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The Great Differentiator

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Branding is a strategic lever driving trust, preference and profitability in a highly competitive, commodity-driven market. By blending regional relevance, digital innovation and the art of storytelling, cement brands are transforming product parity into emotional and reputational differentiation.

In a price-sensitive market like India, cement has traditionally been viewed as a commodity—chosen more for availability and cost than for emotional appeal or consumer perception. However, this perception is rapidly shifting. India’s cement industry, which recorded over 3,755 million tonnes of production in FY23 and demonstrated a staggering 65 per cent CAGR between 2016 and 2022, is now embracing branding not just as an added value, but as a core business strategy. Especially in Tier-2 and Tier-3 towns, where numerous brands vie for attention, companies are investing heavily in building visibility and loyalty to stand out in an otherwise homogenous product landscape.
A well-established brand in cement signifies more than product availability—it conveys trust, performance consistency and service dependability. For contractors, masons and even individual home builders, a trusted brand name helps mitigate the perceived risk of using poor-quality material. With limited access to third-party testing and technical evaluation, stakeholders often rely on branding as a proxy for quality. Through our industry interaction on this subject, we at Indian Cement Review strongly believe that an effective branding strategy can be both the differentiating and deciding factor. In a sector where technical specs across brands may seem similar, perception can be a game changer.
Furthermore, as India’s infrastructure and housing needs accelerate, the stakes have grown higher. Government-led initiatives such as the PM Awas Yojana, Smart Cities Mission, and increased capex in highways and railways have raised demand for fast, reliable construction. Brands that promise durability, consistency and after-sales support gain an edge, particularly with institutional buyers and project developers. This reliability often allows manufacturers to command a pricing premium, turning branding into a profitability lever—not just a marketing expense.
Ultimately, branding elevates cement from a low-engagement commodity to a strategic, experience-driven product. In a scenario where physical differentiation is limited, emotional and reputational moats—such as legacy, trust, and service quality—become key drivers of growth. Companies that position themselves as partners in construction, not just suppliers, will be best poised to influence long-term customer loyalty and market leadership. Branding, therefore, is not just about logos or slogans—it is a strategic imperative that transforms business outcomes in India’s high-stakes cement sector.

Tactics that transform branding
Cement branding in India has undergone a radical evolution—from static billboards and rural hoardings to dynamic, omnichannel strategies rooted in data, emotion, and digital intelligence.
In an interview, Meghna Mittal, Co-Founder and CRO of Hoopr, shared that music holds a unique power to tell stories that people don’t just hear but truly feel. She explained that with UltraTech Cement, the goal was not just to create a song but to give a voice to millions of Indians who leave their hometowns to earn a living while holding onto the dream of building their own home—reclaiming their identity in the place they come from. According to her,‘Ek Ghar Banaunga’ represents their journey and emotion, with every lyric and melody crafted to evoke feelings of nostalgia, belonging, and the unbreakable connection to one’s roots.
Mittal added that the team leveraged deep audience insights to ensure the composition resonated with regional cultures and emotional nuances. She emphasized that the song is not just a brand asset but an anthem for every home builder—a tribute to those who, regardless of where life takes them, strive to build a home of their own.
And a sense of familiarity continue to drive impact—especially among contractors, dealers and masons who form the backbone of cement distribution and recommendation.
Sushrut Pant, Head – Marketing, Shree Cement, says, “Our approach blends emotional storytelling with functional delivery. Campaigns like ‘Solid Ghar Sirf Bangur’ tap into the pride and aspirations of Individual Home Builders (IHBs), helping them connect with the idea of building something enduring. Similarly, during the general elections, we launched ‘Vote Solid, Desh Solid,’ which drew a parallel between responsible voting and choosing a solid cement brand resulting in over 17 lakh pledges through an interactive digital experience. At the same time, strategic branding has helped build emotional equity with contractors, engineers, dealers and masons encouraging preference beyond price.
Regional outreach, omni-channel engagement, and purposeful brand activations have improved visibility, driving conversion and long-term loyalty. This shift from transactional buying to brand-led preference is also validated by the successful introduction of premium offerings like Bangur Magna, Bangur Marble and Bangur Roofon aligned with evolving customer needs and aspirations.”
Digital storytelling, meanwhile, is unlocking new audience segments—particularly urban millennials, architects, and independent homebuilders. JK Cement has embraced this trend with its campaigns #YehPuccaHai and #AndarSeSundar, promoting the idea that building materials are not just structural but emotional investments. Using platforms like LinkedIn, Instagram, and Facebook, the brand weaves a narrative that links quality with personal values—such as commitment, inner beauty, and lasting legacy. These content strategies aim to shift cement from a transactional good to a value-laden choice, increasing emotional attachment and long-term preference.
Sanchit Dua, Founder and Principal Strategist, WeGress Media says, “Even in a specification-driven category like cement, decision-makers now start their journey online. High-impact digital campaigns can therefore position the brand long before the purchase order is raised. I focus on three levers: (a) Account-based targeting on LinkedIn, programmatic B2B networks and trade-specific WhatsApp lists to reach architects, structural consultants and project engineers with technical proof points; (b) Storytelling around reliability and sustainability, delivered via short-form video, interactive 3-D site walk-throughs and AR demos that let engineers “see” performance in simulated conditions; and (c) Community-building—hosting webinars, CPD credits and job-site masterclasses that turn the brand into a knowledge partner, not just a supplier. When these touch-points are orchestrated through a unified data layer (CRM + pixel data), every digital interaction steadily increases familiarity, favourability and, most importantly, inclusion in tender specs and BOQs.”
“Content is now the credibility engine. In India, 70 per cent+ of construction professionals research materials online before short-listing vendors, so authoritative content closes the trust gap faster than any sales pitch. Effective cement brands publish: (1) Technical deep dives—mix-design guides, IS code explainers, durability case studies; (2) Localised, vernacular storytelling—site-visit reels in Hindi, Tamil, Kannada, etc., showing real outcomes for local climate conditions; and (3) Thought-leadership on green construction—LC3 blends, clinker-factor reduction, ESG scorecards. Pairing this with micro-influencers such as civil-engineering professors or respected contractors turns the brand into a peer-endorsed authority. The result: higher perceived competence, reduced perceived risk and a smoother path from curiosity to consideration to advocacy”, he adds.
Finally, sustainability has become a powerful branding lever. In a sector known for high CO2 emissions, brands that openly commit to green practices are gaining credibility and consumer goodwill. Campaigns that highlight investments in alternative fuels (AFR), waste heat recovery, and low-carbon cement production do more than signal compliance—they build reputation. As decarbonisation becomes central to global construction conversations,
cement companies that lead the narrative will not only earn customer trust but also align with ESG-conscious investors, builders, and government stakeholders. In today’s cement branding, being environmentally responsible is not just ethical—it’s strategically essential.

