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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

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

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