ICR delves into the groundbreaking innovations transforming India’s cement industry — from carbon capture and digitalisation to sustainable engineering and material resilience. Discover how technology and collaboration are shaping a low-carbon, competitive future.
India’s cement industry is at a pivotal turning point—evolving from traditional production methods to an era defined by advanced technology, sustainability, and operational reinvention. According to a report by the India Brand Equity Foundation (IBEF), demand growth of 6 per cent to 7 per cent is projected for FY25, following a robust 7 per cent to 8 per cent YoY increase in the last quarter of FY24. This momentum, driven by urbanisation, infrastructure expansion, and policy pushes like the PM Gati Shakti National Master Plan, underscores the need for the industry to evolve not just in capacity but in how it innovates, optimises, and decarbonises. Meanwhile, a report by ResearchAndMarkets estimates the Indian cement market will reach US $18.39 billion by 2025 at a 6.6 per cent CAGR, while the green-cement segment is expected to grow from US $2.31 billion (2024) to US $3.28 billion (2030)—clear signs that innovation has shifted from aspiration to necessity for competitiveness and carbon compliance. Amid this growth and environmental urgency, path-breaking innovations are transforming every link in the cement value chain—from carbon capture and digitalisation to sustainable packaging, data-driven manufacturing, and energy optimisation. As plants embrace Industry 4.0 and embed sustainable engineering at their core, the industry is transitioning from volume-led expansion to value-led transformation. The trajectory is clear: India’s cement producers are no longer just making cement—they are redefining it, building a low-carbon foundation for the nation’s next phase of infrastructure and sustainable growth.
CCUS: Cement’s Net-Zero Catalyst
For hard-to-abate process emissions in cement, Carbon Capture, Utilisation and Storage (CCUS) has moved from concept to large-scale implementation. Global first-of-a-kind projects are proving commercial viability: Heidelberg Materials’ Brevik CCS facility in Norway will capture ~400,000 tCO2/year (~50 per cent of the plant’s emissions), with its evoZero cement already pre-sold for 2025, as reported by Reuters. Similarly, Holcim’s GO4ZERO project in Belgium targets ~1.1 MtCO2/year capture by 2029, part of a broader 5 MtCO2/year ambition supported by the EU Innovation Fund. India is preparing to follow this trajectory—Dalmia Cement, in partnership with Carbon Clean, is developing a 500,000 tCO2/year CCUS plant in Tamil Nadu, aligning with its carbon-negative 2040 goal, as mentioned in company releases and an ADB analysis. Policy mechanisms are also emerging: the Global CCS Institute/GCCA policy brief (2024) proposes a Carbon Capture Finance Corporation and innovative funding tools to de-risk early projects, while NITI Aayog’s CCUS roadmap highlights the urgent need for large-scale demonstrations. Together, these moves signal that CCUS is shifting from research to reality, and India aims to be part of this global transformation.
Dr SB Hegde, Global Industry Expert say, “The cement industry’s path to net zero requires a phased and coordinated innovation roadmap. In the near term (2025–2030), emphasis must be on energy efficiency, clinker substitution, AFR, WHR, and digital optimisation, which are already proven and cost-effective. The next decade (2030–2040) will see wider adoption of electrification and carbon capture technologies, supported by renewable energy and green hydrogen. By 2040–2050, advanced low-carbon clinkers, carbon-negative binders, and circular material use will dominate, enabling deep decarbonisation. Together, these phases form a realistic pathway to cut CO2 emissions by over 70 per cent while ensuring competitiveness and resilience.”
