Economy & Market

Smart Motion Systems Power Cement Plants

Published

1 year ago

July 23, 2025

admin

ICR explores how advanced gears, drives, and motors are transforming cement manufacturing by enhancing reliability, reducing energy use, and enabling predictive maintenance. With digitalisation, electrification, and sustainability at the forefront, motion systems now play a strategic role in driving operational excellence and Net Zero goals.

Gears are the unsung workhorses of cement plants, critical to the operation of equipment ranging from crushers and conveyors to milling units and kilns. Built to endure heavy-duty conditions—dust, heat, shock and continuous load—they are often made from carburised, electro-welded steel, precision-ground to withstand high torque and ensure longevity. The failure of a single girth gear or pinion can halt an entire production line, emphasising the importance of quality-focused design and maintenance.
In grinding applications, such as those involving ball mills and vertical roller mills (VRMs), gearboxes play a pivotal role in power transmission. For instance, ring gears and planetary gear systems manage loads up to 8?MW, balancing efficiency with structural resilience. While planetary drives may add a 5 per cent –15 per cent premium over conventional girth-drive systems, their improved lifecycle, reduced maintenance and enhanced control often justify the higher upfront cost.
Gears also facilitate the precise rotation of kilns. Dual-drive systems, each powering pinions on opposite sides of the kiln, ensure balanced torque delivery and smooth operation. This configuration reduces shell distortion, mechanical stress, and vibration, extending component life and reducing unplanned downtime. Regular maintenance, alignment checks and vibration monitoring underpin the reliability of these high-capacity systems.
Innovation continues to advance gear performance. Companies like MAAG Gear and others have embraced high-strength materials, optimised tooth profiles and modular gearbox architectures to improve serviceability and energy efficiency. The coexistence of traditional weld-and-grind gearboxes and modern planetary or gearless drives reflects the balance between proven reliability and future readiness in cement plant design.

Lifecycle costs and return on investment
In capital-intensive industries like cement, the upfront cost of gears, motors and drives is only one piece of the financial puzzle. What truly matters over time is the total cost of ownership (TCO)—including maintenance, energy use, downtime losses and equipment lifespan. High-efficiency gearboxes or premium VFDs may appear costlier initially, but they often deliver far superior ROI through reduced power consumption and longer operational life. For example, using a high-efficiency IE4 motor can save up to 30 per cent in energy costs over a decade compared to IE1-rated models.
Modern procurement is increasingly driven by this lifecycle approach. Maintenance teams, once focused on price, now calculate costs over a 10–15-year horizon. A planetary gearbox with precision-machined gears and sealed lubrication may offer double the life of a conventional pinion system, with 40 per cent fewer breakdowns. When downtime in a cement plant can cost lakhs per hour, these savings become significant. The ability to track and predict maintenance intervals using sensor-based diagnostics only improves financial predictability.
Pradip Kalra, CEO, Stotz Gears, says, “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.”
Additionally, energy audits and drive optimisation programs have become key tools in ROI evaluation. By measuring baseline power usage and simulating post-retrofit performance, plant heads can make data-backed investment decisions. For instance, the ROI period for installing VFDs on ID fans or mill motors has dropped from 3 years to under 18 months in many Indian plants, thanks to energy savings and extended motor life.
Some cement companies are also entering into performance-based contracts with OEMs—where vendors guarantee uptime, energy efficiency, or availability, with penalties and bonuses linked to performance. This shifts the focus from product cost to value delivered, and aligns all stakeholders toward plant profitability. Lifecycle thinking is no longer optional—it’s a strategic lens for both capital budgeting and operational optimisation.

