Concrete
Automation Builds Industry 4.0
Published
11 months agoon
By
admin
Automation is the propellent behind the transformation of the cement sector. From robotic arms to smart sensors, advanced technology is redefining how cement is manufactured, stored and distributed. ICR delves into the innovations that are taking cement manufacturing towards a Net Zero future.
The cement industry, long perceived as conservative and process-heavy, is undergoing a significant transformation. As the world builds more while aiming to emit less, automation has emerged as the backbone of modern cement manufacturing. The Indian cement industry is at the forefront of the green initiatives, with precision, speed and sustainable practices combined into a driving force. Today automation isn’t just a matter of convenience; it’s a competitive imperative.
Cement production is notoriously energy-intensive, responsible for about 8 per cent of global CO2 emissions. With net-zero goals looming and ESG expectations rising, manufacturers are under immense pressure to reduce their carbon footprint. Here, automation plays a crucial role. From optimising kiln operations using artificial intelligence (AI)-powered control systems to deploying digital twins that simulate and improve plant performance, there are a plethora of innovations that are proving instrumental for this sector. Companies such as Holcim and UltraTech have started using predictive maintenance systems that cut downtime by up to 30 per cent and reduce emissions by optimising fuel use, as per a report by McKinsey.
According to ICRA, India’s cement industry is expected to reach 480–485 million tonnes per annum (MTPA) capacity by 2026, with a projected growth of 6-7 per cent year-on-year. Manual interventions can no longer support this scale. Real-time data analytics, automated quality checks and autonomous vehicle systems for material handling are becoming standard practice in next-gen plants.
As per a report by PricewaterhouseCoopers (PwC) titled ‘Decoding the Fifth Industrial Revolution: Marching towards a resilient, sustainable and human-centric future (2024),’ executives from the cement sector believe that their industry would see the most significant gains from the adoption of Industry 5.0, with potential revenue expansion exceeding 7 per cent. More than 95 per cent of respondents in the cement and industrial goods sectors are prioritising investments in real-time inventory tracking to optimise inventory levels, reduce stockouts, and minimise excess inventory this year and next
From smart sensors in rotary kilns to robotic arms in bagging units, automation is redefining cement’s industrial DNA. But are Indian players ready to scale up digitally? How can automation integrate with alternative fuels and low-clinker cements? These are questions worth exploring as the cement sector prepares for its most intelligent decade yet.
Key areas of automation
Automation in cement manufacturing spans a broad spectrum of functions—from raw material handling to final despatch. The most widely adopted systems include Distributed Control Systems (DCS), Programmable Logic Controllers (PLCs) and SCADA systems that control key equipment like kilns, mills and conveyors.
Modern plants now deploy autonomous vehicles for internal logistics, automated bagging lines for despatch and smart weighing systems that eliminate manual errors. Automated quality control labs have also become mainstream, ensuring that product specifications are met with precision and consistency.
Speaking about innovations in automation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, says, “At Nuvoco, we are strengthening our automation capabilities by adopting advanced technologies and digital solutions that optimise processes, boost operational efficiency and elevate customer experience. Our approach integrates structured innovation, robust quality management and a comprehensive digital transformation framework—enabling us to stay agile, competitive and sustainable in a dynamic marketplace.”
Adding his dynamic view about the latest development in automation, Dijam Panigrahi, Co-founder and COO, GridRaster, states, “One of the most significant advantages of integrating collaborative robots (cobots) in cement manufacturing is their ability to offload repetitive, dangerous or physically demanding tasks from human workers, such as bagging cement, loading trucks, or operating in dusty environments. This frees up the human workforce to concentrate on higher-value activities that demand critical thinking, problem-solving and creativity – uniquely human attributes that machines cannot replicate.”
“This integrated approach not only drives remarkable gains in productivity, flexibility and safety but also cultivates a truly synergistic relationship between cutting-edge technology and a skilled, adaptable human workforce,” he adds.
