Economy & Market

Application of Load Cells in Cement Plants

Published

7 months ago

November 20, 2025

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Rakesh Valeja, Managing Director, Thames Side Sensors India, highlights how advanced load cell technology enhances accuracy, process efficiency and legal compliance across every stage of cement production.

Load cells are electronic sensors that convert force or weight into an electrical signal. In cement plants, they provide the backbone for accurate measurement across the entire value chain – from quarrying limestone to dispatching finished cement – enabling inventory control, process automation, quality assurance, safety and legal-for-trade weighing.
The most widely used form in heavy industry weighing is the strain gauge load cell, which measures deformation of a small elastic element and converts that strain into a stable millivolt output proportional to load. Strain gauge load cells are rugged, reliable and available in compression, tension (S type) and shear/bending forms to suit different application, mounting and environmental needs.
Thames Side Sensors, with over 40 years of expertise, designs and manufactures precision load cells and weighing electronics for industries like cement, process weighing, and automation. Produced in Barcelona with stringent quality control, its products—ranging from 300g to 1,000 tonnes—ensure accuracy, durability, and global reliability. With warehouses in Mumbai and the UK, and certifications like ATEX, OIML, IP68, and IP69K, Thames Side provides trusted, high-performance solutions for diverse industrial weighing applications.

Load cells: From limestone to cement
Load cells are used at every stage, as part of weighing systems, during conversion of limestone to cement. Limestone undergoes a multi-stage transformation before becoming cement. The journey begins at open-pit mines, where drilling and controlled blasting techniques are used to extract the raw limestone. Once recovered, the material is transported to crushing units that reduce it to manageable fragments. These crushed particles are then combined with other essential ingredients such as clay and milled into a fine, homogenous powder. This raw mix is fed into a rotary kiln and subjected to intense heat, typically exceeding 1400°C, which initiates chemical reactions that form solid nodules known as clinker.
After cooling, the clinker is finely ground together with a small proportion of additives such as gypsum, fly ash, calcined clay, granulated blast furnace slag, iron ore, manganese oxide, tricalcium aluminate etc., resulting in the finished cement product ready for packaging and distribution.

Quarry and limestone handling (mining, haulage and stockpiles)
Truck scales (or the weighbridges) at the quarry use large compression or double ended shear beam load cells installed under the deck to capture the vehicle plus load. These cells must tolerate impact, shock and wide temperature swings; Thames Side Sensor’s rugged compression load cell models such as the T34 and T35 family are suitable for robust static weighbridges installations. These load cells are available in both – analogue and digital versions.
Under hopper load cells provide real time feed rate and mass flow control to crushers and conveyors; shear/bending beam cells with IP68 protection and overload stops are recommended. Thames Side single ended shear beam/bending solutions work well in this role.
For intermediate inventory control, a combination of weighbridge and belt weighers is common. Rugged Compression load cells and Robust bending beam models from Thames Side Sensors ensure long service life in dusty quarry environments.
Continuous mass flow on long conveyors is monitored by idler mounted instrumentation and Belt scales that often use Thames Side Sensors’ Bending Beam T66, Shear Beam T85 or S type (T60/T61) load cells. These load cells are specifically designed for conveyor and batching plant duties and offer the sensitivity and sealing needed for accurate dynamic measurements.

Raw material dosing and batch plant (crushing, grinding, blending)
High-accuracy weighing systems, including load cells on hoppers and feeders, play a critical role in maintaining blend precision and process stability.
Accurate batching of limestone, clay and additives is done with hopper or bin weighing systems. Vessel/silo weighing with multiple load cells provides static inventory and batch control; Thames Side supplies legal-for-trade approved silo, tank and hopper weighing load cells along with mounting assemblies designed for this purpose.
For controlled dosing into ball mills and raw mix blenders, Single point T12 or Bending beam T66 load cells deliver precise weight measurement for weigh feeder applications.
Loss in weight or weigh belt controls using single ended shear beam T85 or bending beam cells T66 ensure steady throughput to the ball mill and protect downstream process stability.