Drives and motors: Energy efficiency and control
Electric motors and drives constitute one of the largest operational cost centres in cement manufacturing—accounting for as much as 75 per cent of electrical energy usage. Motors power crushers, grinders, fans, pumps and conveyors. Without precise speed control, these systems operate inefficiently, especially under partial load conditions. As the industry strives to reduce energy intensity—currently averaging 4.69?GJ/t of clinker with a 0.69?GJ/t potential improvement—the role of drives is critical.
Variable Frequency Drives (VFDs) or Variable Speed Drives (VSDs) optimise motor operation by adjusting speed to load. Since power consumption follows a cubic relationship with speed, even a 10 per cent reduction in fan speed can yield up to 27 per cent energy savings. ABB estimates VSD adoption can cut fan energy use by up to 60 per cent, and similar savings apply to pumps and conveyors. Additionally, soft-start capabilities reduce mechanical wear and electricity demand.
Medium-voltage drives are increasingly favoured in kilns and mills, offering efficient and controlled propulsion for large motors (>375?kW). These include design variants like scalar, vector and direct torque control, each enhancing process stability and reliability. Smart motor-control centres and digital monitoring add predictive maintenance capabilities, lowering downtime and protecting components from damage.
Digitalisation helps further boosts efficiency. Sensors track vibration, temperature and torque, sending alerts when anomalies appear—allowing proactive intervention. Coupled with cloud-enabled dashboards, these systems give plant managers real-time operational visuals. Emerging strategies include motor-driven kilns, optimised compressor control and regenerative braking in conveyors—all promising integrated energy savings and system longevity.

Maintenance and digital condition monitoring
Robust gear and motor performance depends as much on diligent maintenance as on quality hardware. Cement plants operate in abrasive environments, where dust ingress and heat accelerate wear on gearboxes and bearings. Traditional preventive schedules are being enhanced with condition-based monitoring (CBM), employing vibration, oil quality and thermal sensors to detect anomalies before breakdowns occur.
“The products we manufacture are primarily made from 42CrMo4 alloy steel, which is well-known for its strength and durability. This type of steel is highly resistant to corrosion and mechanical stress, which is essential in an environment like a cement plant. We also advise our customers to use protective covers while the machines are operating to further reduce environmental wear and tear. As for material performance, the tensile strength of the steel we use is around 900 N/mm². In comparison, many competitor products fail at around 600 N/mm². This shows that we never compromise on material quality, even if it means our costs are higher. Our philosophy is to prioritise long-term durability over short-term price reductions, and this approach has helped us build a strong reputation for reliability,” says Dheepan Ramalingam, Managing Director, Ringfeder Power Transmission (I).
CBM-enabled gearboxes report early signs of wear—uneven vibration, tooth damage, or gearbox play—well in advance of delays. Remote monitoring allows engineers to schedule maintenance during planned shutdowns, reducing unplanned downtime. This approach is especially valuable for critical components like kiln pinions or mill drives, where failures can stall production lines for hours or
even days.
For motors, performance data such as current fluctuations, temperature rise, and RPM deviations are tracked. Alerts flag performance drift or impending failure, triggering targeted maintenance and preventing catastrophic breakdowns. Coupled with operator training, these data-driven tools build a maintenance culture that extends asset longevity and optimises operational costs.
As plants scale in complexity, digital twins are gaining traction. By simulating gear stresses and motor behaviours under load scenarios, engineers can anticipate and resolve potential issues. Predictive analytics, powered by AI, further enhance reliability, enabling asset care programs that are cost-effective and aligned with safety and sustainability objectives.