Juan Ortega, Cement Operational and Productive Optimisation Specialist and Team Leader, Independent Cement Consultants (ICC), comments, “The cement industry, historically cautious in adopting new technologies, now finds itself at a turning point. Automation is no longer a competitive advantage—it is a necessity. As global production scales up to meet urbanisation and infrastructure demands, operational efficiency, cost control and emissions reduction have become non-negotiable goals. We are witnessing a shift from basic SCADA and DCS systems toward advanced digital ecosystems: predictive maintenance powered by AI, real-time process optimisation using machine learning and Industrial Internet of Things (IIoT) networks that collect and analyse data across the entire plant.”
He further explains, “In cement kilns, advanced process control (APC) systems now autonomously adjust parameters like fuel feed, airflow and kiln speed based on real-time analytics. This improves heat rate, reduces thermal losses and stabilises clinker quality. In finish mills, AI-based models are optimising Blaine fineness and power draw, saving up to 5 kWh/tonne cement (see: ECRA Technical Report TR-128, 2023, Section 4.2.1).
India, the world’s second-largest cement producer with an installed capacity exceeding 600 MTPA, is at a crossroads. While many greenfield plants have begun integrating automation, the vast majority of existing facilities remain semi-automated or manually optimised. Bridging this digital divide is critical.”
These foundational technologies are now converging with advanced digital tools, making way for intelligent automation. This leads us to a deeper exploration of how AI, machine learning (ML) and digital twins are shaping this evolution.
AI, ML and Digital Twins
Powerful insights from plant data that were previously underutilised are now being put to good use. Predictive algorithms are used to forecast maintenance needs, identify energy inefficiencies and even fine-tune process parameters in real time. For example, ML-based kiln optimisation can reduce specific energy consumption and emissions while improving throughput.
Digital twin technology is gaining momentum, allowing operators to simulate plant processes before implementing them physically. These virtual replicas help forecast outcomes, reduce downtime and test scenarios without interrupting operations.
“The combination of AI, digital twins and cobots today represents a fundamental modernisation of the cement manufacturing landscape. AI provides the intelligence, digital twins offer the foresight and cobots provide the physical execution, all while workforce enablement technologies ensure that humans remain at the centre of innovation and decision-making in cement plants. This integrated approach promises a future where operations are more efficient, resilient and adaptive, ultimately leading to unprecedented levels of productivity and a more fulfilling work environment for all in the cement industry,” explains Panigrahi.
Tushar Kulkarni, Business Division Head – Solutions, Cement, Mining Minerals, Test Applications and Hydrogen, Innomotics India, elaborates, “The current advancement in electrical and automation technologies has enabled the system to achieve its peak performance for day-to-day activities far smoother than it was earlier. Also, Industry 4.0 has enabled automation systems to provide efficient and consistent data.
“With this advancement, AI-based systems have started receiving continuous meaningful data to perform many activities, which has allowed AI / ML models to predict outcomes accurately, thereby helping customers achieve their sustainability goals,” he adds.
“At RIPIK AI, we’re redefining automation in cement manufacturing through advanced computer vision and AI. Unlike traditional systems that rely on delayed manual interventions, our proprietary Vision AI platform delivers real-time monitoring and decision-making by capturing up to 6 frames per second from critical plant areas. This enables plant operators to take immediate, data-driven actions, drastically improving operational efficiency and safety,” shares Abhijit Kumar, Director – India Business, Ripik.AI.
“We’re also transforming raw material assessment. With Vision AI, we monitor the size, volume and quality of incoming materials—helping plants better manage deteriorating raw material sources and maintain consistent throughput and product quality. This granular visibility was never possible with legacy systems,” he adds.
Together, AI, ML and digital twins are not only making cement plants smarter but also more responsive to change. But the power of these tools depends entirely on the quality, accessibility and integration of data—bringing us to the next crucial layer in cement automation.
Data integration
Cement plants generate terabytes of data daily—from temperature sensors, pressure gauges and vibration monitors to ERP systems and market inputs. Without integration, this data remains fragmented and underutilised. The shift towards Industry 5.0 calls for interconnected data networks that seamlessly link shop floor machines with enterprise-level platforms.
