Economy & Market

Cementing Change: India’s Innovation Blueprint

Published

6 months ago

November 17, 2025

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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.

– Kanika Mathur

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PROMECON introduces infrared-based tertiary air measurement system for cement kilns

Published

1 day ago

May 20, 2026

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The new solution promisescontinuous, real-time tertiary air flow measurement in cement plant operations.

PROMECON GmbH has launched the McON IR Compact, an infrared-based measuring system designed to deliver continuous, real-time tertiary air flow measurement in cement plant operations. The system addresses the longstanding process control challenge of accurate tertiary air monitoring under extreme kiln conditions. It uses patented infrared time-of-flight measurement technology that operates without calibration or maintenance intervention.

Precise tertiary air measurement is a critical requirement for stable rotary kiln operation. The McON IR Compact is engineered to function reliably at temperatures up to 1,200°C and in the presence of abrasive clinker dust. Its vector-based digital measurement architecture ensures that readings remain unaffected by swirl, dust deposits or drift. Due to these conditions conventional measurement systems in pyroprocess environments are often compromised.

The system is fully non-intrusive and requires no K-factors, recalibration or periodic readjustment, enabling years of uninterrupted operation. This design directly supports plant availability and reduces the maintenance overhead typically associated with process instrumentation in high-temperature zones.

PROMECON has deployed the McON IR Compact at multiple cement facilities, including Warta Cement in Poland. Plant operators report that the system has aided in identifying blockages, optimising purging cycles for gas burners, and supplying accurate flow data for AI-based process optimisation programmes. The practical outcomes include more stable kiln operation, improved process control, and earlier detection of process disturbances.

On the energy side, real-time tertiary air data enables reduction in induced draft fan load and helps flatten process oscillations across the pyroprocess. This translates to lower fuel and energy consumption, fewer unplanned shutdowns, and a measurable reduction in NOx peaks. This directly reflects on the downstream cost implications for plants operating SCR or SNCR systems for emissions compliance.

Concrete

Filtration Technology is Critical for Efficient Logistics

Published

6 days ago

May 15, 2026

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Niranjan Kirloskar, MD, Fleetguard Filters, makes the case that filtration technology, which has been long treated as a routine consumable, is in fact a strategic performance enabler across every stage of cement production and logistics.

India’s cement industry forms the core for infrastructure growth of the country. With an expected compound annual growth rate of six to eight per cent, India has secured its position as the second-largest cement producer globally. This growth is a result of the increasing demand across, resulting in capacity expansion. Consequently, cement manufacturers are now also focusing on running the factories as efficiently as possible to stay competitive and profitable.
While a large portion of focus still remains on production technologies and capacity utilisation, the hidden factor in profitability is the efficiency of cement logistics. The logistics alone account for nearly 30 per cent to 40 per cent of the total cost of cement, making efficiency in this segment a key lever for profitability and reliability.
In the midst of this complex and high-intensity ecosystem, filtration often remains one of the most underappreciated yet essential enablers of performance.

A demanding operational landscape
Cement production and logistics inherently operate in some of the harshest industrial environments. With processes such as quarrying, crushing, grinding, clinker production, and bulk material handling expose the machinery to constant high temperatures, heavy loads, and dust, often the silent destructive force for engines.
The ecosystem is abrasive, and often one with a high contamination index. These challenging conditions demand equipment such as the excavators, crushers, compressors, and transport vehicles to perform and perform efficiently. The continuous exposure to contamination across every aspect like air, fuel, lubrication, and even hydraulic systems causes long-term damage. Studies have also shown that 70 to 80 per cent of hydraulic system failures are directly linked to contamination, while primary cause of engine wear is inadequate air filtration.
For engines as heavy as these, even a minor contaminant has a cascading effect; reducing efficiency, performance and culminating to unplanned downtime. Particles as small as 5 to 10 microns, far smaller than a human hair (~70 microns), can cause significant damage to critical engine components. In an industry where margins are closely linked to operational efficiency, such disruptions can significantly affect both cost structures and delivery timelines.