Safety, reliability and compliance standards
In heavy industries like cement, safety and compliance are non-negotiable—and the gear and drive systems play a central role in risk prevention. Gear failures can result in catastrophic downtime or physical hazards such as shattered components or oil fires. Similarly, motor overheating, shaft misalignment, or electrical surges can pose serious threats to personnel and equipment. Therefore, selecting systems that comply with international standards like ISO 9001, IEC 60034, ISO 6336, or OSHA guidelines is critical.
Many high-performance drives now come equipped with built-in safety features: torque limiting, electronic braking, soft-start functions, thermal overload protection, and arc-flash prevention systems. These features not only protect the drive system itself but also safeguard connected equipment and operators. For example, a kiln drive motor with real-time torque monitoring can alert operators before any mechanical over-torque incident occurs, reducing the risk of accidents or
gear damage.
Regulatory compliance is another layer cement manufacturers cannot afford to overlook. Indian plants, especially those supplying to government or infrastructure projects, are now required to submit compliance records for emissions, energy consumption, and equipment safety. Components like drives and motors are increasingly scrutinised for CE marking, RoHS conformity, and BIS certification. This has elevated the importance of sourcing from certified vendors who can provide full documentation and after-sales support.
Training is also part of the safety ecosystem. OEMs and drive manufacturers now offer onsite and digital certification programs for plant technicians, enabling them to detect faults, align motors and gearboxes correctly, and safely shut down systems when needed. The result is not just improved compliance—but also a more resilient and skilled maintenance workforce, better equipped to manage evolving plant demands.

Sustainability impact and energy savings
Driven by climate targets and energy cost pressures, the cement industry is elevating energy efficiency as a sustainability imperative. Cement plants are working to reduce their energy-intensity—both in electricity (e) and thermal—through advanced drives, efficient gears, and digital controls. They aim to reduce electrical use toward 4?GJ/t and overall energy consumption below global best-practice levels.
The switch to VSD-equipped fans, pumps, and kilns reduces CO2 emissions and energy expenses. For example, a kiln fan retrofitted with VFDs at a Chinese plant lowered annual energy consumption by 10 per cent, saving US?$124,000. In India,
embracing dry-process technology and VSDs has helped most plants meet or outperform PAT-II efficiency benchmarks.
Gear innovations also contribute to sustainability. High-efficiency planetary and helical gear systems reduce friction losses and require less frequent oil changes and part replacements. Gearboxes designed with optimised tooth profiles and high-strength alloys, such as carburised steel, cut mechanical drag and electrical demand. Brands are also exploring low-lubricant and sealed gearbox systems to reduce environmental contamination.
Energy savings compound when drives and gears are integrated with alternative energy sources. Waste Heat Recovery (WHR) systems supply power to drives, reducing grid load. Solar/battery systems and kinetic energy recovery (e.g., regenerative braking) help close the efficiency loop. Together, these measures support the industry’s decarbonisation ambition toward Net Zero by 2070.

Smart factories, electrification trends
As Industry 4.0 gains momentum, gears, motors, and drives are no longer just mechanical components—they are becoming intelligent nodes in the cement plant’s digital nervous system. The integration of sensors, IoT-enabled monitoring and cloud-based analytics is turning static assets into dynamic, responsive systems.
Today, predictive maintenance dashboards allow engineers to visualise gearbox temperature trends, motor vibration or torque fluctuations in real time—enabling proactive interventions and optimising asset life.
Ramalingam exemplifies, “One of the most exciting developments is the integration of electronic feedback systems into our product lines. This represents a step toward smart technology, where products can provide real-time performance data. We are currently working on embedding sensors and feedback modules into our systems, which can give users predictive insights and maintenance alerts.”
One major trend is the emergence of digital twins—virtual replicas of physical systems that simulate their behaviour under real-world conditions. In cement applications, digital twins can model gearbox loads, monitor motor efficiency curves, and forecast failure modes. Paired with machine learning algorithms, they enable optimisation of process parameters, drive tuning, and asset scheduling without physical trials—cutting downtime and testing costs.
Another exciting development is the shift toward fully electrified drive systems, especially in rotary kilns and large vertical mills. While traditional hydraulic or mechanical drive systems still dominate in many plants, high-torque electric drives are gaining adoption due to their precision, lower maintenance, and ability to integrate with control systems. These drives also support energy recovery strategies—such as regenerative braking—enabling significant reductions in net power consumption.
Looking ahead, innovations like sensorless motor control, self-healing gear coatings, and edge AI processors for real-time condition assessment will redefine how cement plants view motion systems. These advancements won’t just boost uptime—they will provide the agility, traceability, and efficiency required for the future-ready, low-carbon smart
cement plant.