Regional vs national branding
India is not one cement market—it is many. Each region, from the limestone-rich corridors of Rajasthan and Andhra Pradesh to the Northeast’s hilly terrain, presents unique cultural, linguistic, and infrastructural contexts. This diversity demands that branding strategies evolve from a one-size-fits-all model to a regionally nuanced approach that resonates locally while reinforcing national brand identity.
“Trust is a cornerstone of our brand strategy. Recognising its importance, we have revisited and redefined our mission statement which reads: ‘Trusted Building Materials Company Creating Value for our Stakeholders.’ This wasn’t just a cosmetic change, it was a conscious, strategic decision that reflects our intent to be recognised not merely for the scale of our operations, but as a trusted brand that delivers lasting value to our most important stakeholder—our customer. By placing customer centricity at the centre of our approach, we aim to understand evolving needs, respond with agility and ultimately create experiences that drive customer delight, reinforcing trust at every touchpoint” says Chirag Shah, Head – Marketing, Nuvoco Vistas.
National brands like UltraTech, Shree Cement and ACC have invested in creating umbrella brand identities that project strength, scale, and trust. But they are also acutely aware that local adaptation is critical for resonance. Language is a key lever—campaigns in South India often feature regional celebrities and vernacular scripts, while in Gujarat and Rajasthan, brands draw on visual symbolism and local idioms. Even product packaging may vary subtly to reflect market-specific certifications, batch codes, or slogans that carry regional emotional weight.
Regional brands such as Dalmia Cement, Penna Cement, and Star Cement have used their geographical roots to their advantage. Their branding emphasises regional pride, accessibility, and cultural alignment—projecting themselves as ‘closer to the people’ and ‘partners in local progress.’ These companies are often more agile in sponsoring local festivals,
sports teams, and community infrastructure—embedding their presence not just on the shelves, but in the social fabric. For example, Star Cement’s deep involvement in the Northeast has made it the go-to brand in a logistically challenging yet high-potential market.
The future of cement branding lies in balancing brand consistency with local sensitivity. This could mean deploying hyper-targeted mobile ads in rural Bihar, influencer-driven digital campaigns in Tamil Nadu, and grassroots activations during harvest seasons in Madhya Pradesh. In a country with over 20 official languages and hundreds of dialects, regional nuance is not a creative luxury—it is a branding imperative. Winning the hearts of India’s diverse construction ecosystem requires brands to speak not just in their voice, but in the voices of the markets they serve.

