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We build in extra safeguards beyond standard practice

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Simmy Maan, Proprietor, Constromech Engineering Solution, gives insights into customised solutions that are AI-driven, ensuring smoother operations, reduced downtime and a greener, safer working environment.

In this interview, Simmy Maan, Proprietor, Constromech Engineering Solution, shares insights on how advanced design and technology are revolutionising bulk material handling in cement plants. From minimising spillage and dust to optimising energy use and throughput, he highlights practical solutions and next-generation innovations that enhance efficiency, sustainability and operational reliability.

How do you design bucket-elevators and belt conveyors to minimise spillage and dust in cement plants?
At Constromech, we build in extra safeguards beyond standard practice: fully sealed loading / unloading chutes, deflector liners, anti-spill lips, segmented dust curtains and primary / secondary air extraction ports. For instance, in a cement line upgrade, we retrofitted transfer zones with diving chutes and side sealing plates, reducing carry back by approximately 25 per cent. We also use high-precision alignment of head and tail shafts, skirting with tensioned rubber seals, and incorporate self-cleaning belt scrapers (primary/secondary) as per good belt conveyor design guidelines. In high-dust zones, we provide vented or negative-pressure enclosures.

What advantages do plate-link / round-link chain elevators offer vs traditional systems for heavy raw materials?
Plate-link and round-link chain elevators provide high durability, temperature tolerance, minimal elongation and resistance to abrasive material impact. In our practice, we often combine these with belt-bucket elevators in projects where gentler handling of materials is required (e.g., additives or blended raw mix). The belt-bucket hybrid allows quieter operation, lower noise, and reduced wear on chains when loads are moderate, while chain types are used for aggressive duty. In one cement plant, we substituted a conventional bucket elevator with a belt-bucket design for handling hydrated lime. The result: lower vibration, less maintenance and longer chain life.

How do apron feeders or drag chain conveyors help in ensuring steady material feed without overloading?
Apron feeders give a metered, consistent flow using rigid pans and heavy drive chains. We are currently developing and soon introducing our belt-apron feeder variants that combine belt flexibility and pan-type strength. For drag conveyors, we have both forged chain and fabricated chain versions, available in single or double strand and with various attachments (flights, paddles, blades). Selection is based on material density, load profile and abrasiveness. In one case, for raw mix at 2,500 kg/m³, we used double strand forged drag chain with paddles and achieved stable feed to the kiln without surges.

What challenges do you face when scaling material-handling equipment for the high throughput needed in large cement plants?
When scaling conveyors, feeders or elevators for 500+ tph regimes, structural rigidity, vibration, drive sizing and thermal expansion become significant design challenges. We address this by using finite element stress analysis, oversizing bearings, modular supports, and pre-engineered expansion joints. We also routinely carry out retrofit jobs — e.g. converting chain elevators to belt-bucket systems or vice versa, enhancing capacity, changing inclination angles, or upgrading cross-sections. In one plant, we converted a chain elevator of 600 tph to a belt-bucket modular model, improving uptime and reducing wear.

How important is maintenance and spare parts availability for flow conveyors and reclaimer systems in reducing downtime?
Downtime in flow conveyors or reclaimers directly impacts production continuity. At CMECH, we supply ready-made spares in standard sizes — sprockets, rollers, rim segments, chain pins and bushes (for specific designs) — which our agents or clients can stock locally. We design equipment with easy access panels and quick-release modules, so replacement takes minimal time.

With increasing focus on sustainability,how do you optimise power consumption in equipment like deep pan conveyors and elevators?
We embed energy-efficiency in mechanical design: optimising pan or bucket pitch to minimise drag, using low-friction chain and liners, selecting high-efficiency gearboxes, and sizing drives with a proper safety margin (not oversizing excessively). In one 1,500 tph deep-pan conveyor, we reduced drive power by approximately 7 per cent by optimising pan depth and chain clearances. Additionally, we offer laser and IR guided monitoring modules, which operate without reliance on internet or mobile coverage and transmit data directly to mobile phones with graphical reports and AI-driven diagnostics. These modules can measure physical, chemical, or kinetic parameters (e.g. temperature, vibration, load trends) on conveyor belts, kilns, coolers, crushers, ball mills, VRMs, roller presses and packing lines. This real-time data allows operators to fine-tune speed settings, reduce idling, and detect inefficient consumption early — promoting sustainable operation.

How does Constromech customise bulk handling solutions to the different raw / processed material densities (limestone, clinker, additives)?
We begin by characterising bulk density, moisture content, abrasiveness and flow characteristics. Based on that, we size bucket volumes, chain pitch, belt width, conveyor inclination, and liner materials. For example, for clinker (~2,900 kg/m³) we may use shorter bucket spacing, heat-resistant liners, and forged chains; for lighter additives (1,200–1,500 kg/m³) we may use belt-bucket systems or gentler chain pitch. In one project, we provided hybrid conveyors in a plant handling both raw mix and gypsum, tailoring each section’s geometry to its specific material behaviour.

What innovations or design improvements do you believe will define the next generation of material handling in the cement sector?
Looking ahead, modular plug and play conveyor units, adaptive control via AI, self-aligning mechanisms, self-lubricating chains and IoT-integrated monitoring will set new benchmarks. Our integrated laser/IR modules with local-edge AI will be a part of that evolution. Use of predictive maintenance algorithms (deep reinforcement learning) will determine the optimal inspection intervals and minimise unplanned stoppages at the specific plant levels. Enclosed conveyors with active dust suppression, use of eco hoppers, dynamic flow control and modular upgradeability will also shape the next generation of material-handling systems in the cement sector.

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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