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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

Nuvoco Vistas, CleanMax Partner for Wind-Solar Hybrid Project in Rajasthan

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The project – comprising 20 MW of wind and 26.4 MWdc of solar capacity – will support Nuvoco’s cement operations with cleaner power while strengthening its renewable energy and decarbonisation strategy.

Mumbai, September 29, 2026

Nuvoco Vistas Corp Ltd, part of Nirma Group and one of India’s leading cement companies, has partnered with Clean Max Enviro Energy Solutions Limited (CleanMax), a renewable energy solutions provider for the commercial and industrial (C&I) sector, to develop a 46.4 MW wind-solar hybrid renewable energy project in Rajasthan.

The project will support Nuvoco’s cement operations with cleaner power while strengthening its renewable energy and decarbonisation strategy. It is expected to increase the share of renewable energy in Nuvoco’s power mix, reducing fossil fuel consumption and associated emissions.

Developed by CleanMax, an Independent Power Producer (IPP), at Bhikamkhore, Rajasthan, the project will comprise 20 MW of wind capacity and 26.4 MWdc of solar capacity, along with a 2-MWh Battery Energy Storage System (BESS). Power generated from the facility will be supplied to Nuvoco through the State Transmission Utility (STU) Open Access network.

The hybrid project is expected to generate approximately 100 million units (MU) of renewable electricity annually and help avoid around 1,25,485 tonnes of CO₂ emissions every year across Scope 1 and Scope 2 emissions.

The initiative supports Nuvoco’s ongoing efforts to reduce the carbon intensity of its manufacturing operations through renewable energy adoption, Waste Heat Recovery Systems (WHRS), energy-efficiency measures and increased use of alternative fuels. It also aligns with the company’s DIRE (Digitalisation, Innovation and Renewables) agenda, which focuses on climate action, renewable energy transition, water stewardship, circularity and biodiversity conservation across its manufacturing ecosystem.

Commenting on the initiative, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said, “This marks an important step in advancing Nuvoco’s journey towards more sustainable and resilient operations. Our collaboration with CleanMax will increase the share of renewable energy across our Rajasthan operations, strengthening our energy mix while improving long-term cost efficiency and reducing our dependence on conventional power sources. Initiatives such as these reinforce our commitment to operational excellence and responsible growth, while supporting our vision of Building a Safer, Smarter and Sustainable World.”

Kuldeep Jain, Founder and Managing Director, CleanMax, said, “Cement plants run continuously, so the power behind them has to be dependable for decades, not years. We’re seeing manufacturing industries view clean energy as an integral part of their core operations and long-term strategy. Our partnership with Nuvoco reflects that shift, and we’re pleased to support its decarbonisation journey. This wind-solar hybrid project is designed to deliver long-term cost certainty while supporting the Company’s transition to cleaner power.”

Nuvoco has been advancing its sustainability initiatives through renewable energy, operational efficiency and technology-driven solutions. The company operates across Cement, Ready-Mix Concrete (RMX) and Modern Building Materials (MBM) segments, with a presence across East, North and West India.

The company began operations in 2014 with a greenfield cement plant in Nimbol, Rajasthan, and later acquired Lafarge India Limited, which entered India in 1999, along with Emami Cement Ltd in 2020 and Vadraj Cement Limited in April 2025. With planned expansion initiatives, including a new grinding mill at the Arasmeta Cement Plant and multiple debottlenecking projects, Nuvoco aims to achieve a cement capacity of 35 MMTPA.

The company reported total income of Rs 113.62 billion in FY 2025-26, reflecting its continued growth trajectory. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem brands, while its RMX business offers products under Concreto, Artiste, InstaMix, X-Con and Ecodure brands. Nuvoco also provides construction solutions under its Zero M range of modern building materials.

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Concrete

UltraTech Cement achieves 100% green energy milestone at Chhattisgarh plant

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UltraTech Cement’s Kukurdih Works becomes its first integrated unit to meet 100 per cent electricity needs through green energy every month.

Raipur (Chhattisgarh)

UltraTech Cement Limited, the world’s largest cement company outside China, has achieved a significant decarbonisation milestone, with its Kukurdih Cement Works integrated unit in Chhattisgarh meeting 100 per cent of its electricity requirement through green energy every month since April 2026.