Kiln feed, clinker handling and kiln support systems
Accuracy in kiln feed is vital for kiln stability and fuel efficiency. Loss in weight feeders and weigh feeders typically use bending beam or single point load cells; Thames Side load cell model T66 and T12 are suitable for both the dosing accuracy and industrial sealing required.
For the clinker transfer bunkers and hot material handling robust load cells are required with appropriate thermal isolation and protective housings; Thames Side’s silo and hopper weighing solutions include Rugged Compression column T34 load cells with its mounting assemblies and instrumentation tailored for bulk solids monitoring in challenging environments. The T34 cells are available in 10t to 1000t capacities.

Cement finish milling, storage silos and load out
Cement finish milling reduces cooled clinker and additives to a fine powder, with precise grinding and gypsum addition to control setting time. Accurate feeders and load cell equipped hoppers ensure consistent mill feed and uniform product quality. Finished cement is stored in silos monitored by Bin Level Measuring Systems for inventory control and dispatch planning. Loadout operations use silo discharge controls, bulk tanker filling systems, and legal-for-trade approved weighbridges to ensure correct quantities for customers.
Thames Side Sensors offers complete silo/tank/hopper weighing solutions designed for bulk storage measurement and communication with plant control systems.
For the cement mill and final blending stage, precise small hopper weighing enables consistent cement fineness and additive dosing. Static vehicle weighbridges at despatch use heavy duty compression load cells (e.g., T34/T35) selected for long term reliability and trade accuracy, allowing accurate ticketing for commercial dispatch.

Packing, bagging and palletising
Bagging lines fill and seal cement into sacks using highspeed gravimetric or volumetric fillers that prioritise accuracy and throughput. Load cell equipped fillers and platform scales ensure each bag meets target weight and maintains tight tolerances for quality control. Automated palletisers and case packers then arrange filled bags onto pallets for secure storage and transport, with checkweighers and inline scales providing final verification. Integrated data capture from the weighing systems feeds traceability, production reporting, and despatch reconciliation.
Highspeed bagging and valve type packers
require fast, repeatable weight measurement at the filling nozzle or weigh platform. Thames Side Sensors’ bending beam load cell model T66 is explicitly recommended for batching and cement packer applications where speed and resolution matter.
Big bag (FIBC) filling machines suspend the bag from load cells during fill; S type or specially designed suspended weighing cells are ideal. Thames Side S beam T60/T61 and Single ended Shear Beam T85 load cells are designed for suspended tank/vessel and big bag filling duties and are a practical standard for plant spares and maintenance.

Transit, despatch and legal-for-trade approved weighing Transit and despatch operations rely on legal-for-trade approved weighbridges to provide legally valid mass measurements for customer deliveries and revenue reconciliation. Weighbridge systems, calibrated and certified to local metrology standards, ensure accuracy and defensible transaction records.
Complementary checks use bulk tanker scales, on-board systems and batch tickets to cross-verify loads before release. Integrated weighing data is linked to ERP and dispatch systems for invoicing, inventory control and audit trails.
For legal for trade transactions at dispatch, the weighing system must meet regulatory approvals and be mounted with heavy duty compression
load cells. Thames Side’s heavier compression load cell families like the T34/T35 meet the structural and environmental requirements for weighbridge installations.

Instrumentation, integration and environmental considerations
Accurate load cell measurement requires properly matched transmitters, junction boxes and controllers with protocols for PLC/DCS/SCADA integration. Thames Side’s weighing systems include instrumentation options compatible with common industrial protocols to integrate silo inventory and despatch data into plant systems.
Dust, moisture, corrosive atmospheres and vibration demand high-IP rated welded load cells with robust cable sealing and protective mounts. Thames Side’s product families cited above are designed and specified for industrial bulk solids environments and include suitable sealing and mounting assemblies.