Beyond capture, CO2 utilisation is equally vital—turning emissions into economic value through mineral carbonation, CO2-cured concrete, and carbonated aggregates. Europe’s Northern Lights project under Norway’s Longship program has already begun receiving CO2 shipments from Brevik, with plans to scale to ~5 MtCO2/year, as mentioned in the Financial Times. For India, where geological storage mapping and pipeline infrastructure are still evolving, near-site utilisation in construction materials or chemical feedstocks can bridge the economic gap until storage clusters—such as those planned along the west coast—are operational. The strategic path forward involves modular, retrofit-friendly capture systems, integration with energy efficiency and AFR initiatives, and the use of offtake and CFD-style instruments to offset early costs. As a report by TERI emphasises, India’s net-zero pathway by 2070 hinges on CCUS alongside clinker substitution, alternative binders, and renewable integration. The opportunity for Indian cement lies in acting early—turning CCUS from an obligation into a competitive advantage in the race for sustainable manufacturing.
Digital transformation
From quarry to kiln to bagging, Indian cement plants are rapidly shifting from manual set-points to sensor-driven, AI-supervised operations. Advanced Process Control (APC) and machine learning now fine-tune dozens of variables in real time—stabilising the pyroprocess, optimising fuel use, and minimising quality variance. As mentioned in ABB’s Expert Optimiser materials, these systems typically deliver 3 per cent to 5 per cent energy savings and 3 per cent to 5 per cent production gains while cutting emissions—results that have converted skeptics into advocates. For Indian operators navigating volatile fuel mixes and ambitious Thermal Substitution Rate (TSR) goals, such optimisations provide tangible, repeatable ROI. India already holds a global efficiency edge—as reported by the CII–Sohrabji Godrej Green Business Centre (2023), the top 10 plants operate below 70 kWh/t cement and 690 kcal/kg clinker, with best-achieved benchmarks of 56.1 kWh/t and 675 kcal/kg, underscoring the impact of digitisation on sustaining world-class performance.
Tushar Kulkarni, Business Head – Minerals – Cement & Mining, Innomotics India says, “India’s cement industry has long been at the forefront of adopting cutting-edge industrial technologies—ranging from Intelligent MCCs and MV/LV drive systems to full-scale plant DCS automation—placing it among the global leaders in energy-efficient and digitally enabled manufacturing. These initiatives have translated into significant gains in energy reduction and operational efficiency across plants. The sector is now entering a new phase of transformation, embracing innovations like AI-driven process optimisation (AI Pyro, AI Mill), electrification of kilns, and Carbon Capture, Utilisation & Storage (CCUS). Encouragingly, several of these technologies are already under feasibility assessment or pilot implementation, reflecting the industry’s readiness to leverage advanced automation and electrification as key enablers of decarbonisation.”
“However, scaling these innovations industry-wide still faces tangible barriers. Many plants continue to operate with legacy systems that lack seamless data connectivity or structured historians, making AI model training and deployment difficult. Challenges such as non-standardised data formats, limited transparency of AI model performance, and uncertainty in calculating ROI often slow down investment decisions. Strengthening data infrastructure, building trust in AI outcomes, and upskilling teams in digital analytics will be crucial to unlocking the full potential of smart drives, advanced predictive control, and electrification. In the coming years, AI-based optimisation tools and CCUS technologies are poised to become game changers—helping India’s cement sector strike the balance between industrial productivity and its low-carbon future” he adds.
The next leap lies in scaling the digital flywheel—integrating process, maintenance, and logistics data into unified platforms powered by AI and predictive analytics. Plants combining APC, predictive maintenance, and digital twins will achieve steadier clinker quality, lower specific energy, and reduced downtime while preparing for CCUS-ready, low-carbon operations. With six-stage preheaters globally averaging 717–812 kcal/kg, India’s continuous optimisation keeps it at the efficient end of this spectrum. The lesson is clear: Industry 4.0 isn’t a parallel initiative—it’s the operating system of tomorrow’s path-breaking cement plant, where automation, data, and intelligence drive both sustainability and competitiveness.
