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We manage our oil usage sustainably

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Pradip Kalra, CEO, Stotz Gears, discusses the role of innovation in making the Indian cement machinery industry self-reliant and globally competitive.

With an unwavering focus on quality and precision, Stotz Gears has been empowering India’s cement sector with world-class girth gears, kiln shells and tyres. In this candid conversation, Pradip Kalra, CEO, Stotz Gears, explains how engineering excellence and sustainability go hand in hand, and his pioneering contribution towards import substitution in critical cement plant components.

Tell us about your journey in the engineering industry and your association with the cement sector.
My journey in the engineering industry began from humble beginnings, with practically no infrastructure in place. With consistent hard work, dedication and a deep commitment to transform industry standards—especially in terms of cost efficiency and quality—I was able to carve a niche in the manufacturing and supply of critical components to the Indian cement industry.
Today, I find a sense of satisfaction in having initiated and contributed to the manufacturing of vital cement plant components such as girth gears, union assemblies, tyres, support rollers, trunnions, mill heads, kiln shells and mill shells. We have maintained a consistent track record—since 2004, everything we have manufactured and supplied continues to perform reliably, with zero failures. That long-term dependability is a testament to our commitment to quality and precision.

How did you begin with the manufacturing of girth gears, and how has their relevance grown in India?
I started out by manufacturing small gears for modest-scale industries, such as oil mills and small cement plants. But I always dreamed bigger.
I often asked myself: why not manufacture larger gears? That dream became a target, and I pursued it relentlessly.
In 1986, I travelled to Germany and purchased advanced machinery that allowed us to produce girth gears that could match, or even surpass, international standards. Before this, India had to rely heavily on imports from France, Germany, and the USA for such components. By investing in the right machinery and tools—specifically German ones—we raised our quality standards and gradually achieved parity
with global manufacturers. We also invested in
skill development.
The knowledge I gained was shared with our engineers and workers, and that collective learning laid the foundation for quality manufacturing in India. I am proud to say that this initiative has helped India move towards the vision of Atmanirbhar Bharat, championed by our Honourable Prime Minister.

How did your company begin manufacturing tyres, and how did that lead to applications in cement?
Tyres, like girth gears, are cast products, and they require a similar level of metallurgical and engineering expertise. Over time, the quality
and technology of casting in India improved significantly. We didn’t work in isolation—we actively encouraged and guided our casting partners to innovate and meet international standards. We passed on knowledge, provided feedback and set high expectations.
The result was a win-win: the casting industry evolved and we were able to manufacture tyres of international-grade quality domestically. This directly benefited the cement sector, which depends on the reliability and durability of such components.

How are kiln shells serving the cement industry, and how do you ensure their precision and performance?
Kiln shells, like other critical cement plant components, are manufactured in accordance with international quality standards. These standards are set by OEMs and well-known across the cement industry. I believe the foundation of delivering high-quality products lies in honesty—honesty towards quality standards, material procurement, and the will to achieve excellence. Personally, I have always repeated to myself: I must achieve it, I must achieve it. That self-motivation and conviction have taken me a long way.
Every kiln shell we produce reflects that commitment. We source certified raw materials, maintain stringent manufacturing controls, and ensure precision across every stage. The final product not only meets OEM specifications but also earns the long-term trust of our clients.

Could you elaborate on any sustainability practices you follow in your company?
Absolutely. First and foremost, our industry is not a major polluter. The only minimal emission we produce is a small amount of smoke during heavy gear cutting operations. Even this is addressed responsibly—we have installed smoke arrestors in our facility roofs, which capture the smoke and discharge it safely via high-speed fans. This ensures that no harmful emissions reach the areas where people live or work.
Additionally, we manage our oil usage sustainably. Used industrial oils are collected and sold to licensed refineries, where they are reprocessed and reused. We do not discharge any waste oils or chemicals into drains or public waterways.
Beyond that, we also make a conscious effort to maintain greenery around our plant. Every year, we plant numerous trees, maintain flower beds and promote green spaces around our premises to enhance biodiversity and environmental balance.

What are some of the challenges you face in your line of work, and how do you address them?
Challenges are constant, especially in engineering and manufacturing. One of the biggest challenges is the increasing demand for precision and reliability from cement plants. Every year, the expectations rise. Clients demand tighter tolerances, better materials and longer-lasting components—even if the products we supplied years ago are still running without a single complaint.
To address this, we continuously work to improve. We tighten our precision parameters, upgrade our machinery and metrology equipment and invest in employee training. We impose strict quality control standards at every level—from raw material inspection to final testing. This proactive approach helps us meet evolving demands and deliver even better results.

What are your thoughts on the Net Zero mission and how do you see the journey evolving for the cement sector?
That’s an important question. Although I am not a cement plant operator or technical head, I have been closely observing the sustainability trends over the past few years. In fact, I have been attending conferences to better understand the Net Zero mission. Pollution is everyone’s concern—not just the plant owners. I am genuinely proud of how far the Indian cement industry has come in the last decade. Initially, we were focused on increasing production. Then we moved to improve quality. Later, the focus shifted to logistics and transport. And now, we are tackling emissions.
It is a remarkable progression, and the fact that Indian cement companies are now talking about and achieving targets for zero emissions is something to truly admire. We are not just following global trends—we are matching, and in some cases, even leading. My heartfelt compliments to all stakeholders in the cement industry—whether it is plant operators, general managers or company owners.

Concrete

Adani’s Strategic Emergence in India’s Cement Landscape

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Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.

India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.

Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:

  • September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
  • December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
  • August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
  • April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
  • Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
  • Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
  • Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
  • Orient Cement: It would serve as a principal manufacturing facility following the merger.

Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:

  • By FY 2026: Reach 118 MTPA
  • By FY 2028: Target 140 MTPA

These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).

Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.

Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.

Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.

Challenges potentially include:

  • Integration challenges across systems, corporate cultures, and plant operations
  • Regulatory sanctions for pending mergers and new capacity additions
  • Environmental clearances in environmentally sensitive areas and debt management with input price volatility

When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.

Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.

About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.

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Concrete

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

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PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.

Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

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Concrete

Driving Measurable Gains

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Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.

Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.

Beyond energy efficiency, the retrofit significantly improved operational parameters:

  • Lower thermal stress on equipment
  • Extended lubricant drain intervals
  • Reduction in CO2 emissions and operational costs

These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.

Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:

  • Enhanced component protection
  • Extended oil life under high loads
  • Stable performance across fluctuating temperatures

By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.

Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.

A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

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