“Effective automation relies on a strong and secure data infrastructure that enables seamless, real-time connectivity across the plant. Smart sensors and PLCs integrated into key machinery—such as kilns, crushers, and packing units—collect live performance and process data, which is then analysed through a centralised control room or cloud-based platform to enable timely, data-driven decision-making. Equally important are strong cybersecurity
protocols that safeguard operational systems and sensitive production data from disruptions or breaches, ensuring plant safety and uninterrupted performance,” states Suryam.
Commenting about enterprise-wide data lake to enable Industry 4.0 / 5.0 use cases, Himanshu Ghawri, Partner, PwC India, states, “Analysing the massive quantities and types of data generated in an industrial setting can enable effective predictive maintenance, improved demand forecasting, device fleet management and visibility into production challenges at all levels, and so much more. However, data silos make it difficult to capitalise on advanced, real-time and predictive analytics or to use AI/ML to determine the best actions to take to improve production and implement Industry 4.0 use cases. Using data lakes to store structured and unstructured data can help cement organisations address these issues.”
Integrated data architecture enables real-time decision-making, streamlines operations, and supports advanced analytics. Cloud-based dashboards and centralised control rooms are becoming essential, providing stakeholders with visibility into every stage of production and logistics.
Sustainability through automation
Reducing environmental impact is now central to cement industry strategy—and automation is proving to be the driving force. Automated energy management systems monitor usage patterns and optimise load distribution. Waste heat recovery systems, guided by AI, are improving energy efficiency in pyroprocessing. Emission monitoring tools automatically calibrate pollution control equipment to meet compliance norms, reducing particulate matter and NOx emissions.
Moreover, automation facilitates the use of alternative fuels and raw materials (AFR), ensuring consistent feed ratios and combustion efficiency.
Suryam highlights, “Automation is a key enabler of building safer, smarter and sustainable energy management systems at Nuvoco. A major milestone in this journey was the commissioning of our Grid Integration Project, which connected three of our geographically isolated cement plants through a common transmission line, creating a unified power network and setting a new benchmark for energy optimisation in the industry.”
Ghawri expounds, “At PwC India, we conducted our research between May and July 2024, covering 180 senior manufacturing executives from six industries – automotive, cement, chemicals, industrial goods, metals, clothing and textiles and our key findings – a whopping 93 per cent of senior executives across six industries would like to be known for their sustainability initiatives, and yet achieve 2x to 3x profitable growth over the next three to five years. Most senior executives agree that their readiness pertaining to Industry 5.0 capabilities would
help enhance their revenues over the next one to two years.”
Sustainability also intersects with how productively and safely the workforce operates in such high-risk industrial environments, making workforce productivity the next area of focus.
Workforce productivity
In terms of workforce, use of automation and advanced technology helps in predictive safety measures as well as upskilling.
Ganesh W Jirkuntwar, Senior Executive Director and National Manufacturing Head, Dalmia Cement (Bharat), says, “Technology is helping us see, think and act faster to prevent incidents before they happen. The company is making targeted investments in digital and AI-powered solutions to enhance safety outcomes. For instance, the KAVACH app provides employees and contractors a platform to report hazards, submit near-miss data and access standard operating procedures (SOPs) on the go.”
“AI-enabled cameras now support behaviour recognition, enabling predictive analysis of unsafe conditions even before a violation occurs. Devices that track worker fatigue and proximity to moving equipment are currently under pilot. Combined, these systems create a proactive safety environment that acts as a second line of defence alongside trained personnel,” he adds.
Ortega lists out recommendations for successful digital transformation:
1. Digital upskilling: A 2023 ECRA survey found that ‘only 32 per cent of cement plant engineers in Asia had formal training in digital tools or data analytics’ (ECRA Digital Skills Gap Report, 2023, pg7).
2. Interoperability: Ensuring legacy PLCs and
field devices communicate with modern platforms is essential.
