Concrete

In India, waste management is a complex issue

Published

1 year ago

April 18, 2025

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Jignesh Kundaria, Director and CEO, Fornnax Technology, discusses revolutionising waste management with cutting-edge shredding technology.

Fornnax Technology is driving sustainability in the Indian cement industry by providing advanced shredding and recycling solutions. By enabling efficient processing of alternative fuels and raw materials, the company helps cement plants reduce reliance on fossil fuels and lower carbon emissions. Jignesh Kundaria, Director and CEO, sheds light on how they are supporting the industry’s goal of achieving a 30 per cent Thermal Substitution Rate (TSR) by 2030.

How does Fornnax Technology’s expertise in shredding and recycling equipment enhance operational efficiency and sustainability in the cement industry?
Fornnax Technology is accelerating the Indian cement industry’s goal of reaching up to 30 per cent by 2030 TSR from the current four to six per cent by setting up alternative fuels and raw materials and refuse derived fuel plants, thereby reducing reliance on fossil fuels.
Our expertise in developing robust shredding and recycling machinery directly addresses this need.
By providing advanced solutions for processing AFR, we enable cement plants to efficiently utilise waste materials.
Our SR-MAX series primary and R-Max series secondary shredders, for example, are engineered to handle challenging waste streams, including contaminated municipal solid waste, transforming them into valuable alternative fuels for cement kilns.
This will not only enhance operational efficiency by optimising waste processing but also significantly contributes to sustainability by lowering greenhouse gas emissions and promoting a greener approach to cement production.
Essentially, we empower the cement industry to close the gap between current AFR usage and its potential, driving them towards a more sustainable and environmentally responsible future.

What role does advanced technology play in optimising waste recycling for cement production, and how does Fornnax ensure its solutions contribute to energy efficiency and carbon footprint reduction?
Advanced technology is pivotal in optimising waste recycling for cement production. The cement industry’s carbon footprint is substantial, and technology offers the means to significantly reduce it.
At Fornnax, we are at the forefront of this innovation. Our inhouse expert research and development teams are focused on creating cutting-edge recycling solutions that address the specific challenges of waste processing in the cement sector with customised approach.
Our shredders, for instance, are specifically designed to efficiently process heterogeneous and unorganised waste materials and capable of operating for over 200 to 100 tonne per day ensuring consistent and high-quality outputs suitable for AFR and RDF Plants.
This extended operational capacity has given us a distinct advantage over many of our European, American and Chinese competitors.
We believe that innovative recycling technology is the key to providing effective and economical solutions, thus we constantly upgrade our technology as per the evolving regulations and industry standards, ensuring our solutions not only meet but exceed expectations for energy efficiency and carbon footprint reduction.

How does Fornnax differentiate itself from competitors in providing tailored shredding and recycling solutions for cement plants, and what level of customisation do you offer to meet industry-specific requirements?
Fornnax distinguishes itself by offering a comprehensive range of modern, robust, and large-capacity recycling solutions that are specifically tailored to the unique needs of the cement industry.
Our deep understanding of the cement industry’s challenges, combined with our expertise in advanced shredding and recycling technologies, allows us to provide efficient and sustainable solutions.
We prioritise a customer-centric approach, embodied in our Customer-Based Product Development Process (CBPD). This involves close collaboration with clients to understand their specific pain points and develop solutions that meet their exact requirements.
We offer a high level of customisation – from the design and configuration of our shredders to additional features and services that enhance performance and efficiency.
Our highly qualified engineering team works closely with clients to address their specific needs, including production capacity, waste type, desired output size and power constraints.
This ensures that our machinery aligns perfectly with their distinct visions and operational requirements. We also provide robust after-sales support across India, ensuring prompt and timely resolution of any issues.

Can you share insights into any recent innovations by Fornnax that have the potential to transform waste management and alternative fuel processing in the cement industry?
Our recent launch of the SR-MAX2500 primary shredder at IFAT 2024 Mumbai marks a significant innovation with the potential to transform waste management and alternative fuel processing in the cement industry.
This hydraulic drive motor-powered shredder is specifically designed to efficiently shred challenging materials into manageable sizes. The application areas include municipal solid waste (MSW), industrial and commercial waste, bulky waste, construction and demolition debris, wood waste and more.
The SR-MAX2500 Primary Shredder is designed with ease of maintenance in mind, featuring specially designed knives with hard face multiple times for low-cost operations. Additionally, the replaceable cartridge assembly eliminates the need to change the full cutting chamber in case of a worn-out cartridge, reducing downtime and increasing overall efficiency.
In terms of the longevity, the SR-MAX2500 is built to last, boasting a completely hard-faced shaft knives assembly, hard-faced knives and replaceable wear plates to increase the durability of the cutting chamber. Furthermore, the hydraulic hoses are always connected to the motors, ensuring oil cleanliness and prolonging the lifespan of the motors. The heavy-duty, open-grate cartridge and static knives/fingers placement also ensure that abrasives, including aggregate, sand, soils and metal fragments, will fall directly through the cartridge, reducing wear and operating costs. This robust design ensures that the SR-MAX2500 will provide years of reliable service, even in the toughest operating conditions.
Therefore, by prioritising sustainability and aligning with the vision of achieving Net Zero emissions, we believe the SR-MAX2500 primary shredder has the potential to revolutionie waste management and alternative fuel processing in the cement industry, and we are excited to see the impact it will have.