Tangible and intangible ROI
In the Indian cement sector, effective branding delivers a powerful combination of tangible business benefits and intangible competitive advantages. Brands like UltraTech Cement have demonstrated how a well-executed strategy can significantly influence buyer perception and behaviour. The company’s ‘Mauka Ek’ campaign, for instance, resulted in a 62 per cent increase in endorsement share, 72 per cent surge in recall, and a noteworthy 44 per cent of homebuilders naming it their most trusted brand. These metrics highlight the direct correlation between strategic branding and measurable commercial success—where perception drives preference,and preference translates into market share and repeat business.
Arun Shukla, President and Director, JK Lakshmi Cement in an interview said, “Our new TVC aims to inspire the Indian youth to understand that a successful future starts with big dreams. Our overall campaign, ‘Soch Karo Buland,’ embodies our philosophy of building. aspirations and trust. Through this brand refresh, we aim to align with the evolving needs of our customers, combining innovation, sustainability, and delivering customer-centric solutions. As we move forward, we aim to build structures and contribute to creating enduring legacies.”
For both B2C consumers and institutional clients, branding serves as a proxy for quality and reliability—especially when the product category offers limited scope for visible differentiation. In such scenarios, emotional trust and professional credibility become deciding factors. Research shows that cement buyers, even in procurement-heavy institutional roles, often opt for brands they perceive as superior—even when technical specifications are comparable. This ‘perceived value’ allows strong brands to command premium pricing, thereby improving margins without necessarily increasing costs—a compelling case for sustained brand investment in a low-margin industry.
Love Raghav, AVP & Head of Branding, JK Cement, said that with their new brand identity and bold campaign #GameBadalDe, the company was breaking barriers and reshaping the narrative in the cement industry. He explained that Jasprit Bumrah’s story of perseverance aligned with JK Cement’s brand values and offered a fresh perspective on construction and growth. By featuring Bumrah as a symbol of transformation, the brand aimed to inspire game-changing stories across all walks of life.
Anusree V Yannam, Marketing Consultant, says, “When we think about influencer marketing, we often picture glamorous content creators or social media personalities driving purchase decisions. But in industries like cement- where the business is predominantly B2B – influencing looks and functions very differently. As an average consumer building a home or undertaking construction, I wouldn’t instinctively know which cement brand is best. Instead, I’d rely on someone more experienced- my contractor, builder, or even the local distributor- to guide me. That’s where the real influence lies. In the cement business, these allied professionals act as everyday influencers. They’re the ones who understand product performance, availability, pricing, and consistency. Their recommendations carry weight and directly shape consumer choices, even though they’re not on Instagram or YouTube talking about it.”
“This makes influencer marketing in the cement sector unique. The brand’s communication strategy must target this network of contractors, resellers, and distributors, not just as end-users but as crucial brand advocates. Unlike conventional influencer campaigns, this relies heavily on offline trust-building, relationship management, loyalty programs, on-ground activations, and training sessions. It’s about empowering these on-field influencers with the right knowledge and motivation to recommend your brand consistently. In short, in the world of cement, influence is built brick by brick- offline, through people who build trust every day,” she adds.
The dealer and distributor network forms the lifeline of cement sales in India, and branding plays a pivotal role in building this channel loyalty. UltraTech’s expansive network of 5,500 dealers and 30,000+ retailers, and Ambuja’s 50,000+ outlets, are not simply a result of distribution logistics—they are the outcome of strong brand pull. Dealers prefer associating with brands that move faster off the shelves, minimise returns, and carry the assurance of consistent quality. For them, a strong brand means better credit terms, faster turnover, and repeat demand—factors that reinforce long-term partnerships and increase market penetration.
Khushboo Mulani Founder and ShEO, Slay Media, says, “Branding is the antidote to commoditisation. Cement might physically be a uniform grey powder, but a strong brand identity can elevate it beyond a mere commodity. We’ve long sought to shun the pejorative tag of being a mere commodity by transforming cement into a differentiated brand. A trusted brand carries a promise of quality and consistency that sets it apart from generic alternatives. In a price-competitive market, branding helps build preference and loyalty.”
Intangibly, a strong brand acts as a shield during times of uncertainty or transformation. A prime example is ACC, which retained a positive brand image among stakeholders even during its merger with Holcim/Lafarge. Despite the organisational upheaval and changes in leadership, dealers and customers continued their association with the brand because it stood for reliability. This kind of brand equity—earned over years of consistent performance, trust-building, and emotional connection—proves invaluable when navigating market volatility or corporate restructuring. Ultimately, branding in cement is not just about advertising—it’s about building reputational capital that sustains through cycles.