Dust management: A persistent challenge
Dust is a natural by-product in cement operations. From drilling and blasting in the quarries to packing in plants, this fine particulate matter does occupy a large space in operations. Dust concentration levels in quarry and crushing zones often create extremely high particulate exposure for equipment. These fine particles, when enter the engines and critical systems, accelerates the wear and tear of the component, affecting directly the operational efficiency. Over time every block fall; engine performance declines, fuel consumption rises, and maintenance cycles shorten. In this case, effective air filtration is the natural first line of defence. Advanced filtration systems are designed to capture high volumes of particulate matter while maintaining consistent airflow, ensuring that engines and equipment operate under optimal conditions.
In high-dust applications, as in cement production, even the filtration systems are expected to sustain performance over extended periods without the need of frequent replacement. This becomes crucial in remote quarry locations where access to frequent maintenance may be limited.

Fluid cleanliness and system integrity
Beyond air filtration, fluid systems also play a crucial role for equipment reliability in cement operations. Fuel systems are required to remain free from contaminants for efficient working of combustion and injection protection. Additionally, lubrication systems also need to maintain the oil purity to reduce friction and prevent any premature wear of moving parts. The hydraulic systems, which are key to several heavy equipment operations, are especially sensitive to contamination.
If fine particles or water enters these systems, it can lead to reduced efficiency, erratic performance, and eventual failure of the system. Modern filtration systems are designed with high-efficiency media capable of removing extremely fine contaminants, with advanced fuel and oil filtration solutions filtering particles as small as two to five microns. Multi-stage filtration systems further ensure that fluid performance is maintained even under challenging operating conditions.
Another critical aspect of fuel systems is water separation. Removing moisture helps prevent corrosion, improves combustion efficiency and enhances overall engine reliability. Modern water separation technologies can achieve over 95 per cent efficiency in removing water from fuel systems.

Ensuring reliability across the value chain
Filtration plays a critical role across every stage of cement logistics:
• Quarry operations: Equipment operates in highly abrasive environments, requiring strong protection against dust ingress and hydraulic contamination.
• Processing units: Crushers, kilns, and grinding mills depend on clean lubrication and cooling systems to sustain continuous operations.
• Material handling systems: Pneumatic and mechanical systems rely on clean air and fluid systems for efficiency and reliability.
• Transportation networks: Bulk carriers and trucks must maintain engine health and fuel efficiency to ensure timely deliveries.
Across these operations, filtration plays a vital role; as it supports consistent equipment performance while reducing the risk of unexpected failures.
Effective filtration solutions can reduce unscheduled equipment failures by 30 to 50 per cent across heavy-duty operations.

Uptime as a strategic imperative
In cement manufacturing, uptime is currency. Downtime not only delays the production, but it also greatly impacts the supply commitments and logistics planning. With the right filtration systems, contaminants are kept at bay from entering the
critical systems, and they also significantly extend the service intervals.
Optimised filtration can extend service intervals by 20 to 40 per cent, reducing maintenance frequency while maintaining consistent performance across demanding operating conditions. Filtration systems designed for heavy-duty applications sustain efficiency throughout their lifecycle, ensuring reliable protection with minimal interruptions. This leads to improved equipment availability, lower maintenance costs, and more predictable operations, with well-maintained systems capable of achieving uptime levels of over 90 to 95 per cent in challenging cement environments.

Supporting emission and sustainability goals
With the rising environmental awareness, the cement industry too is aligning with the stricter norms and sustainability targets. In this scenario, the operational efficiency is directly linked to emission control.

Air and fuel systems that are clean enable
much more efficient combustion. They also reduce emissions from both the stationary equipment and transport fleets. Similarly, with a well-maintained fluid cleanliness, emission systems function better. Poor combustion due to contamination can increase emissions by 5 to 10 per cent, making clean systems critical for compliance.
Additionally, efficient and longer lasting filtration systems significantly reduce any waste generation and contribute to increased sustainable maintenance practices. Extended-life filtration solutions can reduce filter disposal and maintenance waste by 15 to 20 per cent. Smart and efficient filtration in this case plays an important role in meeting the both regulatory and environmental objectives within the industry.

Advancements in filtration technology
Over the years, there has been a significant evolution in the filtration technology to meet the modern industrial applications.
Key developments include:
• High-efficiency filtration media capable of capturing very fine particles without restricting flow
• Compact and integrated designs that combine multiple filtration functions
• Extended service life solutions that reduce replacement frequency and maintenance downtime
• Application-specific engineering tailored to different stages of cement operations
Modern multi-layer filtration media can improve dust-holding capacity by up to two to three times compared to conventional systems, while maintaining consistent performance. These advancements have transformed filtration from a basic maintenance component into a critical performance system.