Data-driven decisions
Across Indian cement plants, production is becoming data-rich and model-driven, with IoT sensor networks, AI models, and APC systems working in tandem to optimise kiln stability, fuel mix, and quality in real time. As mentioned in Holcim’s program page and a Global Cement report, the company’s Plants of Tomorrow initiative has deployed 2,100+ digital applications across 40+ countries, with AI software expected in ~100 plants by 2028. Indian leaders already operate at world-class efficiency, achieving ~56.1 kWh/t cement (electrical) and ~675 kcal/kg clinker (thermal), benchmarks maintained through data analytics and condition-based maintenance, as reported by the CII–Sohrabji Godrej Green Business Centre (2023). Downstream, digital control towers and route analytics have helped UltraTech cut average lead distance to ~400 km and logistics costs by ~2 per cent YoY. As mentioned in reports by the GCCA (2024/25) and the World Economic Forum (2024), digitalisation is now a central pillar of the global net-zero cement strategy, proving essential for an industry that contributes ~6 per cent of global CO2 emissions to maximise efficiency from kiln to dispatch.
Sustainable engineering
Sustainable engineering in India’s cement sector is advancing beyond efficiency gains toward holistic life-cycle design, where plant layout, raw materials, and product use all align with low-carbon goals. As mentioned in TERI’s roadmap, the industry must cut CO2 intensity to ~0.35 tCO2/t cement by 2050, down from 0.62 in 2010, while as per the OECD report, new plants should target ˜70 kWh/t (electrical) and ˜680 kcal/kg clinker (thermal). On the materials front, Limestone Calcined Clay Cement (LC³) and similar low-carbon binders can reduce emissions by 30 per cent to 40 per cent versus OPC. According to the Department of Science and Technology, cement and brick production currently emit 200–250 MtCO2 annually, underscoring vast decarbonisation potential. Sustainable engineering is thus no longer conceptual—it’s materialising through plant retrofits, alternative binders, and integrated design strategies that link sourcing, production, and construction into a single, optimised low-carbon chain.
Utssav Gupta, Director, Supertech Fabrics says, “India’s cement industry, as the second-largest producer globally, has made remarkable progress in adopting advanced filtration and emission control technologies. The country now enforces some of the most stringent environmental norms among developing economies, and new plants are being commissioned with state-of-the-art filtration systems that rival international benchmarks. More importantly, there is a visible intent among manufacturers to retrofit and upgrade older units, reflecting a strong national commitment to sustainability. As a material-producing nation, India’s openness to embracing innovation has allowed advanced filtration solutions to gain acceptance swiftly. This mindset shift—where manufacturers and end-users alike are eager to align with global best practices—positions India not as a follower but as a fast-rising leader in environmental performance and technological adaptability within the cement sector.”
“When it comes to modernising emission control systems, the challenge is not the lack of technology but the need for stronger instrumentation and data transparency. Real-time monitoring and consistent data sharing between OEMs, operators, and material suppliers remain critical to fine-tuning systems and achieving peak efficiency. Broader adoption of connected instrumentation could help perform deeper root cause analyses, enabling more precise optimisation and accountability. On the technology front, filtration science itself is undergoing a transformation—driven by material innovation that enhances both performance and longevity of filters. The next wave of filtration technologies will not only reduce particulate emissions but also improve plant sustainability and energy efficiency—marking another leap forward in India’s journey toward cleaner, smarter, and more resilient cement production” he adds.
Energy optimisation
Indian plants are squeesing megawatts from every °C of kiln heat while hard-wiring renewables into their grids. Waste-heat recovery (WHR) has scaled rapidly—installed capacity in India rose from ~240 MW to ~1,289 MW over the last decade, with leaders adding triple-digit megawatts in just a few years; UltraTech reports 351 MW of WHR capacity in FY 2024–25, while Ramco commissioned a new 10 MW WHRS in September 2025, signalling steady brownfield gains, as mentioned in a report by the CII–Sohrabji Godrej Green Business Centre and as mentioned in company/press updates. On the consumption side, global pathways raise the bar: the IEA’s NZE trajectory targets average kiln thermal intensity < 3.4 GJ/t clinker and electricity < 90 kWh/t cement by 2030—benchmarks that Indian best-performers are already approaching or beating, as mentioned in a report by the IEA.
