Concrete
Reshaping the Competitive Landscape
Published
2 months agoon
By
Roshna
Adani’s consolidation of its cement businesses marks a major shift in the Indian cement landscape, challenging industry leaders and reshaping competitive dynamics. ICR explores how this move could redefine market strategy, scale, and efficiency—read the full story to uncover the implications.
The Indian cement industry is currently witnessing a wave of consolidation and capacity expansion. UltraTech Cement, part of the Aditya Birla Group, remains the market leader with a capacity of around 135 MTPA. It continues to expand aggressively with a target to reach 200 MTPA in the coming years. UltraTech has recently acquired smaller regional players and is investing in green energy and digital transformation to cement its leadership.
Shree Cement, Dalmia Bharat, JSW Cement, and India Cements are also expanding capacities and investing in sustainability-led innovations. Shree Cement, with over 50 MTPA, is focused on cost-efficiency and clinker optimisation. Dalmia Bharat is rapidly expanding in the eastern and southern markets and has pledged to become carbon-negative by 2040. JSW Cement is banking on eco-friendly cement and targeting capacity additions in western and southern India.
Himanshu Ghawri, Partner, PwC India, says, “Mergers in the cement industry offer substantial opportunities to streamline compliance processes and cut operational overheads by unifying and optimising key functions. By bringing related entities—particularly those operating under contract manufacturing or tolling arrangements—under one roof, companies can consolidate environmental clearances, tax filings, statutory licenses, and other regulatory submissions, thereby reducing the number of filings and administrative complexity. A single corporate structure enables the standardisation of quality management systems across plants and simplifies the process of obtaining and renewing government approvals for product standards, environmental norms, and industrial operations.”
“Consolidation also eliminates redundant processes in procurement, finance, HR, legal, and administration, replacing them with shared services and centralised decision-making to boost agility and lower fixed costs. Economies of scale further improve cost efficiency, as fixed overheads such as compliance staff, legal advisors, and auditors are spread across a larger operational base, while procurement and logistics benefit from bulk efficiencies. Moreover, capital-intensive projects like Waste Heat Recovery Systems (WHRS), IT infrastructure, mining leases, or advanced digital technologies such as AI can be deployed more cost-effectively across a consolidated entity, reducing per-tonne investment costs and enhancing returns on capital” he adds.
The competitive intensity is further magnified by the entry of global players and private equity investments. Companies like HeidelbergCement and Holcim (prior to its exit) brought international best practices to India. Now, Adani’s aggressive consolidation places it in direct contention
with UltraTech—not just in terms of scale, but also influence across procurement, project bidding, and price negotiations.
Cementing a Giant
In a strategic move that is set to reshape the contours of the Indian cement industry, the Adani Group has initiated a sweeping consolidation of its cement operations under a single umbrella. By bringing together Ambuja Cements, ACC, Sanghi Industries, Penna Cement, and Orient Cement under what could be branded as “Adani Cement,” the group aims to unify operations, streamline compliance, and leverage economies of scale. With a combined capacity already crossing 100 million tonnes per annum (MTPA) and ambitious plans to reach 140 MTPA by FY2028, Adani is positioning itself not just as a dominant domestic player, but as a global cement powerhouse.
The National Company Law Tribunal (NCLT) recently approved the merger of Adani Cementation with Ambuja Cements, reinforcing the conglomerate’s “One Business, One Company” vision. The consolidation is more than just a financial maneuver—it reflects a broader industry trend of vertical integration, operational synergy, and market consolidation. As India continues its infrastructure expansion, the race for cement dominance has never been more intense.
Strategic Rationale Behind the Move
Adani’s cement consolidation is designed to streamline multiple brands and capacities into a single, efficient entity. Merging entities like Penna Cement and Sanghi Industries into Ambuja Cements is expected to simplify the organisational structure and reduce administrative overhead. The move
also aligns with Adani’s infrastructure-first vision, enabling a more cohesive supply chain and centralised decision-making.
Moreover, the consolidation is expected to unlock significant cost synergies, especially in logistics and procurement. A single command structure allows for centralised negotiation with vendors, optimised freight movement, and integrated distribution networks. In a sector where logistics can constitute up to 30 per cent of total production costs, such optimisation can significantly improve margins.
Another advantage lies in brand unification. While Ambuja and ACC are legacy names, integrating regional players like Penna and Sanghi under one corporate roof allows Adani to target specific geographies more effectively while still presenting a consolidated brand identity to institutional clients and government buyers.
According to Milind Khangan, Marketing Head, Vertex Market Research, “The Adani Group is carrying out a comprehensive reorganisation of its cement business under its ‘One Business, One Company’ strategy, aimed at integrating its diverse holdings into a single corporate entity named Adani Cement. The consolidation process began in September 2022 with the $6.4?billion acquisition of Holcim’s majority stakes in Ambuja Cements and ACC, positioning Ambuja as the focal point for integration. This was followed by the purchase of Sanghi Industries in December 2023 to strengthen its presence in western India, the acquisition of Penna Cement in August 2024 to expand in the southern market, and in April 2025, an increase in its stake in Orient Cement to 46.66 per cent, making Adani the promoter with control. On 18?July?2025, the National Company Law Tribunal sanctioned the amalgamation of Ambuja Cements with Adani Cement, effective 1?April?2024, bringing limestone reserves and new assets into Ambuja. The group has board approvals to merge Sanghi and Penna into Ambuja by the end of 2025 and is considering integrating ACC as the final step, with Orient Cement set to serve as a principal manufacturing facility post-merger.”
In FY?2025, Adani Cement, including Ambuja, crossed 100?MTPA capacity, ranking among the world’s top ten cement producers and becoming India’s second-largest after UltraTech. The group reported sales of 65?million metric tonnes in FY?2025, claiming to supply nearly 30 per cent of cement used in Indian homes and infrastructure. With a current market share of around 14 to 15 per cent, Adani aims to reach 20 per cent by FY?2028, supported by aggressive brownfield expansions targeting 118?MTPA by FY?2026 and 140?MTPA by FY?2028.
Implications for the Indian
Cement Landscape
The implications of Adani’s consolidation ripple across the value chain. For competitors, this move sets a new benchmark for operational integration and capital efficiency. Smaller and mid-sized players may now face greater pressure to either scale up or align with larger entities to survive.
From a market standpoint, this consolidation may lead to regional duopolies or oligopolies, particularly in high-growth zones like Gujarat, Maharashtra, and Andhra Pradesh. This could improve price stability and supply chain coordination but may also attract regulatory scrutiny concerning market dominance. For suppliers and contractors, the emergence of mega-entities like Adani Cement means larger, more standardised procurement processes and tighter contract terms. Meanwhile, customers—especially institutional buyers and infrastructure developers—could benefit from integrated logistics, consistent product quality, and assured supply.
“Consolidation in the Indian cement sector is expected to reshape the competitive landscape and pricing dynamics in both the short and long term. In the immediate aftermath of a merger, consolidated companies typically focus on improving capacity utilisation across their newly acquired or integrated assets. This drive to maximise production can lead to excess material entering the market, disrupting the supply-demand balance and triggering aggressive price-based promotions, discounts, and dealer incentives as competitors strive to protect market share. However, in the medium to long term, pricing generally stabilises as the market adjusts to the new structure, with a smaller number of dominant players adopting more rational pricing strategies and defending their core markets, resulting in healthier price realisation. Additionally, larger consolidated entities benefit from enhanced bargaining power with suppliers and channel partners, strengthening their ability to sustain prices and margins even in competitive environments” says Pallab Dutta, Partner, PwC India.
This level of integration could set the stage for more digitisation in plant operations, predictive maintenance, and ESG compliance—all areas where Adani has already shown interest through other verticals like energy and logistics.
Conclusion
Adani’s move to bring all its cement businesses under one roof is not just a business consolidation—it’s a strategic statement. It signals a new era where scale, speed, and synergy are central to market leadership. As India’s infrastructure and housing sectors grow, the cement industry will continue to be a bellwether for broader economic trends.
This consolidation also raises the stakes for existing players, pushing them to invest more aggressively in innovation, sustainability, and digital infrastructure. With UltraTech, Shree, Dalmia, and JSW all racing to expand, the Indian cement landscape is set for a phase of intense, high-stakes competition. Whether this leads to long-term price rationalisation or increased market control remains to be seen—but one thing is clear: the cement war is heating up, and Adani has just raised the bar.