3. Cybersecurity: According to ABB Cement Solutions (2023), ‘cyber incidents in the cement sector are rising, with most vulnerabilities linked to unsegmented networks’ (ABB White Paper, Securing the Digital Plant, pg3).
4. Phased integration: Begin with critical areas like fans, kilns or VRMs—then scale based on ROI tracking.
Highlighting the correlation between automated processes, workforce efficiency and manual errors, Frank Ormeloh, Business Unit Manager for Cement, HAVER & BOECKER, states, “A fully automated packing line allows for more flexible line layouts and negates the inefficiencies caused by human error or manual limitations. Automation also allows skilled labour to focus on higher-value tasks, improving overall workforce utilisation. Manual processes, such as bag placement, leave room for lost productivity and errors from tired or distracted workers.”
He adds, “The integration of equipment monitoring technology across all machines is an excellent way to achieve easier equipment optimisation and preventative maintenance tailored to the needs of the plant.”
Challenges in automation
Despite the progress, the path to full automation is not without obstacles. High capital costs, integration issues with legacy equipment and cybersecurity risks are top concerns. There is also a significant digital skills gap, especially in tier II and III cities.
Speaking about the challenges that operators face in adopting AI based control, Kulkarni affirms, “Majorly, we have experienced three challenges operators face in adopting AI-based control.
1. Operators are already used to the UI of existing automation systems like SCADA or DCS.
And adding a new screen with different UI makes it difficult for operators to monitor / operate separate systems.
2. Initial hesitation towards AI systems operating applications with changing plant conditions
like material quality, machine failure and
cement quality variation, which requires operators to make changes in control parameters on a continuous basis.
3. Often operators are also concerned about achieving target KPIs like production, power consumption, quality using AI based control system.”
These challenges make it imperative for cement manufacturers to develop a strategic roadmap to balance innovation with operational feasibility.
Conclusion
Ortega says, “To automate is not to relinquish control. It is to master it—with precision, foresight and responsibility. In the cement industry, the real question is no longer ‘if’ but ‘how’ fast we are willing to move.”
As the Indian cement industry stands on the cusp of a technological leap, it is important for manufacturers to regard automation as both a catalyst and a compass. Success depends on adopting a holistic view, which involves integrating advanced technologies with real-time data, upskilling the workforce and addressing the structural challenges along the way.
As India ramps up infrastructure and green goals, automation will not just support scaling up but define it. While industry experts are confident that the future belongs to cement plants that think, adapt and respond in real time, it is worth noting that this automated future is already here.
– Kanishka Ramchandani
Concrete
Akhoya Gets New 2.2 Km Road Link Under SASCI
Two cement concrete roads opened at Rs 29.1 million (mn) cost
Published
5 hours agoon
July 3, 2026By
admin
Two cement concrete pavement roads covering a total stretch of 2.2 km in Akhoya village were inaugurated on 27th June 2026 by MLA Nuklutoshi Longkumer, who attended as the special guest. The project comprises the one km L Pangersowa Road and the one point two km Longchara Junction to RC Chiten Jamir Memorial Government High School road. A formal programme followed the inauguration at the school auditorium.
A technical report was presented by Er Waloniba of the Urban Engineering Wing-III, Kohima, which stated the project was sanctioned in March 2026 under the Special Assistance to States for Capital Investment scheme for 2025-26 at a sanctioned cost of Rs 29.1 million (mn). The work order was issued to M/s Ensign Construction on thirtieth April 2026 with a stipulated completion period of 12 months. Work commenced on fourth May 2026 and was completed on sixth June 2026, with the contractor and team finishing the tasks in around two months. The project included a single-lane cement concrete pavement with side drains, two slab culverts and breast walls at required locations.
Longkumer acknowledged the Chief Minister, the advisor for urban development, contractors and other stakeholders for the allocation and support, and he commended the contractor for early completion. He noted that cooperation from landowners and the community had been important in resolving land related issues that can otherwise delay developmental works. He emphasised that planned developmental activities carried out with collective effort would enable more projects to be implemented successfully.
