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The main pushback against automation is budget

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Mehul Doshi, Head of Department — Customer Support and Service, HAVER & BOECKER, shares insights on leveraging diagnostics and optimisation tools to address challenges in automation of bagging, packaging, and palletising processes.

In the fiercely competitive cement industry, optimising bagging, packaging and palletising processes is no longer a luxury but a necessity. Cutting-edge diagnostics and tailored optimisation plans are transforming how plants enhance efficiency, reduce waste, and boost safety — all while advancing sustainability goals. Through a seamless blend of digital monitoring and hands-on audits, manufacturers are now able to identify bottlenecks, minimise product loss and future-proof their operations, shares Mehul Doshi, Head of Department — Customer Support and Service, HAVER & BOECKER, in this exclusive interview.

How do QUAT2RO® and POP enhance efficiency in bagging, packaging, and palletising for the cement industry?
Comprising the diagnostics section of HAVER & BOECKER’s PROcheck lifecycle approach, QUAT2RO® and the Plant Optimisation Plan (POP) help operations increase plant performance, optimise machine conditions, set up and use resources, raise health and safety standards and improve energy efficiency.
As the digital tool of HAVER & BOECKER’s diagnostics approach, QUAT2RO® collects short-term and long-term production data on all connected machines. The data combines performance and maintenance reports into a single dashboard to make monitoring equipment settings simple. QUAT2RO® System Monitoring alerts operators to any discrepancy in the packing or palletising machines to allow faster maintenance and increase efficiency on the packing line. HAVER & BOECKER recommends installing QUAT2RO® on packing lines before engaging in a Plant Optimisation Plan (POP) to collect information on the baseline performance of the line.
POP is the human approach toward diagnostics. For the POP, HAVER & BOECKER engineers visit the customer plant to observe the operation and recommend enhancements classified by level of urgency. The full plant audit considers all areas, from product storage and handling to packing, bag transport, palletising and loading lines, as well as surrounding machines and environmental factors. The engineers send a full report tagged with green, yellow or red to highlight areas for improvement, ensuring that critical updates are prioritised.
HAVER & BOECKER’s Bag Optimisation Plan (BOP) is a very important part of the POP and allows it to go beyond the mechanical equipment and into the important role of consumables. While the goal of the POP is to find the perfect harmony between the bag, the product and the machine, the BOP focuses on all aspects of the bag and includes a bag volume test, bag valve check, visual pallet check and a bag specification check. The HAVER & BOECKER Institute tests and analyses the bag and the product to optimise all three major factors in the packing process — machine, bag and product —resulting in the highest levels of productivity and efficiency.

What common challenges in cement packing plants do your diagnostics tools address, and how are the solutions tailored?
HAVER & BOECKER diagnostics tools primarily focus on production issues, whether that’s tracking equipment efficiency through QUAT2RO® or providing recommendations for optimising existing equipment and processes. One of the biggest challenges plants face is dust escaping as bags are filled. Most packing equipment comes in a one-size-fits-all approach, meaning it’s not optimised for each individual product. If not treated properly, free-flowing powder material like cement will settle on the floor, equipment and operators instead of in the bag. HAVER & BOECKER diagnostics, specifically their POP and BOP, considers the individual properties of the cement being poured and how to direct it into the bag most effectively.
The bags used for packing cement can contribute to the amount of material lost in the packing process. Unsealed valve bags rely on the inner pressure of the bag to close, which results in the bag being only 70 per cent closed, leaving a 30 per cent opening for spillage. An improperly sealed bag results in material loss at a rapid rate while in storage and throughout transport, leading to a total product loss of up to 5 per cent. That’s why HAVER & BOECKER offers SEAL technology. Ultrasonic sealing effectively welds bags shut, resulting in the bag being 100 per cent closed. Unlike adhesive closed bags, this type of seal means bags won’t unstick over time and cause spillage if left in storage. This bag also eliminates product loss during transport.
If a facility is seeing similar product loss in their plant, HAVER & BOECKER will address the type of bag being used and recommend an upgrade to SEAL technology in their optimisation plan. They will also address any dust production issues in the full packing line to optimise production.

