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.