Conclusion
Strain gauge load cells are the measurement of backbone across a cement plant’s entire lifecycle. Standardising on proven load cell families such as Thames Side’s Bending Beam T66, Shear Beam T85, Single Point T12 for feeders, conveyors and bagging and T34 compression load cells for heavy weighbridge and silo support simplifies spares, commissioning and maintenance while delivering the accuracy.

ABOUT THE AUTHOR:
Rakesh Valeja, Managing Director, Thames Side Sensors India, holds over 35 years in India’s weighing and automation industry and is known for his ethical leadership and strategic acumen.

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Cement Makers Reaffirm Commitment to Sustainable Growth

Published

12 hours ago

June 5, 2026

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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.

Concrete

Building a Greener Future Together

Published

1 day ago

June 4, 2026

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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.

Concrete

Dalmia Bharat Acquires Jaiprakash Associates Cement Assets for ₹2,850 Crore

Published

2 weeks ago

May 25, 2026

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Dalmia Cement executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra, to acquire 5.2 MnTPA of cement capacity across Madhya Pradesh and Uttar Pradesh.

Dalmia Cement (Bharat) announced on May 22, 2026 that it had signed a Business Transfer Agreement with Jaiprakash Associates Limited and Adani Infra (India) Limited for the acquisition of cement plants located at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh. The deal was struck at an enterprise value of ₹2,850 crore and is expected to close within two weeks of execution.

The acquired assets from Jaiprakash Associates include 5.2 MnTPA of cement capacity and 3.3 MnTPA of clinker capacity. The package also covers 99 MW of thermal power capacity and railway sidings at Rewa, Chunar, and a common siding at Churk. This infrastructure gives the acquisition immediate operational utility beyond just production tonnage.

The transaction has a long backstory. Dalmia Cement had originally entered into a framework agreement with Jaiprakash Associates in December 2022, covering the sale of these business assets along with a long-term clinker supply arrangement. However, before the deal could be completed, Jaiprakash Associates was admitted to insolvency proceedings under the Insolvency and Bankruptcy Code. The earlier agreements could not be consummated as a result.

In an official statement, Puneet Dalmia, Managing Director & CEO, Dalmia Bharat, said, “I am very excited about addition of these assets in our portfolio. This serves as a great strategic fit for Dalmia. It helps us move forward in our journey to be a pan India player and provide a strong head start to serve the high potential markets in Central region. I am optimistic that the expansion potential of these assets along with close proximity with Dalmia’s captive mines will help us create a capacity hub for the future”.

Following the approval of Adani Group’s resolution plan for Jaiprakash Associates under the IBC framework, Dalmia approached the new management to revive discussions. The fresh Business Transfer Agreement was executed to settle all pending disputes, legal proceedings, and arbitration matters arising from the original framework agreement with Jaiprakash Associates.

Expanding market reach

Dalmia added, “Our familiarity with these assets under the earlier tolling arrangement gives us a deep understanding of the facilities and helps us establish strong connect with channel partners and vendors. We believe that this will help us in faster ramp up of capacities and quicker inroads into the market. As we look forward, I am very confident that we will be able to leverage the strengths of Dalmia to operate these assets in a manner where we can maximise value creation for all our stakeholders.”

With the addition of these plants, Dalmia Bharat’s total installed cement capacity will rise to 54.7 MnTPA upon consummation. The company has further expansion projects underway at Belgaum, Pune, and Kadapa, which are expected to take overall capacity to 66.7 MnTPA by Q2 to Q3 FY28.

The Central India location of the Jaiprakash Associates plants gives Dalmia Bharat faster access to markets in Madhya Pradesh and Uttar Pradesh than a greenfield build would have allowed. The company also cited debottlenecking and brownfield expansion as near-term opportunities at the acquired sites. Dalmia Bharat said the assets were expected to contribute positively to EBITDA and overall returns, given the pricing environment in the region and the company’s cost structure.