The influencer chain
In India’s cement industry, purchase decisions are rarely made by the end-user alone. Instead, a complex web of influencers—dealers, site engineers, contractors, and masons—shapes brand preference at the grassroots level. These stakeholders are not just distributors or service providers; they are trusted advisors for homebuilders and project developers, especially in semi-urban and rural markets. As a result, branding strategies that overlook this intermediary chain risk missing the real decision-makers on the ground.
Dealers play a dual role: they are both business partners and brand evangelists. Cement manufacturers invest heavily in dealer development programs—offering volume-based incentives, credit support, and exclusive promotional schemes—to secure shelf space and loyalty. But financial incentives alone are not enough. What matters more is the brand’s pull in the market, which ensures faster turnover, fewer complaints, and repeat business. That’s why national players like UltraTech and Ambuja have structured loyalty platforms and dealer engagement apps that keep them constantly connected and aligned with the brand’s goals.
Masons and site contractors, meanwhile, serve as powerful micro-influencers. Their endorsement can tip decisions, especially in individual home building (IHB) segments, where technical knowledge is limited. Cement companies have begun offering training programmes, loyalty clubs, and on-site demos to educate and engage this vital audience. For example, Ambuja Cement’s ‘Ambuja Abhimaan’ and UltraTech’s ‘Samruddhi’ initiative reward masons with points, gear, and recognition, turning them into brand ambassadors who spread trust through word-of-mouth. Some brands have even gone a step further, linking these efforts to vocational upskilling and insurance support.
The cement industry is beginning to recognise that branding doesn’t stop at mass media. In fact, it starts where the bags are stocked and the walls are built—on-site, in real time. Influencer engagement programmes, built on consistent training, trust, and long-term relationship-building, are now an essential part of the branding playbook. The strength of a cement brand is only as solid as the trust it commands from those who work with it daily.
Discussing the impact of digital branding, Mulani states, “The digital revolution has reached every corner of India. With affordable smartphones and cheap data, even small-town contractors and individual home builders are on WhatsApp, Facebook and YouTube. During the pandemic, we noticed a spike in digital engagement from non-metro regions. Case in point is the JK Cement online campaign (#YehPuccaHai), which got great engagement, including 600+ user-generated videos from those audiences. That was an eye-opener – it proved that if content is relatable (local language, addressing local building challenges, etc.), people will actively participate online. We now use vernacular content marketing, Facebook groups for contractor communities, and YouTube tutorials on best construction practices to connect with our
B2B audience.”

Challenges in cement branding
Branding in the cement industry comes with a distinct set of challenges rooted in its inherently B2B nature and legacy of price-focused operations. Unlike consumer goods where emotional connection drives preference, cement transactions—especially in institutional and bulk markets—are dominated by considerations of price, delivery timelines and volume discounts. Internal stakeholders such as procurement officers, production engineers, and even dealers often focus on operational efficiency rather than brand storytelling. This creates friction when marketing teams attempt to introduce emotional or aspirational narratives, as the value of brand equity is not always immediately recognised in performance-led environments.
A further complication lies in the homogeneity of cement products. With standard types like OPC (Ordinary Portland Cement), PPC (Portland Pozzolana Cement), and PSC (Portland Slag Cement) dominating the market, technical differentiation is minimal and often invisible to the end-user. This makes it difficult for consumers to justify a premium purely on product attributes. As a result, the brand must go beyond specs and focus on perception—crafting compelling stories around quality assurance, sustainability commitments, customer service and reliability. In essence, branding becomes less about what the product is and more about what the brand represents.
However, this branding gap presents an immense opportunity—especially with the rise of digital platforms and the changing information consumption habits of even rural and semi-urban stakeholders. Mobile penetration in rural India enables campaigns through WhatsApp, YouTube shorts, and voice-activated bots, while AI-based targeting helps personalise brand messages. Technologies such as blockchain-based traceability, smart packaging, and digital warranty tracking are being explored to boost transparency and engagement. More significantly, sustainability branding—anchored in carbon reduction, waste heat recovery, use of alternative fuels, and green certifications—is gaining importance. It speaks to not just institutional stakeholders and regulators, but increasingly to environmentally-conscious consumers and developers.
Looking ahead, cement brands that successfully blend digital innovation, localised engagement and ESG narratives will redefine how cement is evaluated and chosen. The winners will be those who understand that in a product category where differentiation is thin, reputation is everything. A strong brand will not only move more bags—it will also command trust, influence purchase cycles, shape industry conversations, and contribute meaningfully to the sector’s Net Zero aspirations. Branding in cement, once a tactical tool, is fast becoming a strategic weapon for future-ready growth.

Conclusion
In what has long been viewed as a commodity-driven industry, branding in cement is emerging as a powerful catalyst for transformation. No longer confined to price wars or distribution strength alone, cement manufacturers are realising that emotional resonance, strategic storytelling, and stakeholder trust are the new currencies of market leadership. From rural murals to mobile dashboards, from dealer clubs to AI-powered campaigns, branding has evolved into a multi-layered discipline—rooted in insight, scaled by technology and shaped by regional nuance.
As demonstrated through leading campaigns by UltraTech, Ambuja and JK Cement, effective branding delivers measurable returns—enhancing recall, enabling pricing premiums, and creating pull through a loyal dealer and contractor ecosystem. It offers both short-term gains and long-term resilience, helping companies navigate market shifts, regulatory changes, and mergers without eroding brand equity. The intangible assets—trust, familiarity, and emotional connection—often become the most valuable differentiators in a market where product specifications are largely uniform.
As India’s construction and infrastructure growth story accelerates, cement brands must go beyond the bag and into the hearts of their stakeholders—contractors, architects, engineers and homebuilders alike. Because in a market built on str

– Kanika Mathurength, it is brand strength that will define the next decade of cement leadership.