The headmaster of RC Chiten Jamir Memorial Government High School, I Chubasenba Longkumer, outlined the school background, noting it was established in 1962, was earlier known as Government High School Changtongya and was renamed in 2014. Local representatives said the improved approach roads would ease access for students, staff, patients and the general public and fulfil a long standing aspiration of residents. A dedicatory prayer was offered by the pastor and the programme concluded with a ribbon cutting attended by village council and town council representatives.
Indian Cement Review (ICR) and Fuller Technologies brought industry, policy and technology leaders together to discuss how cement innovation can drive green construction at scale, writes Rakesh Rao.
India is building at a pace few countries can match. Highways, airports, housing, logistics parks, industrial corridors and urban infrastructure are reshaping the country’s economic geography. But beneath this growth story lies a difficult question: can India continue to build at scale without locking itself into a high-carbon future?
That question formed the core of an online panel discussion titled “Driving Green Construction Through Cement Innovation”, organised by Indian Cement Review (ICR) in association with Fuller Technologies as the Presenting Partner on June 25, 2026. The webinar brought together experts from cement technology, R&D, global industry platforms, building performance policy and international development cooperation to examine how low-carbon cement and material innovation can accelerate India’s green construction transition.
The discussion came at a crucial time. India has committed to achieving net-zero emissions by 2070 and reducing the carbon intensity of its economy by 45 per cent by 2030. At the same time, the country’s construction sector is expanding rapidly, driven by urbanisation, infrastructure development, housing demand and industrial growth. Cement, as one of the most widely used construction materials, sits at the heart of this transition. It is indispensable to development, but also central to the challenge of reducing embodied carbon in buildings and infrastructure.
Moderated by Nitika Krishan, Senior Urban Infrastructure and Sustainable Policy Consultant, the panel featured:
- Kiranmai Sanagavarapu, Director, Low Carbon Solutions, Fuller Technologies;
- Dr Hemantkumar Aiyer, VP and Head R&D, Nuvoco Vistas Corp Ltd;
- Devika Wattal, Innovation Lead, Global Cement and Concrete Association (GCCA);
- Dr Sunita Purushottam, MD, GBPN India (Global Buildings Performance Network); and
- Vaibhav Rathi, Senior Technical Advisor, GIZ (the German Agency for International Cooperation)
Setting the tone for the discussion, Nitika Krishan underlined the scale of the challenge before the sector. “The question before us is no longer whether we build, but how we build sustainably,” she said. She pointed out that construction accounts for nearly 40 per cent of global energy-related carbon emissions when both operational and embodied carbon are considered. Cement production, she added, remains one of the hardest industrial processes to decarbonise.
For India, this is not merely an environmental issue. It is a development issue, a competitiveness issue and increasingly, a market issue. As one of the world’s largest cement producers and among the fastest-growing construction markets, India’s material choices will influence the carbon trajectory of its built environment for decades. As Krishan observed, sustainability solutions in economies such as India must not remain limited to laboratory success. They must be scalable, commercially viable and practical at national level.
The innovation gap: From technology to market
Experts believe that there is a need to bridge the innovation gaps for making decarbonisation in cement and concrete scalable. Devika Wattal of GCCA, explained, “The starting point must be the core cement manufacturing process itself. The first and foremost is the heart of our process, the heart of cement manufacturing. How do we reduce clinker? That is always a topic where industry is working very intrinsically.”
Clinker reduction remains one of the most important pathways for lowering emissions in cement. Since clinker production is energy-intensive and chemically emits carbon dioxide, reducing the clinker factor through supplementary cementitious materials (SCMs), blended cements and new chemistries can have a significant impact. Wattal also noted that carbon capture, utilisation and storage (CCUS) will have a role, though it may not be the first lever for all markets.
However, she stressed that innovation cannot stop at technology development. A solution that works in the lab must also be adaptable to industry, scalable in production and acceptable in construction practice. “It is important for that innovation to be adaptable, to be scalable, and so that it can be executed in real time,” she said.