The fuel and power mix is tilting greener at scale. UltraTech has publicly set 85 per cent “green energy” in the total energy mix by 2030 (with an interim 60 per cent by FY26) and surpassed 1 GW of installed renewable capacity—tying energy optimisation directly to cost and carbon, as mentioned in company disclosures. Shree Cement lifted green power to ~56 per cent to 66 per cent with ~582–586 MW of RE capacity (solar, wind, WHR), as mentioned in broker/market reports. Meanwhile, the switch to alternative fuels remains a major lever: industry assessments show Thermal Substitution Rate (TSR) adoption is rising but uneven across firms, with availability and pre-processing still the bottlenecks—yet TSR is pivotal to hitting sector targets, as mentioned in a report by CARE Edge ESG.
Reinventing packaging and storage
Moisture remains the silent enemy of bagged cement, driving a shift from stitched sacks to block-bottom, valve bags made of coated polypropylene (PP) that resist humidity, burst less, and run seamlessly on automated lines. Designs like AD*STAR® offer higher strength, moisture protection, and recyclability within PP streams, as mentioned in Starlinger’s overview, while Indian brands such as Bharathi Cement highlight tear resistance, micro-perforation, and near-zero bursting. Recycling infrastructure is expanding too—as mentioned in a report by the India Plastics Pact (2023), 819 mechanical recycling units now process recovered PP, supporting EPR-linked sack take-back programs under CPCB’s 2023–24 inventory. On the dispatch front, plants are deploying automatic bagging, robotic palletising, and warehouse control systems to reduce breakage and boost loading efficiency, as reported in automation case studies. With bulk loading, silo telemetry, and RFID-enabled yards improving traceability, India’s cement logistics are evolving toward moisture-resistant, recyclable packaging and end-to-end automation, ensuring every bag reaches the site intact—with its strength and brand promise preserved.
Frank Ormeloh, Business Unit Manager – Cement, Haver & Boecker says, India’s cement industry presents a fascinating paradox when it comes to integrated digital and hardware adoption. Despite the country’s global reputation for software excellence, the current level of integration between digital and mechanical systems in cement plants remains modest. Most investments still lean toward mechanical upgrades—from material handling to process machinery—while digital adoption lags behind. Yet, the potential for digital transformation is immense. Digital tools, from AI-based control systems to predictive analytics and smart mesh technologies, often come with lower cost thresholds and higher ROI compared to conventional mechanical retrofits. The industry’s growing openness to innovation, combined with India’s strong IT foundation, suggests a major opportunity to elevate operational intelligence through integrated digital-hardware ecosystems.”
“The true obstacles, however, are not technological but commercial and cultural. The prevalent “lowest price possible” mindset still overshadows the “maximum profit possible” philosophy needed to scale advanced mesh, AI, and robotic systems. To accelerate adoption, pioneers within the sector must step forward—those willing to demonstrate that smart, data-integrated plants are not only more efficient but also more sustainable, safe, and investor-attractive. HAVER & BOECKER envisions this transformation through Operation & Maintenance (O&M) partnerships, where experts co-manage packing facilities alongside customers, aligning technical excellence with business value. Proven in India’s chemical sector, this service-driven model aims to bring cement producers closer to “Perfect Flow,” redefining the material not as a low-cost commodity but as a high-value, innovation-driven product that embodies efficiency, sustainability, and long-term profitability” he adds.
Material resilience
A new generation of low-carbon binders is redefining cement’s material resilience by cutting emissions without compromising performance. Limestone Calcined Clay Cement (LC3) reduces CO2 by ~40 per cent while matching or exceeding OPC strength, lowering the clinker factor to ~50 per cent or less, as mentioned in or a report by RMI’s 2024 “Business Case for LC3” and the LC3 Global Assessment. Composition-level innovations such as Calcium Silicate Cement (CSC) further show up to 45.5 per cent energy and 35.1 per cent CO2 reductions versus OPC, owing to reduced limestone demand and lower sintering temperatures, as mentioned in or a report by Williams and Yang (2024). Beyond emissions, alkali-activated concretes (AAC) deliver ~54 per cent to 61 per cent lower CO2 and ~39 per cent to 70 per cent lower embodied energy, while maintaining high strength under thermal stress, as noted in peer-reviewed studies (2024–2025). For India, reducing the clinker factor through high-quality SCMs and alternative binders remains central, as mentioned in or a report by the GCCA Net Zero Progress Report (2024/25) and CII–GBC benchmarking data. The message is clear: material resilience now means lower embodied carbon, longer service life, and regionally optimised composites tailored to India’s diverse heat, moisture, and chloride conditions.