How does QUAT2RO® improve process efficiency, and which KPIs are critical?
QUAT2RO® detects issues before they become critical to the packing line. Operators can monitor machines’ production rates in real time to see how their equipment is performing. The results can be used to check production levels and identify solutions to productivity challenges and inefficiencies. This data can show any bottlenecks in the packing line so operators can address the issue immediately.
All data is stored in a single online portal with customisable alert systems and report templates. The portal keeps track of maintenance intervals for all assemblies and components and sends early notifications as a reminder to order wear parts. The system can also be accessed by the HAVER & BOECKER service team, providing cement plants with direct contact with our experts to address any of their concerns.

How do your solutions support sustainability goals like energy efficiency and waste reduction?
Sustainability and energy efficiency are at the heart of what we do. HAVER & BOECKER offers 10 energy saving solutions for packing lines that cover everything from optimising equipment performance to keeping equipment clean and having equipment serviced regularly. Optimising machine performance leads to energy efficiency because any material that escapes the packing process is a loss, which means the rest of the production plant needs to produce more to make up for it. Having a packing line fully optimised is one easy way to ensure energy efficiency and waste reduction.

How does the PROcheck lifecycle approach integrate with existing equipment in cement plants?
One of the many benefits of PROcheck lifestyle approach is that it can be integrated into the cement plant’s processes at any time. The first step to a full PROcheck is the Plant Optimisation Plan where an engineer comes to visit the plant and assess the technology, packing line and product being produced. No matter what technology is currently in use, our engineers provide a full report addressing any concerns and suggesting updates.

What trends in bagging, packaging, and palletising are shaping the cement industry?
Sustainability and automation are prime motivators for the cement industry right now. Whether that’s completely automating processes to increase efficiency or using electric equipment to cut down on carbon emissions, cement producers want to be able to produce better quality cement with more technologically advanced equipment.
The industry has seen a huge push toward automation in many places around the world. However, the main pushback against automation is budget. Budgetary restrictions are universal and often hold cement plants back from taking the plunge. We recognise this need and have started working with The Portland Company to provide Assemble to Order packing equipment with introductory automation that helps plants start their journey with plenty of room to expand into more customised equipment with us later. This ensures that all operations, no matter where in the world they’re located, can get an automated option suited for their unique packing line and access best-in-class service.

How does POP (and BOP) ensure optimal coordination of machines, bags, and products?
A POP includes a full plant audit that considers all areas, from product storage and handling to packing, bag transport, palletising and loading lines as well as surrounding machines and environmental factors. The goal of the report is to give plant managers a thorough, solid idea of how their plant is currently performing and where critical updates need to be made. The full POP, including the BOP, considers machines, bags and products to give an overarching recommendation on how all of them can work together for the best results.
The HAVER & BOECKER Institute completes the BOP, checking the chemical composition of the product, how the machine can aerate the product for maximum efficiency in filling and which bags provide the best protection for that specific product. The goal is to have a cohesive packing line that works together in the most efficient way possible.

What new innovations or upgrades are you introducing to improve packing plant performance?
Our newest products are meant to continually improve the packing line and provide the best support possible throughout the packing process. One major update we’ve introduced is the AMICUS Advanced Robot Family. The AMICUS DEPAL Edition depalletises bags and places them on an automatic bag applicator while the AMICUS PAL Edition palletises bags, boxes, drums and pails for transport. The AMICUS DEPAL replaces a previously manual process and increases safety, which is one of the major benefits of the system. If a facility invests in both an AMICUS PAL and DEPAL, they can create a fully automated packing line from empty to full bag.
Another optimisation HAVER & BOECKER is focused on is the unique ADAMS® Technology. ADAMS® is the system for packing cement into PE bags, offering an unlimited list of advantages. There has been rapid growth in the way ADAMS® is used, including how it has expanded into the cement sector. The FFS film bags used with the ADAMS® ROTO-PACKER protect powder cement from the elements while in transit and in storage. The waterproof, weatherproof bags offer a variety of benefits to all the industries we touch, which is an exciting expansion of our pre-existing line.