Commissioned in 2024, Kukurdih Cement Works has an installed grey cement capacity of 3.3 million tonnes per annum. The unit achieved this milestone through a combination of renewable power sourcing and Waste Heat Recovery Systems (WHRS), which now collectively meet its entire electricity demand while ensuring operational reliability.

Since April 2026, nearly one-third of UltraTech’s 76 manufacturing units in India have maintained green energy utilisation above 50 per cent of their electricity requirements. Five units, including Kukurdih, have exceeded 95 per cent green energy utilisation. The company is also progressively deploying Battery Energy Storage Systems (BESS) across its network to enable deeper renewable energy integration.

As part of its decarbonisation strategy, UltraTech has not invested in additional captive thermal power capacity for greenfield projects or brownfield expansions at its integrated units for over a decade.

As of Q1FY27, the company’s captive green energy capacity stood at 1,897 MW, comprising 1,463 MW of renewable energy capacity from solar, wind and hybrid sources, along with 434 MW of WHRS capacity. Under its RE100 commitment, UltraTech aims to increase the share of green power in its total energy mix to 85 per cent by 2030 and achieve 100 per cent by 2050.

UltraTech Cement Ltd, the cement flagship company of the Aditya Birla Group, is a $10-billion building solutions company and the largest cement producer globally by sales volume outside China. The company has a total grey cement capacity of 210.1 MTPA and white cement/putty capacity of 3.5 MTPA. It is a signatory to the GCCA Climate Ambition 2050 and has committed to the Net Zero Concrete roadmap announced by GCCA.

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Economy & Market

From First Mile to Last Mile

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Praveen Vashistha, Founder, Gxpress Solutions, speaks about building a holistic logistics network that encompasses latest technology and current challenges faced by logistics service providers.

Logistics may seem to only entail transporting a package from one location to another. However, there is more to this term than just that. Logistics refers to the entire process of controlling all movement, transfers and decisions in the correct way at the right time and cost and with the desired level of visibility.

People nowadays want to receive more than just the delivery. They want quick, efficient, reliable and transparent logistics service. On the other hand, companies are facing higher operating costs, broken supply chains, congested cities, changing habits of consumers and growing complexity of logistics services. In this situation, a full logistics package is gaining importance not only as a competitive advantage but also as a necessity for a successful business.

The main challenge lies in uniting the first mile, the middle mile and the last mile into one seamless process.

The journey begins before the package moves

First-mile logistics may be the least recognised part of the logistics chain, but they have a crucial influence on all that follows.

This stage starts from the moment the shipment leaves the manufacturer, supplier, farm, warehouse or distribution centre. Depending on the industry, first-mile logistics may involve grouping shipments from multiple suppliers, compiling paperwork and checking the inventory before sending the shipments to a central hub.

Flaws in first-mile logistics produce effects later down the supply chain. Delays in cargo pickup can affect warehouse operations; improper packaging can damage goods in transit; and incorrect inventory information may cause stockholding or unnecessary replenishments.

This is why building a reliable network involves simplifying the operations done at the beginning of the supply chain.

Companies require accurate demand forecasts, supplier visibility, standard procedures, and software to capture information from the moment a shipment enters the supply chain. Route planning and fleet management are also important at this stage, especially as it may involve contacting multiple suppliers.

The main goal is simply to make the first mile predictable.

The middle mile: Where scale meets complexity

When products leave the original site, they travel through the ‘middle mile,’ which connects fulfilment centres, warehouses, sorting centres, and regional distribution points. In this phase, logistics networks begin operating on a large scale. A shipment can pass through several facilities before reaching the final destination. Each additional transfer entails the risk of delay or damage and information losses. Accordingly, the ideal solution is not to minimise the number of transfers but rather to optimise them. The use of hub-and-spoke networks, regional distribution centres, and strategically placed distribution centres can help companies shorten transportation routes and optimise distribution costs. Besides, data can be used to determine the optimal placement of inventories.

For instance, a retailer may find that it takes more time and is more expensive to deliver goods to customers if everything is stored in a central warehouse. Meanwhile, regional distribution helps meet the customer’s needs quicker and more efficiently.

The last mile is where the customer judges you

When it comes to the logistics experience, the customer experience comes down to the delivery. While the last mile might comprise a small part of the entire journey in actual distance, it could also entail expensive and difficult processes. Delivery runs through densely populated cities, through traffic jams, through unsuccessful delivery attempts, and through changing consumer preferences and narrowed time frames.