Jignesh Kundaria, CEO and Director, Fornnax says, “India’s cement industry has made significant progress in adopting IoT and predictive analytics, though maturity remains uneven across the sector. Leading manufacturers are integrating digital tools for process optimisation, equipment health monitoring, and real-time insights, but adoption is still in the early-to-mid stage compared to Europe, where digital ecosystems are more advanced. Encouragingly, Indian plants increasingly recognise that data drives efficiency, sustainability, and competitiveness, marking a cultural shift toward digitisation. The main barriers lie in infrastructure: many plants still use legacy systems incompatible with modern automation, making integration complex and costly. A shortage of digital talent and high upfront costs further slow progress. Yet the outlook is strong—modular, interoperable, and retrofit-friendly solutions are steadily lowering adoption barriers and enabling a scalable, cost-effective transition toward intelligent, data-driven cement operations across India..”
Human–tech synergy
The cement industry’s digital transformation is as much about people as it is about technology—where human expertise evolves alongside AI, digital twins, and robotics. As plants automate and adopt AI-based process control, job roles are shifting from manual operation to analytical decision-making. According to a report by Deloitte (2024), over 60 per cent of global manufacturers now prioritise reskilling in data analytics, IoT, and automation. India mirrors this trend—as mentioned in CII’s 2024 Future of Work in Manufacturing study, cement and heavy industry players are allocating up to 3 per cent of annual operational budgets to digital training, with UltraTech and ACC establishing in-house digital academies for process engineers and maintenance teams.
Dijam Panigrahi, Co-founder and COO, GridRaster says “The core of Industry 5.0 is the human operator. By having Spatial AI systems safely take over repetitive, monotonous, or highly dangerous tasks, plant personnel are liberated to focus on the highest-value work: complex process management, troubleshooting, and continuous process optimisation. This fosters a human-machine collaboration that drives innovation, enhances safety and ensures sustainability. Spatial AI is not merely a theoretical leap in digital twin technology; it is a concrete, actionable technology that is delivering immediate, impactful change on the plant floor. By simplifying complexity and driving setup time down to minutes, this technology is the essential accelerator that makes advanced industrial automation truly accessible to all cement manufacturers, marking the definitive arrival of the human-centric, high-efficiency world of Industry 5.0.”
As mentioned in a report by the NSDC (2025), over 75,000 workers in India’s materials and infrastructure sectors will require advanced digital skills by 2030. The GCCA calls this “digital sustainability”—training workers to manage systems that cut emissions and energy use, not just boost output. In practice, kiln engineers interpret AI dashboards, maintenance teams conduct predictive analytics, and logistics managers optimise CO2-efficient routes. The cement plant of the future is, therefore, a human–machine collaboration hub, where workforce adaptability is as critical as the algorithms driving efficiency and sustainability.
Conclusion
As India’s cement sector enters its next growth phase, the challenge is no longer scale but sustainability at scale. The nation already leads in energy efficiency and alternative fuels, yet the next leap demands embedding innovation into every tonne of cement—through CCUS, low-clinker blends like LC3, AI-driven process control, and green logistics. Supported by the National Green Hydrogen Mission, PAT scheme, and 2030 renewable targets, India’s ecosystem is aligning toward low-carbon, globally competitive manufacturing that exports not just cement but expertise. Achieving this will require deep collaboration among industry, academia, and policymakers, focusing on scalable CCUS, mineral carbonation, and regionally suited binders. As led by the GCCA and CMA, shared R&D platforms and policy-backed decarbonisation clusters—akin to Europe’s CCS hubs—can fast-track progress, while green bonds, blended finance, and carbon credits can de-risk early adoption. Ultimately, path-breaking innovation is India’s passport to a net-zero construction future—where digital intelligence, sustainable engineering, and circular materials converge to make every plant a lab for efficiency and every engineer an innovator. With bold collaboration and steadfast execution, India can transform its cement industry from a top emitter into a cornerstone of global green growth.