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Concrete

Cement Makers’ Margins To Fall Rs 50-75 Per Tonne Amid West Asia Conflict

Crisil Sees Margins Easing Despite Steady Demand

Published

2 weeks ago

July 29, 2026

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Crisil said operating margins of Indian cement manufacturers are expected to decline by Rs 50-75 per tonne (t) this fiscal to Rs 925-950 per t due to higher input costs triggered by the West Asia conflict. The analysis covered 18 cement companies accounting for nearly 90 per cent of India’s domestic cement capacity and noted margins had improved sharply to around Rs 1,000 per t in fiscal 2026.

Crisil noted that the reduction would be driven mainly by higher power and fuel costs, which account for about 30 per cent of total costs, as petcoke and imported coal prices have surged amid geopolitical uncertainties. Freight costs, which account for about a quarter of total costs, are also expected to remain elevated because of higher diesel prices. The impact on profitability is likely to be more pronounced in the first half of the fiscal year before easing commodity prices moderate cost pressures later.

The rating agency said steady domestic demand and strong balance sheets should keep credit profiles stable despite the moderation in margins. Green energy currently accounts for 35-40 per cent of the sector’s total electricity consumption and is expected to partly cushion higher energy costs. Operating cash flows are likely to remain resilient, supported by projected 6-7 per cent growth in cement demand this fiscal.

Crisil highlighted that demand growth will be driven primarily by infrastructure spending, which meets about one-third of sector consumption, and by a nearly 18 per cent higher budgetary allocation for core ministries that should support project execution. Weaker rural housing demand amid pressure on agricultural incomes from a possible below-average monsoon may be offset by improved urban housing demand supported by favourable home-loan rates and a strong pipeline of Pradhan Mantri Awas Yojana-Urban projects. Ongoing capacity additions will keep capital expenditure elevated and may lift net debt to EBITDA to between 1.2 and 1.4 times from around 1.0 time last fiscal, though ratios are expected to remain healthy.

Concrete

UltraTech Board Approves Rs 50 bn Fundraise Via NCDs

Company to issue half a million debentures for expansion plan

Published

2 weeks ago

July 28, 2026

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UltraTech Cement’s board of directors has approved raising Rs 5,000 crore (Rs 50 bn) through non?convertible debentures issued in rupees.

The finance committee cleared a proposal to issue up to 500,000 fully paid, unsecured, listed, rated, redeemable, rupee?denominated, non?convertible, non?cumulative debentures of Rs 1 lakh each (Rs 0.1 mn each), aggregating to the Rs 5,000 crore programme.

As of June 2026 the firm reported net debt of Rs 15,875 crore (Rs 158.75 bn) and said its capacity expansion projects under execution are backed by capital expenditure of about Rs 17,000 crore (Rs 170 bn) over the next two to two?and?a?half years.

UltraTech spent Rs 9,500 crore (Rs 95 bn) on capital expenditure in financial year 2026 and in April the group crossed 200.1 mn tonnes per annum of domestic grey cement capacity and 205.5 mn tonnes per annum of global capacity.

The chief financial officer indicated the company would take consolidated capacity beyond 242 mn tonnes per annum, with grey cement capacity reaching 212.7 mn tonnes per annum by the end of financial year 2027. He noted the net debt?to?earnings before interest, taxes, depreciation and amortisation ratio stood at 0.87 times as of June 2026 and the company was confident of ending financial year 2027 with the ratio below one time.

In the first quarter of financial year 2026?27 UltraTech’s net profit attributable to owners rose 16.8 per cent year?on?year to Rs 2,599.3 crore (Rs 25.993 bn) and revenue from operations increased 15.9 per cent to Rs 24,648.20 crore (Rs 246.482 bn). The board approval is expected to complement internal cash flows as the company advances its expansion programme.

Concrete

Lokesh Lays Stone For Rs 31 Billion Cement Unit In Kadapa

Line-2 expansion to make Kadapa a major cement hub

Published

3 weeks ago

July 20, 2026

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Andhra Pradesh Education and IT Minister Nara Lokesh on Wednesday laid the foundation stone for the Line-2 expansion of Dalmia Bharat Cement at Chinnakomerla village in Mylavaram Mandal in Kadapa district. The project carries an investment of Rs 31 billion (bn) and is slated for completion by the third quarter of the financial year 2028. The expansion is intended to boost industrial growth and employment generation across the Rayalaseema region.

Once commissioned, the Kadapa facility will become Dalmia Bharat’s largest integrated cement manufacturing ecosystem in southern India, creating over 1,000 direct and indirect jobs and opening new business avenues for regional micro, small and medium enterprises and transport operators. Lokesh said the expansion signalled growing corporate confidence in the state and reflected the practical ease of doing business that secured repeat investment.

He placed the project within the government’s wider economic targets and recalled the Yuvagalam padayatra commitment to generate two million (mn) jobs within five years, noting that the state would cultivate talent while industry created opportunities. Lokesh highlighted Andhra Pradesh’s competitive pursuit of major manufacturing accounts, mentioning past successes and a personal initiative to engage global investors when persuading them to anchor expansion in the state.

The plant will leverage Kadapa’s abundant limestone reserves to scale production and sustainability. Clinker capacity is planned to rise from two point five million tonnes per annum (mn tpa) to six point one mn tpa, while overall cement output will increase from three point six mn tpa to nine point six mn tpa. The unit is designed to operate on over eighty per cent renewable energy and deploy waste heat recovery, zero liquid discharge, water recycling and advanced AI systems to optimise efficiency. Industries Minister TG Bharat, BC Welfare Minister S. Savitha and Jammalamadugu MLA C. Adinarayana Reddy attended the ceremony.