Conclusion
In cement manufacturing, gears, drives and motors serve as the backbone of plant operations—ensuring continuous, controlled motion across critical processes like crushing, grinding, kiln rotation and material handling. Today, these systems are evolving rapidly, with high-efficiency gearboxes, VFD-integrated motors and digital condition monitoring helping plants improve uptime, reduce energy use and extend equipment life.
Keeping up with the changing needs of the cement sector is mandatory for component providers. Kalra states, “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.”
As India’s cement industry scales up capacity while pushing for sustainability and operational excellence, investing in reliable, customisable, and digitally enabled motion systems is no longer optional—it’s strategic. Whether it’s through localised innovation, safety compliance, or predictive maintenance, the performance of gears, drives, and motors will remain central to meeting future efficiency and Net
Zero goals.

– Kanika Mathur

Up Next

We prioritise long-term durability

Don't Miss

Premiumisation is the Future of Cement

Economy & Market

The Road Ahead Begins Here

Published

1 day ago

August 11, 2026

admin

The future of India’s roads took centrestage at RAHSTA Expo 2026, where policymakers, contractors and industry leaders came together under one roof. The event blended thought leadership, technology showcase and industry recognition into a single powerful platform.

India’s roads and highways community gathered in full strength at the Jio World Convention Centre, Mumbai, for the 16th edition of the RAHSTA Expo (Roads and Highways Sustainable Technologies & Advancement). Over two action-packed days, the event brought together policymakers, contractors, consultants, developers, equipment manufacturers, material suppliers, technology providers and investors to deliberate on the future of India’s ,infrastructure while showcasing the latest innovations driving the sector.

The event culminated in the prestigious RAHSTA Awards, where Shri. Ajay Tamta, Union Minister of State for Road Transport & Highways, felicitated organisations and professionals for their outstanding contributions to road construction, engineering, safety, sustainability and technology. With leading contractors, senior government officials, industry veterans and technology providers under one roof, the event reaffirmed RAHSTA’s position as one of India’s most influential platforms for the roads, highways, bridges and tunnels ecosystem.

Organised by FIRST Construction Council in association with ASAPP Info Global Group, RAHSTA has steadily evolved beyond an exhibition into a platform where policy, technology, engineering and business converge to address the opportunities and challenges shaping India’s next generation of transport infrastructure.

Beyond expansion, towards value

The conference opened with a thought-provoking address by Pratap Padode, Founder and Editor-in-Chief, Construction World, who observed that India’s highways sector has reached an important inflection point. Introducing this year’s theme – ‘From Expansion to Value: The Next Phase of India’s Highways’ – he noted that while the country has successfully expanded its road network over the past two decades, the industry’s priorities are now shifting towards building infrastructure that delivers greater lifecycle value, durability, safety and operational efficiency. With funding pressures, asset monetisation and evolving project models changing the sector’s dynamics, he said the focus must now move beyond kilometres constructed to the quality and long-term performance of every asset.

Dr Brijesh Dixit, Managing Director, Maharashtra State Infrastructure Development Corporation (MSIDC), reminded delegates that successful infrastructure delivery is ultimately a collective effort. Emphasising on collaboration between government, industry and engineering professionals, he remarked, “There is no loser in a winning team, and there is no winner in a losing team,” urging stakeholders to work together to deliver projects with quality, financial sustainability and technological excellence.

Delivering the keynote address, Bidur Kant Jha, Director, New Technologies for Highway Development, Ministry of Road Transport & Highways (MoRTH), outlined the Government’s long-term vision for India’s highway network. Highlighting the country’s 6.26 million km roads network, he spoke about the growing adoption of digital planning tools such as BIM and GIS, bridge health monitoring systems and Integrated Smart Transport Corridors under the Vision 2047 roadmap. He emphasised that while India remains open to global innovations, every new technology must be adapted to Indian conditions before large-scale deployment.