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:
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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Specialised rail logistics will move fly ash from power plants to infrastructure industries.
New Delhi
Indian Railways is planning a large-scale green logistics initiative to transport fly ash from thermal power plants to industries where it can be reused in infrastructure and construction activities.
The initiative was discussed during a review meeting chaired by Union Minister for Railways Ashwini Vaishnaw. Union Ministers of State for Railways V Somanna and Ravneet Singh Bittu were also present.
India generates nearly 340 million tonnes of fly ash every year from thermal power plants. The proposed initiative aims to create an efficient rail-based transport system using specialised containers and dedicated logistics arrangements to move fly ash safely from power plants to end-use industries.
Fly ash is widely used in road construction, cement manufacturing, brick production, concrete, blocks and boards. By improving its movement through the railway network, the initiative is expected to support better utilisation of this industrial by-product while reducing environmental concerns linked to storage and disposal.
The move also aligns with India’s circular economy goals by converting waste from thermal power generation into a useful raw material for the construction and infrastructure sectors. Wider availability of fly ash can help reduce material costs in areas such as bricks and cement, supporting more affordable infrastructure and housing development.
Through this initiative, Indian Railways aims to provide a cleaner, safer and more organised transport solution for fly ash, turning an environmental challenge into an infrastructure resource.
Gears, drives, and motors have evolved from essential mechanical components into strategic enablers of reliability, efficiency, and sustainability in modern cement plants. ICR explores how advanced motion technologies, predictive maintenance, digitalisation, and intelligent drive systems are helping cement manufacturers reduce downtime, optimise energy use, and build future-ready operations.
As the Indian cement industry prepares for another phase of capacity expansion, the focus is shifting from merely increasing production volumes to improving operational efficiency, reliability, and sustainability. According to industry estimates, India is expected to add nearly 160–170 million tonnes of cement capacity between FY26 and FY28, driven by infrastructure investments, urbanisation, and housing demand. In this environment, gears, drives, and motors have emerged as critical enablers of productivity, forming the backbone of every major process from raw material extraction and grinding to clinker production and cement dispatch. Motors alone account for nearly 60 per cent to 70 per cent of industrial electricity consumption globally, according to the International Energy Agency (IEA), while rotating equipment failures remain among the leading causes of unplanned downtime across heavy industries. In cement plants, where equipment operates under high loads, extreme dust conditions, elevated temperatures, and continuous-duty cycles, the performance of gears, drives, and motors directly influences energy consumption, maintenance costs, plant availability, and overall profitability. As digitalisation and Industry 4.0 technologies gain momentum, these systems are evolving from passive mechanical components into intelligent assets capable of delivering real-time operational insights.