Wattal also called for stronger enabling systems around innovation. These include performance-based standards, product-level embodied carbon databases and clearer frameworks for evaluating green materials. Without these, low-carbon cement products may struggle to compete with conventional materials in procurement and design.
R&D must balance carbon, cost and performance
Bringing in the R&D perspective into the discussion, Dr Hemantkumar Aiyer of Nuvoco Vistas emphasised that low-carbon cement development cannot be treated as a single-variable exercise. Cement must perform in real construction conditions. It must deliver strength, durability, consistency and cost competitiveness, while also reducing carbon.
“The root of understanding and balancing all these aspects lies in materials, and knowing the materials,” he said.
According to Dr Aiyer, R&D teams must understand the variability of raw materials such as fly ash, slag and clinker. Different sources produce different material behaviours. This makes mix optimisation, material characterisation and processing-property relationships critical. When performance is affected, cement manufacturers must understand how strength enhancers, admixtures and other performance chemicals interact with the material system.
He also linked material science with process efficiency. Clinkerisation takes place at extremely high temperatures, around 1,400 to 1,450 degrees Celsius. Any improvement in raw mix design, process control or energy optimisation can, therefore, help reduce emissions and cost. Dr Aiyer pointed to artificial intelligence-based optimisation, Cement 4.0 tools and advanced software as important enablers for real-time process and material control.
“The more you understand the materials, the more you can control it,” he said.
LC3: The promise is proven, the sequencing is not
Limestone calcined clay cement, commonly referred to as LC3, has attracted global attention because it can reduce clinker content significantly by using calcined clay and limestone while maintaining performance in many applications. Kiranmai Sanagavarapu of Fuller Technologies said the technology itself has already moved beyond proof of concept. Fuller Technologies has worked with calcined clay technology for nearly two decades and has seen plants running in France and Ghana. These plants, she said, are meeting local and national specifications, while the economics are beginning to make sense.
“The calciner is performing, the economics is stacking up, it is making business sense to produce,” she said.
But if the technology is viable, why has adoption not scaled faster? For Sanagavarapu, the answer lies in project sequencing. Too often, clay characterisation happens after equipment is specified. This, she warned, is a backward approach because calciner design depends on clay mineralogy, kaolinite content, iron levels, reactivity, moisture and other variables.
“If you don’t know what your deposit looks like before you commit for the equipment, you are, in a way, going blind into designing,” she said.
She also identified permitting and plant integration as major bottlenecks. Environmental clearances, mining permissions and local regulatory approvals must begin early. Similarly, calcined clay must be integrated into existing grinding, blending and logistics systems from the design stage, not treated as an afterthought during commissioning.
India already has IS 18189:2023 standard for LC3, but Sanagavarapu pointed out that the standard is not yet visible enough in procurement documents. “The gap between what is technically being permitted and what the procurement is asking is the single biggest bottleneck,” she said.
In her view, successful scale-up depends on getting the sequence right: clay characterisation first, permitting in parallel, standards aligned with construction, and integration built into plant design.
India’s LC3 journey: Progress, but demand remains thin
Providing details of India’s LC3 commercialisation experience, Vaibhav Rathi of GIZ noted that JK Cement carried out the first commercial production of LC3 at its Rajasthan plant, followed by JK Lakshmi Cement three months later. These initiatives were supported by the International Climate Initiative of the Government of Germany, with IIT Delhi contributing deep institutional knowledge on LC3 research and BIS certification.
Rathi said India’s early experience has produced clear lessons. One of the biggest was the need to build capacity among regulators. While BIS certification existed, State Pollution Control Boards were unfamiliar with the technology and unsure about the approval pathway.
“The capacity building is not just needed amongst the producer and the users of the cement, but also the regulators who are working with this technology for the first time,” he said.
He also highlighted the need for better information on China clay deposits. Since China clay is currently classified as a minor mineral, centralised data on availability, quality and location is limited. If cement manufacturers are to adopt LC3 at scale, stronger mineral intelligence will be important.