Concrete
The primary high-power applications are fans and mills
Published
1 day agoon
October 10, 2025By
admin
Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.
As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.
How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.
What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.
Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.
Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.
How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.
What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.

Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.
In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.
How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.
What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.
What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.
What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.
How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.
What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.
Concrete
Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport
The airport is set to become Asia’s largest air connectivity hub.
Published
1 day agoon
October 10, 2025By
admin
Enlight Metals has supplied 3,200 metric tonne of steel for the newly inaugurated Navi Mumbai International Airport, marking a major contribution to one of India’s largest infrastructure projects and reinforcing the company’s commitment to supporting national development.
The Navi Mumbai International Airport, developed under a Public-Private Partnership led by the Adani Group, was inaugurated today by Prime Minister Narendra Modi. The airport is set to become Asia’s largest air connectivity hub, enhancing regional connectivity, boosting economic growth, and expanding trade opportunities. Prime Minister Modi described the project as a “glimpse of Viksit Bharat,” highlighting its transformative impact on infrastructure and development in the region.
“The supply of 3,200 metric tonne of steel for this key project aligns with our focus on supporting critical infrastructure development through reliable and timely metal sourcing. Enlight Metals is committed to enhancing transparency and efficiency in the steel supply chain, contributing to projects integral to India’s growth objectives,” said Vedant Goel, Director, Enlight Metals.
Enlight Metals has implemented technology-driven solutions to strengthen supply chain efficiency, ensuring consistent availability of construction materials for large-scale projects nationwide. Its contribution to the Navi Mumbai International Airport underscores the company’s growing role in supporting India’s infrastructure development initiatives.
This milestone reflects Enlight Metals’ ongoing engagement in delivering quality materials and timely services for major national projects, further cementing its position as a reliable partner in India’s infrastructure sector

The primary high-power applications are fans and mills

We conduct regular internal energy audits

Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport

World of Concrete India 2025 Showcases Global Expertise and Green Solutions

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The primary high-power applications are fans and mills

We conduct regular internal energy audits

Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport

World of Concrete India 2025 Showcases Global Expertise and Green Solutions

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