Concrete

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

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FORNNAX TECHNOLOGY has appointed industry veteran Dieter Jerschl as its new sales partner in Germany to strengthen its presence across Central Europe. The partnership aims to accelerate the adoption of FORNNAX’s high-capacity, sustainable recycling solutions while building long-term regional capabilities.

FORNNAX TECHNOLOGY, one of the leading advanced recycling equipment manufacturers, has announced the appointment of a new sales partner in Germany as part of its strategic expansion into Central Europe. The company has entered into a collaborative agreement with Mr. Dieter Jerschl, a seasoned industry professional with over 20 years of experience in the shredding and recycling sector, to represent and promote FORNNAX’s solutions across key European markets.

Mr. Jerschl brings extensive expertise from his work with renowned companies such as BHS, Eldan, Vecoplan, and others. Over the course of his career, he has successfully led the deployment of both single machines and complete turnkey installations for a wide range of applications, including tyre recycling, cable recycling, municipal solid waste, e-waste, and industrial waste processing.

Speaking about the partnership, Mr. Jerschl said,
“I’ve known FORNNAX for over a decade and have followed their growth closely. What attracted me to this collaboration is their state-of-the-art & high-capacity technology, it is powerful, sustainable, and economically viable. There is great potential to introduce FORNNAX’s innovative systems to more markets across Europe, and I am excited to be part of that journey.”

The partnership will primarily focus on Central Europe, including Germany, Austria, and neighbouring countries, with the flexibility to extend the geographical scope based on project requirements and mutual agreement. The collaboration is structured to evolve over time, with performance-driven expansion and ongoing strategic discussions with FORNNAX’s management. The immediate priority is to build a strong project pipeline and enhance FORNNAX’s brand presence across the region.

FORNNAX’s portfolio of high-performance shredding and pre-processing solutions is well aligned with Europe’s growing demand for sustainable and efficient waste treatment technologies. By partnering with Mr. Jerschl—who brings deep market insight and established industry relationships—FORNNAX aims to accelerate adoption of its solutions and participate in upcoming recycling projects across the region.

As part of the partnership, Mr. Jerschl will also deliver value-added services, including equipment installation, maintenance, and spare parts support through a dedicated technical team. This local service capability is expected to ensure faster project execution, minimise downtime, and enhance overall customer experience.

Commenting on the long-term vision, Mr. Jerschl added,
“We are committed to increasing market awareness and establishing new reference projects across the region. My goal is not only to generate business but to lay the foundation for long-term growth. Ideally, we aim to establish a dedicated FORNNAX legal entity or operational site in Germany over the next five to ten years.”

For FORNNAX, this partnership aligns closely with its global strategy of expanding into key markets through strong regional representation. The company believes that local partnerships are critical for navigating complex market dynamics and delivering solutions tailored to region-specific waste management challenges.

“We see tremendous potential in the Central European market,” said Mr. Jignesh Kundaria, Director and CEO of FORNNAX.
“Partnering with someone as experienced and well-established as Mr. Jerschl gives us a strong foothold and allows us to better serve our customers. This marks a major milestone in our efforts to promote reliable, efficient and future-ready recycling solutions globally,” he added.

This collaboration further strengthens FORNNAX’s commitment to environmental stewardship, innovation, and sustainable waste management, supporting the transition toward a greener and more circular future.

 

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Budget 2026–27 infra thrust and CCUS outlay to lift cement sector outlook

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Higher capex, city-led growth and CCUS funding improve demand visibility and decarbonisation prospects for cement

Mumbai

Cement manufacturers have welcomed the Union Budget 2026–27’s strong infrastructure thrust, with public capital expenditure increased to Rs 12.2 trillion, saying it reinforces infrastructure as the central engine of economic growth and strengthens medium-term prospects for the cement sector. In a statement, the Cement Manufacturers’ Association (CMA) has welcomed the Union budget 2026-27 for reinforcing the ambitions for the nation’s growth balancing the aspirations of the people through inclusivity inspired by the vision of Narendra Modi, Prime Minister of India, for a Viksit Bharat by 2047 and Atmanirbharta.