Concrete

Refractory demands in our kiln have changed

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Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, points out why performance, predictability and life-cycle value now matter more than routine replacement in cement kilns.

As Indian cement plants push for higher throughput, increased alternative fuel usage and tighter shutdown cycles, refractory performance in kilns and pyro-processing systems is under growing pressure. In this interview, Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, shares how refractory demands have evolved on the ground and how smarter digital monitoring is improving kiln stability, uptime and clinker quality.

How have refractory demands changed in your kiln and pyro-processing line over the last five years?
Over the last five years, refractory demands in our kiln and pyro line have changed. Earlier, the focus was mostly on standard grades and routine shutdown-based replacement. But now, because of higher production loads, more alternative fuels and raw materials (AFR) usage and greater temperature variation, the expectation from refractory has increased.
In our own case, the current kiln refractory has already completed around 1.5 years, which itself shows how much more we now rely on materials that can handle thermal shock, alkali attack and coating fluctuations. We have moved towards more stable, high-performance linings so that we don’t have to enter the kiln frequently for repairs.
Overall, the shift has been from just ‘installation and run’ to selecting refractories that give longer life, better coating behaviour and more predictable performance under tougher operating conditions.

What are the biggest refractory challenges in the preheater, calciner and cooler zones?
• Preheater: Coating instability, chloride/sulphur cycles and brick erosion.
• Calciner: AFR firing, thermal shock and alkali infiltration.
• Cooler: Severe abrasion, red-river formation and mechanical stress on linings.
Overall, the biggest challenge is maintaining lining stability under highly variable operating conditions.

How do you evaluate and select refractory partners for long-term performance?
In real plant conditions, we don’t select a refractory partner just by looking at price. First, we see their past performance in similar kilns and whether their material has actually survived our operating conditions. We also check how strong their technical support is during shutdowns, because installation quality matters as much as the material itself.
Another key point is how quickly they respond during breakdowns or hot spots. A good partner should be available on short notice. We also look at their failure analysis capability, whether they can explain why a lining failed and suggest improvements.
On top of this, we review the life they delivered in the last few campaigns, their supply reliability and their willingness to offer plant-specific custom solutions instead of generic grades. Only a partner who supports us throughout the life cycle, which includes selection, installation, monitoring and post-failure analysis, fits our long-term requirement.

Can you share a recent example where better refractory selection improved uptime or clinker quality?
Recently, we upgraded to a high-abrasion basic brick at the kiln outlet. Earlier we had frequent chipping and coating loss. With the new lining, thermal stability improved and the coating became much more stable. As a result, our shutdown interval increased and clinker quality remained more consistent. It had a direct impact on our uptime.

How is increased AFR use affecting refractory behaviour?
Increased AFR use is definitely putting more stress on the refractory. The biggest issue we see daily is the rise in chlorine, alkalis and volatiles, which directly attack the lining, especially in the calciner and kiln inlet. AFR firing is also not as stable as conventional fuel, so we face frequent temperature fluctuations, which cause more thermal shock and small cracks in the lining.
Another real problem is coating instability. Some days the coating builds too fast, other days it suddenly drops, and both conditions impact refractory life. We also notice more dust circulation and buildup inside the calciner whenever the AFR mix changes, which again increases erosion.
Because of these practical issues, we have started relying more on alkali-resistant, low-porosity and better thermal shock–resistant materials to handle the additional stress coming from AFR.

What role does digital monitoring or thermal profiling play in your refractory strategy?
Digital tools like kiln shell scanners, IR imaging and thermal profiling help us detect weakening areas much earlier. This reduces unplanned shutdowns, helps identify hotspots accurately and allows us to replace only the critical sections. Overall, our maintenance has shifted from reactive to predictive, improving lining life significantly.

How do you balance cost, durability and installation speed during refractory shutdowns?
We focus on three points:
• Material quality that suits our thermal profile and chemistry.
• Installation speed, in fast turnarounds, we prefer monolithic.
• Life-cycle cost—the cheapest material is not the most economical. We look at durability, future downtime and total cost of ownership.
This balance ensures reliable performance without unnecessary expenditure.

What refractory or pyro-processing innovations could transform Indian cement operations?
Some promising developments include:
• High-performance, low-porosity and nano-bonded refractories
• Precast modular linings to drastically reduce shutdown time
• AI-driven kiln thermal analytics
• Advanced coating management solutions
• More AFR-compatible refractory mixes

These innovations can significantly improve kiln stability, efficiency and maintenance planning across the industry.

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Concrete

Digital supply chain visibility is critical

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MSR Kali Prasad, Chief Digital and Information Officer, Shree Cement, discusses how data, discipline and scale are turning Industry 4.0 into everyday business reality.

