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Digital technologies are transforming safety

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Raju Ramchandran, SVP and Head Manufacturing – Eastern Region, Nuvoco Vistas, on how the company is setting new benchmarks in industrial safety and operational resilience, with smart technologies and a proactive approach.

In the high-risk environment of cement manufacturing, safety is more than a compliance requirement—it is a strategic imperative. Raju Ramchandran, SVP and Head – Manufacturing, Eastern Region, Nuvoco Vistas, shares how the company is redefining workplace safety through technology, accountability and next-generation systems. In this in-depth conversation, he outlines the evolving risks, robust safety frameworks and the future of digital-first safety culture.

How has the approach to safety evolved in cement manufacturing over the past decade?
Over the past decade, safety in cement manufacturing has evolved from being a regulatory checkbox to becoming an intrinsic part of organisational culture. At Nuvoco, safety is not just a priority, it is a core value, deeply woven into the way we operate every single day. Guided by our ‘Zero Harm’ philosophy, we strive to ensure that every individual stepping into our premises returns home safely.
We have moved towards a more proactive and preventive approach and building strong behavioural safety practices. Specialised training programmes, regular incident reviews and active Safety Committee engagements have strengthened accountability and vigilance across all units. Initiatives such as Cross-Unit Safety Audits, improved workplace hygiene standards, and the successful rollout of the ‘Safety Buddy’ programme reflect our emphasis on collaboration and shared responsibility for safety.
Additionally, best-in-class measures from mandatory safety nets and harnesses to advanced risk assessments for high-hazard tasks are now standard practice across our sites. Supported by leadership commitment, digital monitoring tools and real-time feedback mechanisms, these efforts have transformed safety from a procedural obligation into a shared mindset.
At Nuvoco, safety is a non-negotiable tenet—it is a way of life, and we are constantly raising the bar to protect every member of our workforce.

What are biggest safety risks unique to cements plant today?
Cement manufacturing is an intense, high-temperature and operation-heavy process, where safety is paramount at every stage. The environment presents several unique risks that require constant vigilance and robust preventive measures.
Mining operations within the industry bring their own set of hazards, with strict adherence to Directorate General of Mines Safety (DGMS) guidelines being essential. Exposure to dust is another area of concern, necessitating advanced dust suppression systems and protective equipment to safeguard workers’ health.
Electrical safety and proper energy isolation are also crucial, given the complexity of the equipment involved. Confined space entries, conveyor belt operations and machine guarding present additional risks that call for specialised procedures and continuous monitoring to prevent accidents. Preheaters and precalciners also pose challenges during maintenance activities, such as cleaning cyclone jams, while fire hazards remain present in areas with flammable materials. Additionally, working at heights continues to be one of the major risk activities, making stringent fall protection protocols a non-negotiable.
At Nuvoco, we tackle these risks with a layered approach combining engineering controls, digital monitoring and rigorous safety protocols backed by continuous training and regular mock drills to ensure preparedness for any eventuality. Safety is an unwavering commitment to safeguarding everyone who works in and around our plants.

What role does technology play in enhancing plant safety?
Digital technologies are transforming safety management in cement manufacturing, enabling a shift from reactive measures to a predictive and preventive approach. At Nuvoco, we leverage cutting-edge tools and systems to minimise risk, strengthen hazard management and create safer workplaces for everyone.
Our advanced energy isolation systems such as Lock Out, Tag Out, Try Out (LOTOTO) processes are in place to safeguard electrical operations, while machines are fitted with Visual Cutoff Switches (VCS) for enhanced local control. GPS and Vehicle Tracking Systems (VTS) ensure the safe movement of commuting vehicles across sites.
Real-time monitoring through IoT sensors allows us to track critical parameters like, temperature fluctuations, harmful gases in coal mills and machinery vibrations. These early alerts help prevent potential fires, explosions, and equipment failures. To limit human exposure to hazardous environments, drones are used for inspecting kilns, chimneys and high structures during shutdowns, while robots perform cleaning tasks in preheaters and confined spaces, keeping people out of high-risk areas.
We have also introduced devices such as gas detectors and real-time location trackers that enables faster emergency responses.
Complementing these efforts, our STARS (SHE [Safety, Health & Environment], Tracking, Analysis and Reporting System) software ensures comprehensive tracking of leading and lagging indicators, while mobile apps enable instant reporting of near misses, safety observations and audits. These tools ensure quick corrective actions and strengthen our safety culture across all operations.
By embedding technology into every layer of safety management, Nuvoco has built a digitally enabled, proactive safety framework—one that not only mitigates risks but empowers employees to work confidently, knowing their well-being is protected at every step.