Addressing the gathering during the awards ceremony, Tamta underlined the increasing role of specialised equipment and modern construction technologies in executing complex infrastructure projects across diverse terrains. Referring to challenging tunnel projects in Uttarakhand, he noted how advanced machinery has transformed execution capabilities, while also acknowledging the rapid evolution of Indian contractors into globally competitive infrastructure companies. Recognising excellence through industry awards, he said, motivates organisations to continually raise performance standards and embrace innovation.

Meanwhile, Dr Sanjay Mukherjee, IAS, Metropolitan Commissioner, MMRDA, highlighted that infrastructure development must increasingly focus on integrated urban mobility. Reflecting on Mumbai’s engineering journey – from its historic underground utility network to the Coastal Road and other transformative projects – he underlined that future infrastructure planning must seamlessly integrate roads, metro systems and public transport to create efficient, multimodal cities.

Uttar Pradesh takes centrestage

One of the highlights of the second day was Uttar Pradesh’s comprehensive presentation on its infrastructure-led industrial transformation.

Srihari Pratap Shahi, IAS, Additional CEO, Uttar Pradesh Expressways Industrial Development Authority (UPEIDA), demonstrated how the state’s expanding expressway network is evolving into a catalyst for industrial development through integrated manufacturing and logistics clusters. Expressways, he noted, are no longer merely transport corridors but engines of economic competitiveness.

Building on this narrative, Deeksha Jain, IAS, Additional Chief Executive Officer, Uttar Pradesh State Industrial Development Authority (UPSIDA), showcased the state’s rapidly expanding industrial ecosystem supported by extensive expressway connectivity, dedicated freight corridors, airports, industrial townships and investor-friendly policies. She highlighted Uttar Pradesh’s strong manufacturing growth, expanding industrial land bank, plug-and-play infrastructure and increasing use of digital governance to facilitate investments.

Further underlining the significance of the platform, Deepak Kumar, IAS, Infrastructure & Industrial Development Commissioner, Government of Uttar Pradesh, remarked, “RAHSTA provides an excellent platform for states to showcase our infrastructure progress and investment ecosystem. Uttar Pradesh has transformed significantly over the past decade, backed by more than 34 investor-friendly industrial policies, and platforms like RAHSTA help communicate these developments to industry stakeholders from across the country.”

Ideas that shaped the industry conversation

The two-day conference featured seven panel discussions, each examining a critical dimension of India’s evolving roads and highways sector.

The opening discussion on ‘Financing Roads & Highways in a Capital-Constrained Era’ brought together experts from Cube Highways, NIIF, SBI Capital Markets, Centrum Capital and Bandhan Infra Fund, who examined how the financing landscape is changing. Discussions revolved around asset monetisation, InvITs, institutional investments and new funding structures, with panellists agreeing that better project preparation, transparent governance and predictable returns will be crucial for attracting long-term capital into infrastructure.

Attention then shifted to execution realities during the panel on ‘Contractors’ Perspective: Execution Realities, Risks & the Quality Imperative.’ Representatives from GHV Infra Projects, PNC Infratech, NCC and Maccaferri candidly discussed the challenges of delivering projects amid contractual complexities, land acquisition delays, rising costs and tight timelines. While execution pressures remain significant, the discussion reinforced that better collaboration across the project value chain is essential for achieving both speed and quality.

Day 2 opened with a technically rich discussion on ‘Designing Roads for Sustainability, Durability & Climate Resilience’. Experts from CSIR-CRRI, IIT Bombay, IIT Madras, Zydex Group and SRMB Steel explored advanced pavement technologies, recycled materials, climate-resilient designs and scientific construction practices that can significantly improve durability while lowering lifecycle costs. Sustainability, they agreed, must become an integral part of road design rather than an afterthought.

The subsequent session on ‘Bridges & Tunnels: Complex Engineering, Safety & Future Readiness’ highlighted the growing complexity of India’s infrastructure projects. Panellists discussed advances in structural engineering, digital monitoring, risk management and safety practices that are enabling the successful delivery of increasingly ambitious bridge and tunnel projects across the country.