Over the past five years, digitalisation in Indian cement manufacturing has moved decisively beyond experimentation. Today, it is a strategic lever for cost control, operational resilience and sustainability. In this interview, MSR Kali Prasad, Chief Digital and Information Officer, Shree Cement, explains how integrated digital foundations, advanced analytics and real-time visibility are helping deliver measurable business outcomes.

How has digitalisation moved from pilot projects to core strategy in Indian cement manufacturing over the past five years?
Digitalisation in Indian cement has evolved from isolated pilot initiatives into a core business strategy because outcomes are now measurable, repeatable and scalable. The key shift has been the move away from standalone solutions toward an integrated digital foundation built on standardised processes, governed data and enterprise platforms that can be deployed consistently across plants and functions.
At Shree Cement, this transition has been very pragmatic. The early phase focused on visibility through dashboards, reporting, and digitisation of critical workflows. Over time, this has progressed into enterprise-level analytics and decision support across manufacturing and the supply chain,
with clear outcomes in cost optimisation, margin protection and revenue improvement through enhanced customer experience.
Equally important, digital is no longer the responsibility of a single function. It is embedded into day-to-day operations across planning, production, maintenance, despatch and customer servicing, supported by enterprise systems, Industrial Internet of Things (IIoT) data platforms, and a structured approach to change management.

Which digital interventions are delivering the highest ROI across mining, production and logistics today?
In a capital- and cost-intensive sector like cement, the highest returns come from digital interventions that directly reduce unit costs or unlock latent capacity without significant capex.
Supply chain and planning (advanced analytics): Tools for demand forecasting, S&OP, network optimisation and scheduling deliver strong returns by lowering logistics costs, improving service levels, and aligning production with demand in a fragmented and regionally diverse market.
Mining (fleet and productivity analytics): Data-led mine planning, fleet analytics, despatch discipline, and idle-time reduction improve fuel efficiency and equipment utilisation, generating meaningful savings in a cost-heavy operation.
Manufacturing (APC and process analytics): Advanced Process Control, mill optimisation, and variability reduction improve thermal and electrical efficiency, stabilise quality and reduce rework and unplanned stoppages.
Customer experience and revenue enablement (digital platforms): Dealer and retailer apps, order visibility and digitally enabled technical services improve ease of doing business and responsiveness. We are also empowering channel partners with transparent, real-time information on schemes, including eligibility, utilisation status and actionable recommendations, which improves channel satisfaction and market execution while supporting revenue growth.
Overall, while Artificial Intelligence (AI) and IIoT are powerful enablers, it is advanced analytics anchored in strong processes that typically delivers the fastest and most reliable ROI.

How is real-time data helping plants shift from reactive maintenance to predictive and prescriptive operations?
Real-time and near real-time data is driving a more proactive and disciplined maintenance culture, beginning with visibility and progressively moving toward prediction and prescription.
At Shree Cement, we have implemented a robust SAP Plant Maintenance framework to standardise maintenance workflows. This is complemented by IIoT-driven condition monitoring, ensuring consistent capture of equipment health indicators such as vibration, temperature, load, operating patterns and alarms.
Real-time visibility enables early detection of abnormal conditions, allowing teams to intervene before failures occur. As data quality improves and failure histories become structured, predictive models can anticipate likely failure modes and recommend timely interventions, improving MTBF and reducing downtime. Over time, these insights will evolve into prescriptive actions, including spares readiness, maintenance scheduling, and operating parameter adjustments, enabling reliability optimisation with minimal disruption.
A critical success factor is adoption. Predictive insights deliver value only when they are embedded into daily workflows, roles and accountability structures. Without this, they remain insights without action.

In a cost-sensitive market like India, how do cement companies balance digital investment with price competitiveness?
In India’s intensely competitive cement market, digital investments must be tightly linked to tangible business outcomes, particularly cost reduction, service improvement, and faster decision-making.
This balance is achieved by prioritising high-impact use cases such as planning efficiency, logistics optimisation, asset reliability, and process stability, all of which typically deliver quick payback. Equally important is building scalable and governed digital foundations that reduce the marginal cost of rolling out new use cases across plants.
Digitally enabled order management, live despatch visibility, and channel partner platforms also improve customer centricity while controlling cost-to-serve, allowing service levels to improve without proportionate increases in headcount or overheads.
In essence, the most effective digital investments do not add cost. They protect margins by reducing variability, improving planning accuracy, and strengthening execution discipline.

How is digitalisation enabling measurable reductions in energy consumption, emissions, and overall carbon footprint?
Digitalisation plays a pivotal role in improving energy efficiency, reducing emissions and lowering overall carbon intensity.
Real-time monitoring and analytics enable near real-time tracking of energy consumption and critical operating parameters, allowing inefficiencies to be identified quickly and corrective actions to be implemented. Centralised data consolidation across plants enables benchmarking, accelerates best-practice adoption, and drives consistent improvements in energy performance.
Improved asset reliability through predictive maintenance reduces unplanned downtime and process instability, directly lowering energy losses. Digital platforms also support more effective planning and control of renewable energy sources and waste heat recovery systems, reducing dependence on fossil fuels.
Most importantly, digitalisation enables sustainability progress to be tracked with greater accuracy and consistency, supporting long-term ESG commitments.