Customers want to have control over their delivery. Delivery means that customers expect to know the exact moment when their order is delivered. They need to receive current updates about their orders and the ability to decide whether they want scheduled deliveries, or whether they want their order to be dropped off at a designated location far from their house.

As a result, last-mile logistics must incorporate both efficiency and experience. The technology may be used to ensure timely and accurate delivery, through such products as route optimisation and real-time delivery tracking.

However, technology is not enough to guarantee success in terms of last-mile delivery. Knowledge of the local area is still an important aspect that contributes to successful delivery.

One network, not three separate operations

First, the common mistake that organisations can make is treating the first mile, the middle, and the last mile separately.

An effective first mile of logistics does not matter much if the shipment waits in a hub for many hours. A perfectly working warehouse does not make a happy customer if the last-mile delivery fails. Therefore, even the fastest last-mile delivery can become an expensive operation if the supply is not well geographically positioned.

The three moments should work together as one whole system.

This implies having a common view on inventory, transport capacities, shipment statuses and demand. The Transportation Management System, Warehouse Management System and order management system should give information to each other instead of acting like separate islands.

That is where real-time information comes into play!

If something happens, such as a vehicle gets delayed, the company has to know that from the start. If not, someone from Customer Service should be informed about the situation.

Visibility is the new infrastructure

Previously, companies had to rely on physical assets, such as warehouses, trucks, and sorting facilities, to create their logistics networks. Today, they have an additional layer of technology providing visibility.

Command-and-control systems now include GPS tracking, Internet of Things devices, bar-coding, RFID, cloud computing, artificial intelligence, and analytics, which allow companies to know what the goods are doing, how well they are doing, and what is going to happen next.

Predictive analytics reveal possible delays. AI-powered forecasting increases availability. Digital dashboards enable the manager to monitor all operations in one place. The efficiency of such technologies is not measured in the amount of information they gather, but rather in their capability of converting data into knowledge.

Logistics managers should be able to answer the following questions: Where is it? When is it supposed to arrive? What causes the delay? What impact does it have? Can it be delivered some other way? How much will it cost?

The sooner the answers are given, the more resilient the logistics system is.

Resilience must be designed into the network

The events of recent years have highlighted the vulnerability of interconnected supply chains. Geopolitical tensions, bad weather, a lack of labour, poorly developed infrastructure and an unexpected spike in demand are some events that can cause problems for logistics systems without prior notice. Thus, companies should create an end-to-end network not just for normal times but also capable of functioning quickly in problematic situations. In order to create such a network, it is necessary to find alternative suppliers, use several means of transportation, create several routes of delivery, and establish inventory. It is also important to use scenario planning to define what to do if the main hub becomes unavailable or any means of transportation is blocked.

Sustainability: Part of the delivery equation

The future of logistics will also be shaped by environmental considerations.

As delivery volumes rise, businesses are under increasing pressure to reduce emissions without compromising service. Better route planning, load optimisation, electric vehicles, alternative fuels, renewable-energy-powered warehouses and consolidated deliveries can all contribute. The most sustainable shipment is often the one that does not require unnecessary movement in the first place.

Better demand forecasting and inventory placement can reduce empty miles and avoid repeated transportation. Consolidating deliveries can improve vehicle utilisation. Reverse logistics can ensure that products, packaging and materials return efficiently instead of becoming waste.

Sustainability, therefore, should not be treated as a separate initiative. It should be incorporated into network design itself.

The future belongs to connected logistics

An end-to-end logistics network ultimately seeks to close existing gaps between various processes.

Every mile of the process should be interconnected with the other miles. Warehouses should be aware of the restraints imposed by transportation. Delivery crews should be able to know at every moment the inventory at their disposal. Clients must have access to this useful information.

Companies that will be successful in this area will not necessarily be the ones with the biggest fleets or the most warehouses. They will simply be the ones that can employ their resources in the most effective manner.

The future of logistics will be represented by an ecosystem consisting of the combination of the physical aspect, digital intelligence, and personnel decisions. Every mile in the process of delivery is important. However, the key advantage here is getting those miles to work together.

For companies, it means having minimal resistance, enhancing their efficiency and improving customer care. For clients, it means simply having the right product delivered at the right time.

About the author: Praveen Vashistha, Founder, Gxpress Solutions,

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