Technology remained a recurring theme during the discussion on ‘Technology as a Risk-Mitigation Tool for Developers & Investors’. Experts explained how AI, BIM, drones, predictive analytics, digital twins and intelligent monitoring systems are helping improve project planning, minimise execution risks, strengthen quality assurance and enhance asset management throughout the infrastructure lifecycle.

The construction equipment panel brought together leading industry experts to examine how technology, sustainability and digitalisation are redefining construction equipment in an era of rising cost pressures. Discussions centred on enhancing productivity, reducing lifecycle costs and preparing the industry for India’s infrastructure ambitions leading up to 2047.

The conference concluded with an engaging CXO Forum on ‘Rebuilding Confidence in India’s Roads & Highways Sector’, where senior industry leaders emphasised that stronger governance, better project preparation, digitalisation, transparent contracting and closer public-private collaboration will be essential to sustain India’s infrastructure growth over the coming decades.

Technology and recognition under one roof

Beyond the conference halls, RAHSTA Expo reflected the technological transformation underway across India’s road infrastructure ecosystem. Leading equipment manufacturers, technology companies and material suppliers showcased advanced construction equipment, intelligent digital platforms, pavement technologies, structural materials and productivity-enhancing solutions designed to improve project efficiency and asset performance. The exhibition created valuable opportunities for contractors, consultants, government agencies and project developers to evaluate new technologies while interacting directly with solution providers.

The event also served as a celebration of excellence through the RAHSTA Awards 2026, which recognised outstanding achievements across road construction, contracting, materials, equipment, technology, safety, sustainability and infrastructure development. Presented by Minister Tamta, the awards honoured organisations that are setting new benchmarks for quality, innovation and execution across India’s roads sector.

RAHSTA Expo 2026 also received extensive support from across the infrastructure ecosystem. Alongside leading corporate sponsors, the event was backed by industry bodies including the Builders Association of India (BAI), Construction Equipment Rental Association (CERA), Consulting Engineers Association of India (CEAI), International Road Federation (IRF), CSIR-CRRI, CILT India, All India Transporters Welfare Association, Hydraulic Trailer Owners Association (HTOA), Gujarat Contractors Association, Bitumen Forum, Fluid Power Society of India, Indian Institute of Material Management, Ministry of Ports, Shipping and Waterways, Gati Shakti Vishwavidyalaya and Mumbai First, reflecting the industry’s collective commitment to advancing India’s road infrastructure.

As the curtains came down on the two-day event, one message resonated throughout the conference: India’s highways story is entering a new chapter. While expansion will continue, the future will increasingly be defined by smarter planning, stronger partnerships, digital transformation, sustainable engineering and long-term value creation. By bringing together the entire infrastructure value chain on a single platform, RAHSTA Expo 2026 once again demonstrated why it has become one of the country’s most influential forums for shaping the future of roads, highways, bridges and tunnels.

Economy & Market

Fornnax Names Lukas Baur as Authorised Service Partner to Bolster EU Operations

Published

3 weeks ago

July 23, 2026

admin

Strapline: Fornnax Technology has appointed NOBA Maschinenservice’s Lukas Baur as its authorised service partner for the European Union, strengthening its commitment to delivering fast, reliable, and localised after-sales support across the region.

Fornnax Technology, a leading manufacturer of industrial shredding solutions, has announced the appointment of Mr. Lukas Baur of NOBA Maschinenservice as its authorised service partner for the European Union. The partnership, formalised under the authorisation of Fornnax CEO Mr. Jignesh Kundaria, reinforces the company’s commitment to providing dependable, localised service support to its expanding customer base across Europe.

Strengthening Service Through Proven Expertise

With over two decades of experience in servicing, maintaining, and overhauling industrial shredders, Mr. Baur brings extensive technical expertise to the partnership. His capabilities span welding, hardfacing, shaft and knife rebuilding, complex assembly, hydraulics, and complete electrical engineering services, delivered in collaboration with a trusted partner company based in Halle/Saale.

