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Condition-based maintenance avoids over-servicing

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JayaKrishna Kokku, Lead – Technical Operations, APAC & Middle East, Nanoprecise Sci Corp shares how their AI-powered IoT solution boosts productivity and sustainability in dusty cement plants through predictive maintenance. Read the full interview to learn more.

In an industry where dust, heat and vibration constantly challenge the health of critical equipment, predictive maintenance is fast becoming a game-changer. In this conversation, JayaKrishna Kokku, Lead – Technical Operations, APAC & Middle East, explains how Nanoprecise’s IoT solution is tackling the harsh realities of cement environments, delivering real-time equipment insights, accurate Remaining Useful Life (RUL) predictions and ensuring longer asset life and fewer costly breakdowns.

How does Nanoprecise IoT solution tackle equipment monitoring challenges in dusty cement plant environments?
Its wireless sensors are rugged, IP68 rated, and can reliably operate in high-dust environments without degradation. These sensors continuously monitor vibration, temperature, acoustic signals, humidity, Magnetic flux and RPM on critical rotating equipment. Data is transmitted securely to the cloud, enabling continuous, remote asset health monitoring, even in areas difficult for human inspection.

What role does your AI-driven analytics platform play in improving operational efficiency in cement plants?
The AI-driven analytics platform from Nanoprecise processes sensor data using advanced machine learning and physics-based algorithms. It detects early signs of component degradation (e.g., bearing faults, misalignment, imbalance) and provides actionable insights. By identifying potential failures weeks or months in advance, the platform allows cement plant operators to shift from reactive to proactive maintenance.

How do accurate RUL (Remaining Useful Life) insights help cement manufacturers optimise maintenance and reduce downtime?
Nanoprecise RUL predictions are powered by AI models that analyse sensor data fault trends over time. By accurately forecasting how long a component or system will function before failure, maintenance teams can plan interventions only, when necessary, rather than on fixed schedules. This minimises unnecessary maintenance, avoids catastrophic breakdowns, and ensures spare parts and labour are optimally allocated—drastically reducing both planned and unplanned downtime.

Can predictive maintenance be using your technology boost productivity while lowering operational disruptions?
Absolutely! Predictive maintenance enabled by Nanoprecise technology provides early fault detection and automated diagnostics, ensuring that equipment is always in optimal working condition. By addressing issues before they escalate, plants can maintain continuous operations, increase equipment uptime, and reduce the risk of costly shutdowns.

How does your solution support both productivity and sustainability goals in cement manufacturing?

  • Reduced Energy Waste: Equipment running inefficiently consumes more energy. Early detection of faults ensures machines run optimally, reducing unnecessary energy usage.
  • Lower Carbon Emissions: Improved efficiency and reduced downtime mean lower emissions per ton of cement produced.
  • Extended Equipment Life: Condition-based maintenance avoids over-servicing, extending the life of components and reducing waste.

Together, these benefits support sustainable operations without compromising output.

Concrete

Molecor Renews OCS Europe Certification Across Spanish Plants

Certification reinforces commitment to preventing microplastic pollution

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Molecor has renewed its OCS Europe certification for another year across all its production facilities in Spain under the Operation Clean Sweep (OCS) voluntary initiative, reaffirming its commitment to sustainability and environmental protection. The renewal underlines the company’s continued focus on preventing the unintentional release of plastic particles during manufacturing, with particular attention to safeguarding marine ecosystems from microplastic pollution.

All Molecor plants in Spain have been compliant with OCS Europe standards for several years, implementing best practices designed to avoid pellet loss and the release of plastic particles during the production of PVC pipes and fittings. The OCS-based management system enables the company to maintain strict operational controls while aligning with evolving regulatory expectations on microplastic prevention.

The renewed certification also positions Molecor ahead of newly published European regulations. The company’s practices are aligned with Regulation (EU) 2025/2365, recently adopted by the European Parliament, which sets out requirements to prevent pellet loss and reduce microplastic pollution across industrial operations.