The budget underscores India’s steady economic trajectory over the past 12 years, marked by fiscal discipline, sustained growth and moderate inflation, and offers strong demand visibility for infrastructure linked sectors such as cement.

The Budget’s strong infrastructure push, with public capital expenditure rising from Rs 11.2 trillion in fiscal year 2025–26 to Rs 12.2 trillion in fiscal year 2026–27, recognises infrastructure as the primary anchor for economic growth creating positive prospects for the Indian cement industry and improving long term visibility for the cement sector. The emphasis on Tier 2 and Tier 3 cities with populations above 5 lakh and the creation of City Economic Regions (CERs) with an allocation of Rs 50 billion per CER over five years, should accelerate construction activity across housing, transport and urban services, supporting broad based cement consumption.

Logistics and connectivity measures announced in the budget are particularly significant for the cement industry. The announcement of new dedicated freight corridors, the operationalisation of 20 additional National Waterways over the next five years, the launch of the Coastal Cargo Promotion Scheme to raise the modal share of waterways and coastal shipping from 6 per cent to 12 per cent by 2047, and the development of ship repair ecosystems should enhance multimodal freight efficiency, reduce logistics costs and improve the sector’s carbon footprint. The announcement of seven high speed rail corridors as growth corridors can be expected to further stimulate regional development and construction demand.

Commenting on the budget, Parth Jindal, President, Cement Manufacturers’ Association (CMA), said, “As India advances towards a Viksit Bharat, the three kartavya articulated in the Union Budget provide a clear context for the Nation’s growth and aspirations, combining economic momentum with capacity building and inclusive progress. The Cement Manufacturers’ Association (CMA) appreciates the Union Budget 2026-27 for the continued emphasis on manufacturing competitiveness, urban development and infrastructure modernisation, supported by over 350 reforms spanning GST simplification, labour codes, quality control rationalisation and coordinated deregulation with States. These reforms, alongside the Budget’s focus on Youth Power and domestic manufacturing capacity under Atmanirbharta, stand to strengthen the investment environment for capital intensive sectors such as Cement. The Union Budget 2026-27 reflects the Government’s focus on infrastructure led development emerging as a structural pillar of India’s growth strategy.”

He added, “The Rs 200 billion CCUS outlay for various sectors, including Cement, fundamentally alters the decarbonisation landscape for India’s emissions intensive industries. CCUS is a significant enabler for large scale decarbonisation of industries such as Cement and this intervention directly addresses the technology and cost requirements of the Cement sector in context. The Cement Industry, fully aligned with the Government of India’s Net Zero commitment by 2070, views this support as critical to enabling the adoption and scale up of CCUS technologies while continuing to meet the Country’s long term infrastructure needs.”

Dr Raghavpat Singhania, Vice President, CMA, said, “The government’s sustained infrastructure push supports employment, regional development and stronger local supply chains. Cement manufacturing clusters act as economic anchors across regions, generating livelihoods in construction, logistics and allied sectors. The budget’s focus on inclusive growth, execution and system level enablers creates a supportive environment for responsible and efficient expansion offering opportunities for economic growth and lending momentum to the cement sector. The increase in public capex to Rs 12.2 trillion, the focus on Tier 2 and Tier 3 cities, and the creation of City Economic Regions stand to strengthen the growth of the cement sector. We welcome the budget’s emphasis on tourism, cultural and social infrastructure, which should broaden construction activity across regions. Investments in tourism facilities, heritage and Buddhist circuits, regional connectivity in Purvodaya and North Eastern States, and the strengthening of emergency and trauma care infrastructure in district hospitals reinforce the cement sector’s role in enabling inclusive growth.”

CMA also noted the Government’s continued commitment to fiscal discipline, with the fiscal deficit estimated at 4.3 per cent of GDP in FY27, reinforcing macroeconomic stability and investor confidence.

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Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

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Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

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