Adapting to diverse operating conditions
The cement industry of India operates across diverse geographies. Spanning across regions with arid regions with higher dust levels, to the coastal areas with higher humidity, challenges of each region pose different threats to the engines. Modern filtration systems are thus tailored to address these unique challenges of each region.
Indian operating environments often range from 0°C to over 50°C, with some of the highest dust loads globally in mining zones.
Additionally, filtration technology can also be customised to variations which then align the system design with factors like dust load, temperature, and equipment usage patterns. Equipment utilisation levels in India are typically higher than global averages, making robust filtration even more critical. This approach ensures optimal performance and durability across different operational contexts.

Impact on total cost of ownership
Filtration has a direct and measurable impact on the total cost of ownership of equipment.
Effective filtration leads to:
• Lower wear and tear on critical components
• Reduced maintenance and repair costs
• Improved fuel efficiency
• Extended equipment life
• Higher operational uptime
Effective filtration can extend engine life by 20 to 30 per cent and reduce overall maintenance costs by 15 to 25 per cent over the equipment lifecycle. These benefits collectively enhance productivity and reduce lifecycle costs. Conversely, inadequate filtration can result in frequent breakdowns, increased maintenance expenditure, and reduced asset utilisation.

Building a more efficient cement ecosystem
With the rising demand across various sectors, the cement industry is expected to expand at an unprecedented rate. This growth is forcing the production to move towards a more efficient and resilient system of operations. This requires attention not only to production technologies but also to the supporting systems that enable consistent performance. Filtration must be viewed as a strategic investment rather than a routine consumable. By ensuring the cleanliness of air and fluids across systems, it supports reliability, efficiency, and sustainability.

The road ahead
The future of cement logistics will be shaped by increasing mechanisation, digital monitoring, and stricter environmental standards. The industry is also witnessing a shift towards predictive maintenance and condition monitoring, where filtration performance is increasingly integrated with real-time equipment diagnostics.
In this evolving landscape, the role of filtration will become even more critical. As equipment becomes more advanced and operating conditions more demanding, the need for precise contamination control will continue to grow. From quarry to construction site, filtration technology underpins the performance of every critical system. It enables equipment to operate efficiently, reduces operational risks, and supports the industry’s broader goals of growth and sustainability. In many ways, it is the unseen force that keeps the cement ecosystem moving, quietly ensuring that every link in the value chain performs as expected.

About the author
Niranjan Kirloskar, Managing Director, Fleetguard Filters, is focused on driving innovation, operational excellence, and long-term business growth through strategic and people-centric leadership. With a strong foundation in ethics and forward-thinking decision-making, he champions a culture of collaboration, accountability, and technological advancement.

Concrete

Cement’s Next Fuel Shift

Published

6 days ago

May 15, 2026

admin

Jignesh Kindaria highlights how Thermal Substitution Rate (TSR) is emerging as a critical lever for cost savings, decarbonisation and competitive advantage in the cement industry.

India is simultaneously grappling with two crises: a mounting waste emergency and an urgent need to decarbonise its most carbon-intensive industries. The cement sector, the second-largest in the world and the backbone of the nation’s infrastructure ambitions, sits at the centre of both. It consumes enormous quantities of fossil fuel, and it has the technical capacity to consume something else entirely: the waste our cities cannot get rid of.
According to CPCB and NITI Aayog projections, India generates approximately 62.4 million tonnes of municipal solid waste annually, with that figure expected to reach 165 million tonnes by 2030. Much of this waste is energy-rich and non-recyclable. At the same time, cement kilns operate at material temperatures of approximately 1,450 degrees Celsius, with gas temperatures reaching 2,000 degrees. This high-temperature environment is ideal for co-processing, ensuring the complete thermal destruction of organic compounds without generating toxic residues. The physics are in our favour. The infrastructure is not.
Pre-processing is not the support act for co-processing. It is the main event. Get the particle size wrong, get the moisture wrong, get the calorific value wrong and your kiln thermal stability will suffer the consequences.