Operating from Worbis, Germany, Mr. Baur is strategically positioned to provide emergency support across the European Union within 24 hours, covering an operational radius of approximately 1,000 kilometres.

Supporting this capability is a well-equipped service infrastructure comprising 12 Mercedes Sprinter service vans, a team of 24 skilled technicians, specialised bearing-change tools, a fully equipped hydraulic workshop, and a 1,000-square-metre facility with a five-ton crane track. Together, these resources position his team to manage the complete spectrum of Fornnax’s European service requirements efficiently and reliably.

Partnership Driven by Industry Insight

Having spent years servicing Eldan, Lindner, and Vecoplan shredders across the European recycling industry, Mr. Baur’s decision to collaborate with Fornnax is rooted in his understanding of market needs and customer expectations. His experience has provided valuable insight into what recycling plant operators require—not only from their machinery but also from the service teams supporting them.

According to Mr. Baur, Fornnax’s reputation for robust machine construction, superior wear protection, and maintenance-friendly design made the partnership a natural fit.

The collaboration comes at a time when Europe’s tyre recycling industry is facing mounting challenges, including rising cost pressures, shrinking margins, delayed investments, and a shortage of skilled labour. Mr. Baur believes these conditions reinforce the need for technically strong service partners capable of delivering rapid, dependable support.

Commenting on the partnership, he said, “Fornnax, with its exceptional price-performance ratio and superior quality, has the potential to become a market leader in Europe. We would like to be their service partner in this journey.”

Comprehensive Support Across the Equipment Lifecycle

As Fornnax’s authorised service partner, Mr. Baur will oversee the complete lifecycle support of the company’s equipment throughout the European Union. His responsibilities will include installation, commissioning, preventive maintenance, emergency repairs, and spare parts support across mechanical, hydraulic, and electrical systems.

Looking ahead, he also plans to develop a centralised spare parts distribution hub for European customers, particularly if Fornnax establishes a warehouse facility in Worbis to facilitate faster deliveries. To further strengthen service coverage, Mr. Baur intends to expand operations by adding two to three additional service teams and vehicles each year, progressively increasing capacity across the continent.

A Shared Commitment to Customer Excellence

Highlighting the strategic importance of the partnership, Mr. Jignesh Kundaria, Director and CEO of Fornnax, said:

“We strongly believe that by continuously improving our service quality and customer satisfaction index, we can build long-term relationships with our customers. Higher customer satisfaction leads to greater trust, which significantly increases repeat orders and ultimately drives sustained growth in our sales revenue.”

This customer-first philosophy underpins Fornnax’s strategy of building a dedicated European service partner network instead of relying solely on remote support. With Mr. Baur joining this network, customers across the European Union will benefit from faster response times, expert technical assistance, and dedicated on-ground support from a partner with extensive experience in high-throughput shredding operations.

Mr. Baur’s appointment also reflects Fornnax’s broader ambition to establish itself as the preferred shredding solutions provider for the European recycling industry, marking another important milestone in the company’s international growth strategy.

Concrete

Nuvoco Vistas launches Limla cement plant, expands Gujarat footprint

Published

1 month ago

July 13, 2026

admin

Nuvoco Vistas opens a 2 MMTPA grinding unit at Limla, entering Gujarat and advancing its target of 35 MMTPA capacity by FY 2028.

Surat (Gujarat)

Nuvoco Vistas Corporation Ltd, a part of Nirma Group and one of India’s leading building materials company, has inaugurated the Limla Cement Plant in Surat (Gujarat), one of Vadraj Cement Limited’s (VCL) principal manufacturing facilities. The commissioning represents a key milestone in Nuvoco’s acquisition and restoration of VCL, while supporting the company’s expansion across the Western Indian cement market.

Vadraj Cement Limited is a subsidiary of Nuvoco Vistas Corporation Limited and has installed cement capacity of 6 MMTPA across its assets. The Limla inauguration therefore represents the first operational step in the acquired platform’s wider revival, while the Kutch facilities provide clinker supply, mineral security and coastal logistics support for the western business.

