materials Science and Applications, 45(2), 234–246.
9. Indian Cement Review. “Emerging market scope of grinding aids in India.” Published July 2023.
10. Zhang, H., Li, X., & Zhao, Y. (2022). “The role of grinding aids in improving cement hydration kinetics.” Journal of Advanced Materials Science, 17(6), 527–540.
11. Sika AG. “Technical Report on Polycarboxylate Ether (PCE) based grinding aids.” Published 2022.
12. Cement and Concrete Research. “AI-driven optimisation in cement grinding: Case studies and industrial applications.” Volume 152, 2023.
13. Taylor, H. F. W. (1997). Cement Chemistry (2nd Edition). Thomas Telford Publishing.
14. Indian Bureau of Mines (IBM). “Market trends and challenges in cement manufacturing.” Annual Report, 2024.
15. World Cement Association. “Sustainability in grinding aids and cement additives.” Published 2024.
About the author:
Dr SB Hegde, a global cement industry leader with over 30 years of experience, is a Professor at Jain College of Engineering, India, and a Visiting Professor at Pennsylvania State University, USA. Recipient of the ‘Global Visionary’ award, Dr Hegde advises India’s think tank CSTEP on hydrogen usage in cement and consults for major cement companies. He also serves on expert panels of key industry bodies and journals globally.
Concrete
Adani’s Strategic Emergence in India’s Cement Landscape
Published
2 weeks agoon
September 16, 2025By
admin
Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.
India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.
Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:
- September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
- December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
- August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
- April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
- Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
- Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
- Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
- Orient Cement: It would serve as a principal manufacturing facility following the merger.
Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:
- By FY 2026: Reach 118 MTPA
- By FY 2028: Target 140 MTPA
These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).
Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.
Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.
Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.
Challenges potentially include:
- Integration challenges across systems, corporate cultures, and plant operations
- Regulatory sanctions for pending mergers and new capacity additions
- Environmental clearances in environmentally sensitive areas and debt management with input price volatility
When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.
Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.
About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.
Concrete
Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series
Published
1 month agoon
August 16, 2025By
admin
PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.
Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.
Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.
Beyond energy efficiency, the retrofit significantly improved operational parameters:
- Lower thermal stress on equipment
- Extended lubricant drain intervals
- Reduction in CO2 emissions and operational costs
These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.
Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:
- Enhanced component protection
- Extended oil life under high loads
- Stable performance across fluctuating temperatures
By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.
Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.
A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

Adani’s Strategic Emergence in India’s Cement Landscape

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

Driving Measurable Gains

Reshaping the Competitive Landscape

CCU testbeds in Tamil Nadu

Adani’s Strategic Emergence in India’s Cement Landscape

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

Driving Measurable Gains

Reshaping the Competitive Landscape