Extending its sustainability commitment beyond its own operations, Molecor is actively engaging its wider value chain by informing suppliers and customers of its participation in the OCS programme and encouraging responsible microplastic management practices. Through these efforts, the company contributes directly to the United Nations Sustainable Development Goals, particularly SDG 14 ‘Life below water’, reinforcing its role as a responsible industrial manufacturer committed to environmental stewardship and long-term sustainability.

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Coforge Launches AI-Led Data Cosmos Analytics Platform

New cloud-native platform targets enterprise data modernisation and GenAI adoption

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Coforge Limited has recently announced the launch of Coforge Data Cosmos, an AI-enabled, cloud-native data engineering and advanced analytics platform aimed at helping enterprises convert fragmented data environments into intelligent, high-performance data ecosystems. The platform strengthens Coforge’s technology stack by introducing a foundational innovation layer that supports cloud-native, domain-specific solutions built on reusable blueprints, proprietary IP, accelerators, agentic components and industry-aligned capabilities.

Data Cosmos is designed to address persistent enterprise challenges such as data fragmentation, legacy modernisation, high operational costs, limited self-service analytics, lack of unified governance and the complexity of GenAI adoption. The platform is structured around five technology portfolios—Supernova, Nebula, Hypernova, Pulsar and Quasar—covering the full data transformation lifecycle, from legacy-to-cloud migration and governance to cloud-native data platforms, autonomous DataOps and scaled GenAI orchestration.

To accelerate speed-to-value, Coforge has introduced the Data Cosmos Toolkit, comprising over 55 IPs and accelerators and 38 AI agents powered by the Data Cosmos Engine. The platform also enables Galaxy solutions, which combine industry-specific data models with the core technology stack to deliver tailored solutions across sectors including BFS, insurance, travel, transportation and hospitality, healthcare, public sector and retail.

“With Data Cosmos, we are setting a new benchmark for how enterprises convert data complexity into competitive advantage,” said Deepak Manjarekar, Global Head – Data HBU, Coforge. “Our objective is to provide clients with a fast, adaptive and AI-ready data foundation from day one.”

Supported by a strong ecosystem of cloud and technology partners, Data Cosmos operates across multi-cloud and hybrid environments and is already being deployed in large-scale transformation programmes for global clients.

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Concrete

India, Sweden Launch Seven Low-Carbon Steel, Cement Projects

Joint studies to cut industrial emissions under LeadIT

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India and Sweden have announced seven joint projects aimed at reducing carbon emissions in the steel and cement sectors, with funding support from India’s Department of Science and Technology and the Swedish Energy Agency.

The initiatives, launched under the LeadIT Industry Transition Partnership, bring together major Indian companies including Tata Steel, JK Cement, Ambuja Cements, Jindal Steel and Power, and Prism Johnson, alongside Swedish technology firms such as Cemvision, Kanthal and Swerim. Leading Indian academic institutions, including IIT Bombay, IIT-ISM Dhanbad, IIT Bhubaneswar and IIT Hyderabad, are also participating.

The projects will undertake pre-pilot feasibility studies on a range of low-carbon technologies. These include the use of hydrogen in steel rotary kilns, recycling steel slag for green cement production, and applying artificial intelligence to optimise concrete mix designs. Other studies will explore converting blast furnace carbon dioxide into carbon monoxide for reuse and assessing electric heating solutions for steelmaking.

India’s steel sector currently accounts for about 10–12 per cent of the country’s carbon emissions, while cement contributes nearly 6 per cent. Globally, heavy industry is responsible for roughly one-quarter of greenhouse gas emissions and consumes around one-third of total energy.

The collaboration aims to develop scalable, low-carbon industrial technologies that can support India’s net-zero emissions target by 2070. As part of the programme, Tata Steel and Cemvision will examine methods to convert steel slag into construction materials, creating a circular value chain for industrial byproducts.

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