What role does digital supply chain visibility play in managing demand volatility and regional market dynamics in India?
Digital supply chain visibility is critical in India, where demand is highly regional, seasonality is pronounced, and logistics constraints can shift rapidly.
At Shree Cement, planning operates across multiple horizons. Annual planning focuses on capacity, network footprint and medium-term demand. Monthly S&OP aligns demand, production and logistics, while daily scheduling drives execution-level decisions on despatch, sourcing and prioritisation.
As digital maturity increases, this structure is being augmented by central command-and-control capabilities that manage exceptions such as plant constraints, demand spikes, route disruptions and order prioritisation. Planning is also shifting from aggregated averages to granular, cost-to-serve and exception-based decision-making, improving responsiveness, lowering logistics costs and strengthening service reliability.

How prepared is the current workforce for Industry 4.0, and what reskilling strategies are proving most effective?
Workforce preparedness for Industry 4.0 is improving, though the primary challenge lies in scaling capabilities consistently across diverse roles.
The most effective approach is to define capability requirements by role and tailor enablement accordingly. Senior leadership focuses on digital literacy for governance, investment prioritisation, and value tracking. Middle management is enabled to use analytics for execution discipline and adoption. Frontline sales and service teams benefit from
mobile-first tools and KPI-driven workflows, while shop-floor and plant teams focus on data-driven operations, APC usage, maintenance discipline, safety and quality routines.
Personalised, role-based learning paths, supported by on-ground champions and a clear articulation of practical benefits, drive adoption far more effectively than generic training programmes.

Which emerging digital technologies will fundamentally reshape cement manufacturing in the next decade?
AI and GenAI are expected to have the most significant impact, particularly when combined with connected operations and disciplined processes.
Key technologies likely to reshape the sector include GenAI and agentic AI for faster root-cause analysis, knowledge access, and standardisation of best practices; industrial foundation models that learn patterns across large sensor datasets; digital twins that allow simulation of process changes before implementation; and increasingly autonomous control systems that integrate sensors, AI, and APC to maintain stability with minimal manual intervention.
Over time, this will enable more centralised monitoring and management of plant operations, supported by strong processes, training and capability-building.

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Concrete

Redefining Efficiency with Digitalisation

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Professor Procyon Mukherjee discusses how as the cement industry accelerates its shift towards digitalisation, data-driven technologies are becoming the mainstay of sustainability and control across the value chain.

The cement industry, long perceived as traditional and resistant to change, is undergoing a profound transformation driven by digital technologies. As global infrastructure demand grows alongside increasing pressure to decarbonise and improve productivity, cement manufacturers are adopting data-centric tools to enhance performance across the value chain. Nowhere is this shift more impactful than in grinding, which is the energy-intensive final stage of cement production, and in the materials that make grinding more efficient: grinding media and grinding aids.

The imperative for digitalisation
Cement production accounts for roughly 7 per cent to 8 per cent of global CO2 emissions, largely due to the energy intensity of clinker production and grinding processes. Digital solutions, such as AI-driven process controls and digital twins, are helping plants improve stability, cut fuel use and reduce emissions while maintaining consistent product quality. In one deployment alongside ABB’s process controls at a Heidelberg plant in Czechia, AI tools cut fuel use by 4 per cent and emissions by 2 per cent, while also improving operational stability.
Digitalisation in cement manufacturing encompasses a suite of technologies, broadly termed as Industrial Internet of Things (IIoT), AI and machine learning, predictive analytics, cloud-based platforms, advanced process control and digital twins, each playing a role in optimising various stages of production from quarrying to despatch.

Grinding: The crucible of efficiency and cost
Of all the stages in cement production, grinding is among the most energy-intensive, historically consuming large amounts of electricity and representing a significant portion of plant operating costs. As a result, optimising grinding operations has become central to digital transformation strategies.
Modern digital systems are transforming grinding mills from mechanical workhorses into intelligent, interconnected assets. Sensors throughout the mill measure parameters such as mill load, vibration, mill speed, particle size distribution, and power consumption. This real-time data, fed into machine learning and advanced process control (APC) systems, can dynamically adjust operating conditions to maintain optimal throughput and energy usage.
For example, advanced grinding systems now predict inefficient conditions, such as impending mill overload, by continuously analysing acoustic and vibration signatures. The system can then proactively adjust clinker feed rates and grinding media distribution to sustain optimal conditions, reducing energy consumption and improving consistency.