The third issue is demand. LC3 has already been used in projects such as Palava City in Mumbai and Noida International Airport, but these remain limited examples. “It is in a chicken and egg situation,” Rathi said. “Cement companies are saying we need more demand, and users are saying there is not enough cement available.”
Public procurement, he suggested, could help break this cycle. If agencies such as CPWD and other public bodies begin testing, accepting and specifying LC3, it could create the market confidence needed for cement companies to invest in production and storage.
Building codes must catch up with innovation
Dr Sunita Purushottam of GBPN India argued that material choices will determine built environment emissions over the long term, but India’s current policy signals remain fragmented. Although LC3 has received BIS recognition, she pointed out that building codes, municipal bylaws, schedules of rates and sustainability codes do not yet provide uniform guidance on low-carbon cement.
“The current cement regulations are largely prescriptive and favouring traditional materials,” she said. This limits the ability of alternative materials to compete on performance, durability and emissions.
Dr Purushottam also raised the issue of taxation. Cement, including LC3, currently falls under the same GST bracket as conventional cement. A differentiated tax structure, she argued, could help accelerate market adoption. “In order for the market to demand LC3, that differentiation in the GST could go a long way,” she said.
She noted that green building certifications such as IGBC and GRIHA are already creating demand for low-carbon materials by assigning points for embodied carbon and sustainable material use. However, she said large-scale adoption will require regulatory mandates, particularly through building codes and state-level notifications.
She also cautioned that low-carbon cement alone does not solve the entire building performance problem. A material may reduce embodied carbon, but the operational carbon of a building depends on thermal performance, design, insulation and energy use. “The energy part has two elements,” she said. “One is the embodied carbon of the material itself, and the other is the operational carbon.”
Collaboration is the bridge between invention and impact
Wattal said GCCA sees innovation as a strategic priority and works through platforms that connect industry with academia and start-ups. “There is no way we will decarbonise our sector without innovation,” she said.
However, she stressed that research must be connected to actual industry challenges. Innovations developed in isolation may fail when they encounter real-world barriers such as raw material variability, plant integration, cost, standards and finance. Start-ups, too, need industry mentorship and scale-up pathways.
Wattal also flagged the importance of finance. Even strong technologies may struggle to attract investment if there is no common understanding of bankability. “We have always put projects into, is this a bankable project? But the definition of a bankable project has never been defined,” she said.
For India, she saw strong potential in its academic and start-up ecosystem, but said the challenge lies in alignment and prioritisation. The country has the research base, industrial capacity and market size. What it now needs is a coordinated route from innovation to deployment.
There is a practical concern for cement manufacturers: how can existing plants be adapted for lower emissions without compromising reliability or commercial viability?
Kiranmai Sanagavarapu addressed, “The reliability risk in calcined clay retrofit is definitely real, but it is almost always self-inflicted. The risk arises when a new process is added to an existing circuit without properly redesigning grinding and blending configurations.”
Existing cement plants, she explained, can take two broad routes. The first is external sourcing of calcined clay combined with mill optimisation. This requires lower capital investment and can potentially move in 12 to 18 months if other conditions are in place. It may reduce emissions by around 20 to 30 per cent. The second route is integrated calcination on site, which requires higher capital expenditure and longer lead times, but provides greater control over quality, supply and emissions reduction potential.
For Sanagavarapu, the principle is simple: low-carbon retrofits must be designed with intent. “Design it with an intent properly from the start. Start in the market conditions where the economics are already working,” she said.
Circularity: The overlooked advantage
According to Vaibhav Rathi, fly ash and slag are already well established in cement and construction (C&D), but construction and demolition waste remains underutilised. “C&D waste is a growing business opportunity which not many have taken up,” he said. India’s continuous construction and demolition activity creates huge volumes of waste, much of which contributes to air pollution, land degradation and material inefficiency. With the right processing and standards, this waste can be converted into useful construction products.