How do you ensure contractor and third-party compliance with your safety standards?
Ensuring contractor and third-party compliance with safety standards in the building material industry involves a comprehensive process that spans prequalification, onboarding, active supervision and post-contract evaluation. It begins at the selection stage, where contractors are assessed not only for their technical competence but also for their safety track record, relevant certifications, availability of personal protective equipment, and the preparedness of their personnel. These expectations are formalised through contractual agreements that clearly outline health and safety responsibilities, legal obligations and consequences in case of non-compliance.
Prior to starting work, contractors undergo mandatory onboarding and training, which cover site-specific hazards, protocols and emergency procedures often communicated in local languages to ensure clarity. For high-risk activities such as hot work, working at heights or confined space entry, a permit-to-work system is in place, supported by detailed risk assessments jointly signed by contractor representatives and plant personnel to reinforce
shared accountability.
During execution, trained supervisors are deployed to monitor compliance on the ground through daily toolbox talks, spot checks and documented audits. Safety performance is closely tracked using both leading and lagging indicators, such as participation in safety initiatives, near-miss and injury reporting. In the event of repeated violations, appropriate enforcement actions are taken, ranging from temporary work stoppage and financial penalties to permanent disqualification while contractors demonstrating consistent adherence are recognised through structured reward and recognition programmes.
Towards the end of the contract period, each contractor’s safety performance is formally reviewed, with the insights feeding into future selection processes. This continuous cycle of evaluation and improvement ensures that safety expectations remain consistent across all stakeholders working within the plant environment.

How are you investing in next-generation safety equipment or systems?
We are investing in next-generation safety systems that not only reduce risks but also transform the way hazards are detected, monitored and controlled across our operations.
We have invested in IoT-enabled sensors provide real-time insights into high temperatures, carbon monoxide levels in coal mills, oxygen levels in pyro processes, and vibrations in heavy machinery, while flame detection via CCTV ensures early alerts for potential fire incidents.
Robotic descalers are used for refractory de-bricking inside preheaters, while drone surveillance is deployed to inspect tall structures such as stacks and silos. This helps identify structural hazards, material build-up and assess the condition of coatings in silos and preheater cyclones. These technologies significantly reduce human exposure to high-risk areas while improving inspection accuracy and efficiency.
Furthermore, we have strengthened fire and explosion protection with advanced suppression systems in coal mills and dust collectors, supported by thermal imaging, we are also exploring the use of AI-enabled cameras for instant detection and response. In hauling operations, driver fatigue detection cameras provide real-time alerts to prevent accidents, while environmental safety is reinforced through live dust monitoring systems with alarms and visual displays at plant gates for corrective action. By embracing these next-generation technologies, we are building a safer, smarter and sustainable world.

Concrete

Cement Margins Seen Rising 12–18 per cent in FY26

Healthy demand and GST cut to boost cement profits per tonne.

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Cement companies’ operating profit for fiscal year 2026 (FY26) is projected to grow by 12–18 per cent, reaching Rs 900–950 per metric tonne (MT), supported by robust demand, improved realisations, and stable input costs, according to ratings agency Icra.
In FY25, operating profit before interest, depreciation, tax and amortisation (OPBIDTA) stood at Rs 806 per MT, declining 16 per cent year-on-year due to weak realisations amid an extended monsoon and subdued government capital expenditure during the general elections.
Icra’s sample covers ACC, Ambuja Cements, JK Cements, JK Lakshmi Cement, The Ramco Cements, UltraTech Cement, Dalmia Bharat, Birla Corporation, Shree Cement, Sagar Cements, and Heidelberg Cement India, which together account for 74 per cent of industry capacity.
The recent GST cut on cement is expected to lower rural housing construction costs by 0.8–1.0 per cent, boosting volumes and supporting additional capacity. Average cement realisations are expected to rise 3–5 per cent in FY26.
Cement volumes increased by 8.5 per cent in the first five months of FY26, driven by strong demand from housing and infrastructure projects, despite early monsoons in some regions. During this period, cement prices rose 7.4 per cent year-on-year, particularly in northern and eastern markets. Input costs, especially for pet coke and freight, remain sensitive to global crude price movements and geopolitical factors.
Anupama Reddy, vice-president and co-group head of corporate ratings at Icra, said: “With the GST rate cut from 28 per cent to 18 per cent expected to be passed on to consumers, the average retail price of cement, currently Rs 350–360 per bag, will offer savings of Rs 26–28 per bag. Driven by strong demand, capacity additions may rise to 41–43 million metric tonnes per annum (MMTPA) in FY26 from 31 MMTPA in FY25, with the eastern region leading the growth in grinding capacity.”

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Adani’s Strategic Emergence in India’s Cement Landscape

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

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

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

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

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

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

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

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

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

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

Challenges potentially include:

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

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

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

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

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Concrete

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

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

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

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