Nuvoco completed its acquisition of Vadraj Cement Limited, then under the Corporate Insolvency Resolution Process, after paying a consideration of Rs 1,800 crore in June 2025. VCL’s asset portfolio comprises a clinker unit at Kutch and a grinding unit at Limla in Surat. It also includes high-quality captive limestone reserves and a captive jetty at Kutch, supporting more efficient logistics. Following the takeover, Nuvoco began an extensive programme of restoration, refurbishment and expansion at both locations, leading to the commissioning of the Limla plant.

The Limla Cement Plant is expected to support a phased increase in sales volumes across Gujarat. It will also help Nuvoco supply neighbouring markets in Western Maharashtra and release cement capacity from its northern plants, which can consequently be redirected towards markets in North India. The plant will manufacture a full portfolio comprising Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. It will additionally produce the complete Nuvoco Duraguard range, including the premium Nuvoco Duraguard Microfibre product. The acquisition is also expected to generate operational synergies with Nuvoco’s existing plants at Nimbol and Chittorgarh in Rajasthan, improving logistics optimisation and market reach across important regional markets.

The grinding unit at the Limla Cement Plant was completed ahead of schedule, with 2 MMTPA of capacity now inaugurated to expand Nuvoco’s operating scale and customer reach. After Vadraj Cement’s assets become fully operational, plants in North and West India are expected to account for nearly 40 per cent of Nuvoco’s total cement capacity. This will broaden the company’s manufacturing network, strengthen access to high-growth markets and support its plan to increase consolidated cement capacity to 35 MMTPA by FY 2028, reinforcing its longer-term growth strategy.

Commenting on the development, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said: “The inauguration of the Limla Grinding Unit in Surat is an important milestone in Nuvoco’s growth journey and demonstrates our commitment to disciplined, value-accretive expansion. Gujarat is strategically significant for Nuvoco, with substantial opportunities arising from infrastructure investment, industrial growth, rapid urbanisation and continuing demand from the housing and construction sectors. The facility strengthens our regional footprint, improves operational flexibility and increases our ability to serve customers across northern and western markets with greater reliability and efficiency.”

He added: “Through the Vadraj acquisition, we have refurbished and restarted a strategically important asset, returning it to operations in record time through strong execution and collaboration between teams. The achievement demonstrates our ability to create value from acquired assets, fulfil our commitments and retain the confidence of stakeholders. It also highlights the strength of our project delivery capabilities and our continued focus on building sustainable, profitable growth over the long term.”

Nuvoco Vistas Corporation Limited is a building materials company whose vision is to build a safer, smarter and more sustainable world. It is among the leading players in East India and has a significant presence across North and West India. Nuvoco began operations in 2014 with a greenfield cement plant at Nimbol, Rajasthan. It later acquired Lafarge India Limited, which had entered India in 1999, followed by Emami Cement Limited in 2020 and Vadraj Cement Limited in April 2025. The company has also announced an expansion in eastern India through a new grinding mill at the Arasmeta Cement Plant, supported by several debottlenecking programmes involving equipment upgrades, process improvements and internal capacity initiatives. These developments place Nuvoco on track to achieve total cement capacity of approximately 35 MMTPA. The company reported total income of Rs 11,362 crore in FY 2025-26, reflecting its continuing growth trajectory.

Nuvoco operates a diversified portfolio across three segments: Cement, Ready-Mix Concrete and Modern Building Materials. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem, covering Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. Its pan-India RMX business provides value-added products under Concreto for performance concrete, Artiste for decorative concrete, InstaMix for ready-to-use bagged concrete, X-Con covering M20 to M60 grades, and Ecodure for specialised green concrete. Nuvoco has supplied materials to projects including the Mumbai-Ahmedabad Bullet Train, Birsa Munda Hockey Stadium in Rourkela, Aquatic Gallery at Science City in Ahmedabad, and metro railway projects in Delhi, Jaipur, Noida and Mumbai.