Rathi also pointed out that LC3 has a circular economy dimension that is often overlooked. It can use low-grade kaolin-rich clay left behind after high-grade clay is extracted for other applications. “LC3 is not only a low-carbon solution, but also a circular economy solution,” he said.
At the same time, he cautioned that LC3 in India is not yet cheap because it has not reached scale. Site-specific techno-commercial feasibility studies, supported jointly by development agencies and industry, could help companies assess whether LC3 production makes technical and financial sense at a given location.
Dr Purushottam added that India must address both low-carbon cement and construction waste together. “Both low-carbon cement and C&D waste go hand in hand. India does not have an option but to work on both,” she said.
Dr Aiyer called for policy shifts from both government and industry, including preferential purchasing of sustainable materials, minimum supplementary cementitious material requirements in public and public-private projects, and faster regulatory implementation. “If we can fast-track the regulatory standards and their implementation on the ground, that is the way to go,” he said.
From green ambition to green construction
Cement innovation is no longer only about chemistry. It is about systems. Low-carbon cement will scale only when technology, standards, procurement, finance, regulation, education and construction practice move together.
LC3 and other low-carbon technologies have shown promise. India has early commercial examples, strong research capability and growing market interest. But mainstream adoption will depend on whether demand can be created, regulators can be capacitated, standards can be embedded in procurement, and manufacturers can see a clear business case.
For a country building at India’s scale, the opportunity is enormous. Cement will continue to be central to infrastructure and urban development. The challenge now is to ensure that the cement used in India’s growth story carries a lower carbon burden.
- Rakesh Rao
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Concrete
JK Cement Declared Preferred Bidder For Gilund Limestone Block
Shares Edge Higher As Company Wins Rajasthan Block
Published
3 days agoon
June 30, 2026By
admin
JK Cement gained after being declared preferred bidder for the Gilund Limestone Block in Chittorgarh, Rajasthan, a lease area of 370.96 hectares. The firm saw its shares trade at Rs. 5550.05, up by 28.45 points or 0.52 per cent from the previous close of Rs. 5521.60 on the BSE. The scrip opened at Rs. 5569.15 and touched a high of Rs. 5625.00 and a low of Rs. 5531.00.
The stock recorded turnover of 1742 shares on the counter and the BSE group A stock with face value Rs. 10 has a 52 week high of Rs. 7565.00 on 20-Aug-2025 and a 52 week low of Rs. 4670.05 on 12-Jun-2026. Last one week high and low stood at Rs. 5625.00 and Rs. 5329.00 respectively. The promoters holding in the company stood at 45.66 per cent, while institutions and non-institutions held 40.61 per cent and 13.73 per cent respectively.
The e-auction conducted by the Government of Rajasthan resulted in the company being declared preferred bidder for the mining lease, and the allocation will enable the company to plan phased development of the deposit, subject to regulatory approvals. The Gilund block spans 370.96 hectares and its allocation is intended to support raw material security for the company’s cement operations in the region. The designation follows the government auction process and will allow the company to plan development and integration of the deposit into its supply chain.
The current market capitalisation stands at Rs. 430.38 billion (bn), reflecting market response to the mining news and prevailing valuation levels for the sector. Investors and analysts will watch for formal allotment and related disclosures that can clarify timelines, capital expenditure and expected production profiles. The report is intended for informational purposes and does not constitute investment advice, and market participants are advised to consult advisers before making decisions.
Akhoya Gets New 2.2 Km Road Link Under SASCI
Green Construction Through Cement Innovation
JK Cement Declared Preferred Bidder For Gilund Limestone Block
Star Cement Named Preferred Bidder For Boro Lakhindong Block
KERC Proposal To Cut Rooftop Solar Export Tariff Raises Concern
Akhoya Gets New 2.2 Km Road Link Under SASCI
Green Construction Through Cement Innovation
JK Cement Declared Preferred Bidder For Gilund Limestone Block
Star Cement Named Preferred Bidder For Boro Lakhindong Block