Why gears, drives, and motors are the backbone of cement plant operations Every major process in a cement plant depends on the seamless operation of gears, drives, and motors. Raw mills, vertical roller mills, crushers, kiln drives, conveyor systems, fans, and clinker coolers all rely on rotating equipment to maintain continuous production. A failure in any one of these systems can disrupt entire process chains, highlighting their strategic importance. Modern cement plants process thousands of tonnes of material daily, requiring equipment capable of transmitting enormous torque while maintaining precision and reliability. Kiln drives and grinding systems, in particular, operate under some of the highest mechanical loads found in industrial manufacturing. The ability of gears and motors to withstand these conditions directly impacts plant throughput and production stability. Satish Maheshwari, Chief Manufacturing Officer, Shree Cement says, “Effective lubrication management remains one of the most critical factors in extending the lifespan of cement plant drive systems. Proper lubrication, supported by regular oil analysis, vibration diagnostics, and condition monitoring, helps minimise wear, prevent unexpected failures, and maintain the integrity of critical components such as gearboxes, motors, and drive assemblies. By identifying potential issues at an early stage, plants can move from reactive maintenance to a more proactive and reliability-focused approach.” “Smart motors, intelligent drives, and next-generation gearboxes are set to redefine cement plant maintenance and performance. Equipped with embedded sensors, IoT connectivity, digital twins, and AI-driven diagnostics, these technologies enable real-time condition monitoring, predictive maintenance, and seamless digital integration. As the industry embraces Industry 4.0, smart drive systems will play a pivotal role in improving energy efficiency, reducing downtime, and optimising asset performance across the cement manufacturing value chain” he adds. Industry studies suggest that rotating equipment accounts for a significant proportion of maintenance expenditure in process industries. Effective design, selection, and maintenance of gears, drives, and motors therefore have a direct influence on asset utilisation, operational efficiency, and total cost of ownership.
The cost of downtime: reliability challenges in rotating equipment Unplanned downtime remains one of the most expensive challenges facing cement manufacturers. Industry estimates indicate that a major failure involving a critical gearbox, kiln drive, or grinding mill can result in production losses running into lakhs of rupees per hour, depending on plant capacity and operating conditions. Sanjeev Arora, President – Motion Business & IEC LV Motors Division, ABB India says, “One of the most significant shifts taking place in industrial decision-making today is moving away from evaluating equipment based solely on upfront capital cost toward understanding total cost of ownership (TCO). In a typical motor system, the purchase price often represents only a small fraction of the total lifecycle cost however energy consumption, maintenance requirements, downtime and operating efficiency account for the vast majority of long-term operational expenses. For cement manufacturers operating in highly competitive markets, this distinction is critical.” “A high efficiency motor paired with an appropriately configured variable speed drive may require a higher initial investment, but the long-term benefits are substantial. Reduced electricity consumption, lower maintenance needs, longer service intervals and improved process stability can deliver faster payback and stronger profitability over time” he adds. Cement plants present a particularly challenging environment for rotating equipment. Dust ingress, thermal fluctuations, shock loads, vibration, shaft misalignment, and lubrication contamination contribute significantly to equipment degradation. Studies by SKF indicate that nearly 50 per cent of bearing failures are linked to lubrication issues and contamination, while improper alignment and vibration-related problems remain leading causes of gearbox and motor failures.
Energy-efficient motors and drives: unlocking operational savings Energy is one of the largest operating expenses for cement manufacturers, often accounting for 25 per cent to 35 per cent of total production costs. Grinding operations alone can consume nearly 60 per cent to 70 per cent of a plant’s electrical energy, making energy-efficient motors and drives a strategic investment. According to the International Energy Agency, high-efficiency motors combined with Variable Frequency Drives (VFDs) can reduce energy consumption by 20 per cent to 30 per cent in suitable applications. By matching motor speed and torque to actual process requirements, VFDs minimise unnecessary power consumption while reducing mechanical stress on equipment, improving both efficiency and reliability.