The regulatory push is real
The Solid Waste Management (SWM) Rules 2026 mandate that cement plants progressively replace solid fossil fuels with Refuse-Derived Fuel (RDF), starting at a 5 per cent baseline and scaling to 15 per cent within six years. NITI Aayog’s 2026 Roadmap for Cement Sector Decarbonisation targets 20 to 25 per cent Thermal Substitution Rate (TSR) by 2030. Beyond compliance, every tonne of coal replaced by RDF generates measurable carbon reductions which is monetisable under India’s emerging Carbon Credit Trading Scheme (CCTS). TSR is no longer a sustainability metric. It is a financial lever.
Yet our own field assessments across multiple Indian cement plants reveal a sobering reality: the primary barrier to scaling AFR adoption is not waste availability. It is the fragmented and under-engineered pre-processing ecosystem that sits between the waste and the kiln.

Why Indian waste is a different engineering problem
Indian municipal solid waste is not the material that imported shredding equipment was designed for. Our waste streams frequently exceed 40 per cent to 50 per cent moisture content, particularly during monsoon cycles, saturated with abrasive inerts including sand, glass, and stone. Plants relying on imported OEM equipment face months of downtime awaiting proprietary spare parts. Machines built for segregated, low-moisture waste fail quickly and disrupt the entire pre-processing operation in Indian conditions.
The two most common failures we observe are what I call the biting teeth problem and the chewing teeth problem. Plants relying solely on a primary shredder reduce bulk waste to large fractions, but the output remains too coarse for stable kiln combustion. Others attempt to use a secondary shredder as a standalone unit without a primary stage to pre-size the feed, leading to catastrophic mechanical failure. When both stages are present but mismatched in throughput capacity, the system becomes a bottleneck. Achieving the 40 to 70 tonnes per hour required for meaningful coal displacement demands a precisely coordinated two-stage process.

Engineering a made-in-India answer
At Fornnax, our response to these challenges is grounded in one principle: Indian waste demands Indian engineering. Our systems are built around feedstock homogeneity, the holy grail of kiln stability. Consistent particle size and predictable calorific value are the foundation of stable kiln combustion. Without them, no TSR target is achievable at scale.
Our SR-MAX2500 Dual Shaft Primary Shredder (Hydraulic Drive) processes raw, baled, or loosely mixed MSW, C&I waste, bulky waste, and plastics, reducing them to approximately 150 mm fractions at throughputs of up to 40 tonnes per hour. The R-MAX 3300 Single Shaft Secondary Shredder (Hydraulic Drive), introduced in 2025, takes that primary output and produces RDF fractions in the 30 to 80 mm range at up to 30 tonnes per hour, specifically optimised for consistent kiln feeding. We have also introduced electric drive configurations under the SR-100 HD series, with capacities between 5 and 40 tonnes per hour, already operational at a leading Indian waste-processing facility.
Looking ahead, Fornnax is expanding its portfolio with the upcoming SR-MAX3600 Hydraulic Drive primary shredder at up to 70 tonnes per hour and the R-MAX2100 Hydraulic drive secondary shredder at up to 20 tonnes per hour, designed specifically for the large-scale throughput that higher TSR ambitions require.

The investment case is now
The 2070 Net-Zero target is not a distant goal for India’s cement sector. It starts today, with decisions being made on the plant floor.
The SWM Rules 2026 are already in effect, requiring cement plants to replace coal with RDF. Carbon credit markets are opening up, and coal prices are not going to get cheaper. Every tonne of coal a cement plant replaces with waste-derived fuel saves money on one side and generates carbon credit revenue on the other. Pre-processing infrastructure is no longer just a compliance requirement. It is a business investment with a measurable return.
The good news is that nothing is missing. The technology works. The waste is available in every Indian city. The government has provided the policy direction. The only thing standing between where the industry is today and where it needs to be is the commitment to build the right infrastructure.
The cement companies that move now will not just meet the regulations. They will be ahead of every competitor that waits.

About the author
Jignesh Kundaria is the Director and CEO of Fornnax Technology. Over an experience spanning more than two decades in the recycling industry, he has established himself as one of India’s foremost voices on waste-to-fuel technology and alternative fuel infrastructure.