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Uma Suryam, SVP & Head Manufacturing – Northern Region, Nuvoco Vistas, shares details about how automation is helping the company make a shift towards an efficient and sustainable ecosystem.

As India’s cement sector embraces digital transformation, automation is emerging as the cornerstone of future-ready manufacturing. Uma Suryam, SVP & Head – Manufacturing, Northern Region, Nuvoco Vistas, sheds light on how the company is driving intelligent operations, improving energy efficiency and preparing for a data-led future.

What are the key drivers behind the adoption of automation in cement manufacturing today?
Automation in cement manufacturing is being increasingly adopted to meet rising demand due to rapid urbanisation, which drives large scale infrastructure development. To keep pace, manufacturers are embracing automation and digital technologies to streamline operations, reduce manual intervention and ensure consistent product quality.
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

How is automation improving process efficiency and reducing operational costs?
We are continuously investing in automation and process excellence to enhance efficiency and reduce costs across our operations. The roll-out of plant automation at select sites is setting the stage for an Internet of Things (IoT)-enabled smart factory environment, where real-time data and connected systems help optimise production and decision-making.
We have also introduced Robotic Process Automation (RPA) in our Shared Services Centre to fast-track routine processes such as freight bill settlements, significantly reducing manual effort and processing time. To further strengthen supply chain efficiency, the Master Data Repository Management (MDRM) tool ensures improved inventory accuracy, eliminates duplicate stock, and provides better visibility to reallocate excess materials across locations.
Complementing these initiatives, our Integrated Business Planning (IBP) solution by SAP has transformed demand and supply forecasting, enabling inventory planning aligned with demand cycles and ensuring adherence to our Goto market strategies (GTM).
Together, these digital interventions are streamlining end to end operations—optimising resources, minimising wastage, improving cost competitiveness and ultimately creating greater value for customers.

How does automation support energy optimisation and emissions control?
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.
The project, anchored by a Line-In Line-Out (LILO) substation at our cement plant and supported by an optical fibre network, enables real-time communication and automated energy distribution across the cluster. This has significantly reduced contract demand, eliminated power disruptions, enhanced operational flexibility and delivered substantial savings on fixed energy charges.
By minimising energy wastage and optimising power usage, automation directly contributes to lower greenhouse gas emissions, making our operations more environmentally responsible while ensuring safer and more reliable plant performance.

What kind of data infrastructure is needed to enable effective automation?
Effective automation in 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.
We are advancing towards a more data-intelligent manufacturing ecosystem with initiatives such as an AI-enabled dashboard to optimise waste heat recovery systems and kiln operations, enhancing energy efficiency. Additionally, we are developing advanced AI models that identify the most cost-effective fuel combinations by factoring in variables like moisture content, pricing and other operational parameters. These initiatives are laying the foundation for next-generation, data-driven decision-making, driving operational excellence and sustainable performance at scale.
In parallel, recognising the growing cyber threat landscape, we have strengthened our digital security framework by deploying next-generation firewalls, endpoint protection, enhanced network segmentation and implementing multi-factor authentication across all applications—ensuring that our digital infrastructure remains as resilient as our physical operations.

What is your roadmap for scaling automation across the organisation in the next five years?
Over the next five years, the company will focus on automating critical processes especially in production and quality control to drive operational excellence. AI will be integrated to support real-time, data-driven decision-making across functions. Additionally, the organisation is evaluating next-generation digital platforms to simplify and integrate its IT landscape.
As part of this evolving roadmap, there is also a continued emphasis on building a digitally capable workforce to stay aligned with emerging technologies.
These efforts reflect a broader shift towards a connected, future-ready manufacturing ecosystem where people, processes and systems are increasingly integrated to respond with agility to changing business dynamics.

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

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

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

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

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

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

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

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

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

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

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

 

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Concrete

Building a Greener Future Together

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

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

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

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

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

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

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

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

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

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Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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

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

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

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

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