Digital twins: Seeing grinding in the virtual world
One of the most transformative digital tools applied in cement grinding is the digital twin, which a real-time virtual replica of physical equipment and processes. By integrating sensor data and
process models, digital twins enable engineers to simulate process variations and run ‘what-if’
scenarios without disrupting actual production. These simulations support decisions on variables such as grinding media charge, mill speed and classifier settings, allowing optimisation of energy use and product fineness.
Digital twins have been used to optimise kilns and grinding circuits in plants worldwide, reducing unplanned downtime and allowing predictive maintenance to extend the life of expensive grinding assets.

Grinding media and grinding aids in a digital era
While digital technologies improve control and prediction, materials science innovations in grinding media and grinding aids have become equally crucial for achieving performance gains.
Grinding media, which comprise the balls or cylinders inside mills, directly influence the efficiency of clinker comminution. Traditionally composed of high-chrome cast iron or forged steel, grinding media account for nearly a quarter of global grinding media consumption by application, with efficiency improvements translating directly to lower energy intensity.
Recent advancements include ceramic and hybrid media that combine hardness and toughness to reduce wear and energy losses. For example, manufacturers such as Sanxin New Materials in China and Tosoh Corporation in Japan have developed sub-nano and zirconia media with exceptional wear resistance. Other innovations include smart media embedded with sensors to monitor wear, temperature, and impact forces in real time, enabling predictive maintenance and optimal media replacement scheduling. These digitally-enabled media solutions can increase grinding efficiency by as much as 15 per cent.
Complementing grinding media are grinding aids, which are chemical additives that improve mill throughput and reduce energy consumption by altering the surface properties of particles, trapping air, and preventing re-agglomeration. Technology leaders like SIKA AG and GCP Applied Technologies have invested in tailored grinding aids compatible with AI-driven dosing platforms that automatically adjust additive concentrations based on real-time mill conditions. Trials in South America reported throughput improvements nearing 19 per cent when integrating such digital assistive dosing with process control systems.
The integration of grinding media data and digital dosing of grinding aids moves the mill closer to a self-optimising system, where AI not only predicts media wear or energy losses but prescribes optimal interventions through automated dosing and operational adjustments.

Global case studies in digital adoption
Several cement companies around the world exemplify digital transformation in practice.
Heidelberg Materials has deployed digital twin technologies across global plants, achieving up to 15 per cent increases in production efficiency and 20 per cent reductions in energy consumption by leveraging real-time analytics and predictive algorithms.
Holcim’s Siggenthal plant in Switzerland piloted AI controllers that autonomously adjusted kiln operations, boosting throughput while reducing specific energy consumption and emissions.
Cemex, through its AI and predictive maintenance initiatives, improved kiln availability and reduced maintenance costs by predicting failures before they occurred. Global efforts also include AI process optimisation initiatives to reduce energy consumption and environmental impact.

Challenges and the road ahead
Despite these advances, digitalisation in cement grinding faces challenges. Legacy equipment may lack sensor readiness, requiring retrofits and edge-cloud connectivity upgrades. Data governance and integration across plants and systems remains a barrier for many mid-tier producers. Yet, digital transformation statistics show momentum: more than half of cement companies have implemented IoT sensors for equipment monitoring, and digital twin adoption is growing rapidly as part of broader Industry 4.0 strategies.
Furthermore, as digital systems mature, they increasingly support sustainability goals: reduced energy use, optimised media consumption and lower greenhouse gas emissions. By embedding intelligence into grinding circuits and material inputs like grinding aids, cement manufacturers can strike a balance between efficiency and environmental stewardship.
Conclusion
Digitalisation is not merely an add-on to cement manufacturing. It is reshaping the competitive and sustainability landscape of an industry often perceived as inertia-bound. With grinding representing a nexus of energy intensity and cost, digital technologies from sensor networks and predictive analytics to digital twins offer new levers of control. When paired with innovations in grinding media and grinding aids, particularly those with embedded digital capabilities, plants can achieve unprecedented gains in efficiency, predictability and performance.
For global cement producers aiming to reduce costs and carbon footprints simultaneously, the future belongs to those who harness digital intelligence not just to monitor operations, but to optimise and evolve them continuously.

About the author:
Professor Procyon Mukherjee, ex-CPO Lafarge-Holcim India, ex-President Hindalco, ex-VP Supply Chain Novelis Europe,
has been an industry leader in logistics, procurement, operations and supply chain management. His career spans 38 years starting from Philips, Alcan Inc (Indian Aluminum Company), Hindalco, Novelis and Holcim. He authored the book, ‘The Search for Value in Supply Chains’. He serves now as Visiting Professor in SP Jain Global, SIOM and as the Adjunct Professor at SBUP. He advises leading Global Firms including Consulting firms on SCM and Industrial Leadership and is a subject matter expert in aluminum and cement. An Alumnus of IIM Calcutta and Jadavpur University, he has completed the LH Senior Leadership Programme at IVEY Academy at Western University, Canada.

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