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

Lokesh Lays Stone For Rs 31 Billion Cement Unit In Kadapa

Line-2 expansion to make Kadapa a major cement hub

Published

5 days 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.

Concrete

Cement Prices to Stay Flat in Q2 FY27 as Costs Squeeze Margins

HDFC Securities warns monsoon slowdown and higher fuel costs

Published

1 week ago

July 17, 2026

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HDFC Securities has said the cement industry is unlikely to register a sequential increase in prices in Q2 FY27 as monsoon-related demand moderation coincides with rising fuel and packaging costs that will squeeze margins. The brokerage observed that price gains remained modest, with increases of two to three per cent quarter-on-quarter across regions, and noted subdued offtake in May with improvement in June as a delayed monsoon supported construction activity. The brokerage added that modest pricing gains so far have been insufficient to offset the input cost escalation.

The report stated that input cost pressures intensified in Q1 FY27 owing to the West Asia conflict, which pushed up coal and pet coke prices and is expected to keep fuel costs elevated, with a likely peak in Q2 FY27. It assessed that total variable costs, including packing, could rise by around Rs 150 per t quarter-on-quarter and that lower offtake and seasonal operating deleverage could further raise operating expenditure by about Rs 50 per t quarter-on-quarter.

Overall, cement prices were estimated to remain flat in Q2 FY27 as monsoon-led demand weakness offsets limited upside in realisation, and rising fuel costs alongside seasonal deleverage were expected to compress industry margins by over Rs 100 per t quarter-on-quarter to below Rs 880 per t. The brokerage indicated that the combined impact of energy inflation and higher packing expenditure would be the principal drivers of margin contraction in the near term. HDFC Securities projected a recovery in margins in H2 FY27 should the West Asia turmoil subside and energy and packing costs cool off.

The brokerage expressed optimism on long-term demand fundamentals and said improving realisation together with an anticipated cost cool-off should support a margin rebound from H2 FY27 onward, underpinning favourable industry prospects over the medium term. Its outlook rests on monsoon normalisation and a decline in imported fuel prices in the second half of the fiscal year.

Concrete

Dalmia Bharat Begins Rs 31 Bn Green Cement Unit in Kadapa

New Andhra Pradesh plant to add 9.6 MTPA cement capacity by FY28

Published

1 week ago

July 16, 2026

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Dalmia Bharat Limited recently laid the foundation stone for its second manufacturing unit at Kadapa in Andhra Pradesh. The company will invest Rs 31 billion in developing the next-generation integrated cement manufacturing facility.

The foundation-laying ceremony was attended by Nara Lokesh, Andhra Pradesh Minister for Information Technology, Electronics and Communications, Real-Time Governance and Human Resources Development, along with Puneet Dalmia, Managing Director and Chief Executive Officer, Dalmia Bharat, senior government officials and company representatives.

Scheduled to be commissioned by the third quarter of FY28, the Kadapa unit will become Dalmia Bharat’s largest integrated manufacturing facility in southern India. It will have a clinker production capacity of 6.1 million tonnes per annum and a cement manufacturing capacity of 9.6 million tonnes per annum.

The facility is designed to produce what the company describes as one of the world’s greenest cements. It is also expected to generate approximately 1,000 direct and indirect employment opportunities while supporting local MSMEs, transporters, contractors and service providers.

Lokesh said the investment reflected Dalmia Bharat’s confidence in Andhra Pradesh and aligned with the state’s objective of promoting sustainable industrialisation, job creation and technology-led economic growth.

Puneet Dalmia said the project represented the company’s long-term vision of developing low-carbon cement manufacturing assets. He added that the facility would establish new benchmarks in operational efficiency and sustainability while supporting India’s infrastructure and environmental goals.

Dalmia Bharat will also expand its regional community development programmes in education, healthcare, skill development and welfare through its DIKSHa and Gram Parivartan initiatives.

The company currently has an installed cement manufacturing capacity of 54.7 million tonnes across 19 manufacturing units in 12 states. It is also the first cement company globally to commit to the RE100, EP100 and EV100 initiatives.