Advances in gearbox design and power transmission technologies Modern gearbox technology has evolved significantly in response to the increasing demands of cement manufacturing. Advanced materials, case-hardened gears, optimised tooth profiles, improved surface finishing, and enhanced lubrication systems are helping reduce friction, wear, and thermal loading. Girish Hanchate, Director – Industrial Market, India SKF India (Industrial) says, “Smart diagnostics are significantly improving the lifecycle of gears, motors, and other rotating equipment by enabling a shift from reactive maintenance to condition-based asset management. Hidden issues such as vibration anomalies, bearing defects, misalignment, and temperature fluctuations can quietly reduce plant throughput by 10 per cent to 20 per cent while increasing energy consumption long before a breakdown occurs. By leveraging advanced sensors, predictive analytics, machine learning, and real-time monitoring of vibration, temperature, and motor current, cement manufacturers can detect developing faults early, optimise maintenance schedules, and prevent costly secondary damage. This not only improves reliability but also supports energy efficiency and sustainability objectives.” “The next major evolution in drive and bearing technology lies in the development of fully integrated smart mechanical ecosystems that combine high-performance bearings, advanced lubrication management, and digital intelligence. Sensor-enabled condition monitoring embedded directly within bearings and drive systems allows operators to capture critical operational data at the source, enabling predictive maintenance and real-time performance optimisation. Innovations such as SKF’s VA9A1 Spherical Roller Bearing series, engineered specifically for demanding cement applications such as crushers and kilns, demonstrate this trend. By increasing internal bearing space and optimising lubricant flow, these designs improve grease retention, reduce wear, minimise downtime, and create more resilient, energy-efficient rotating equipment systems for the future of cement manufacturing” he adds. Manufacturers are increasingly focusing on compact, high-torque gearbox designs capable of delivering higher power density while maintaining service life. Innovations such as condition-monitored gear systems, improved sealing technologies, and modular gearbox architectures are simplifying maintenance while enhancing operational reliability.
Predictive maintenance, condition monitoring, and asset health management The shift from reactive to predictive maintenance is transforming asset management across the cement industry. Technologies such as vibration monitoring, thermography, oil analysis, ultrasound testing, and motor current signature analysis are enabling operators to identify potential failures before they occur. Research by Deloitte suggests that predictive maintenance can reduce breakdowns by up to 70 per cent and lower maintenance costs by 25 per cent. In cement plants, where shutdown windows are limited and equipment operates continuously, predictive maintenance offers a powerful tool for improving reliability and extending asset life. Digitalisation, industry 4.0, and the rise of intelligent drive systems Industry 4.0 technologies are redefining the role of gears, drives, and motors. Smart sensors embedded within motors, bearings, and gear systems can continuously monitor temperature, vibration, load, lubrication condition, and energy consumption. Girish Hanchate says, “As the industry embraces automation, sustainability, and digital transformation, the importance of intelligent motion technologies will continue to grow. The convergence of advanced engineering, predictive maintenance, and Industry 4.0 solutions is creating a new generation of cement plants where reliability, efficiency, and sustainability work together to deliver long-term value. For cement manufacturers navigating increasing production demands and environmental expectations, investing in smarter gears, drives, and motors is no longer optional—it is a business imperative.” Cloud-based monitoring platforms and Industrial Internet of Things (IIoT) architectures enable maintenance teams to access equipment health data remotely, improving visibility across geographically dispersed operations. Advanced analytics and artificial intelligence are further enhancing fault detection capabilities, enabling more accurate maintenance planning. The emergence of digital twins represents another significant development. By creating virtual replicas of physical assets, operators can simulate operating conditions, predict failures, optimise maintenance schedules, and improve lifecycle management decisions. These technologies are helping transform rotating equipment into intelligent assets that actively contribute to operational decision-making.
Building future-ready cement plants through smart motion technologies The future of cement manufacturing will depend heavily on the ability to integrate mechanical reliability with digital intelligence. Smart motion technologies combine high-efficiency motors, intelligent drives, condition monitoring systems, and automation platforms to create more responsive and efficient operations. Sustainability goals are also accelerating investment in advanced motion technologies. Reduced energy consumption, improved equipment efficiency, and extended asset life contribute directly to lower carbon emissions and reduced resource consumption. These benefits align closely with the industry’s decarbonisation objectives. As capacity expansions continue across India, future-ready cement plants will increasingly prioritise reliability, flexibility, and data-driven decision-making. Organisations that successfully integrate smart motion technologies into their operations will be better positioned to reduce costs, improve productivity, and maintain a competitive advantage in a rapidly evolving market.
Conclusion Gears, drives, and motors are no longer viewed solely as mechanical components; they have become strategic assets that influence every aspect of cement plant performance. Their reliability affects production continuity, their efficiency impacts operating costs, and their digital capabilities increasingly shape maintenance and operational strategies.
