Jignesh Kundaria, Director and CEO, Fornnax Technology, explains how the persistent underperformance of AFR projects in Indian cement plants is an engineering philosophy problem and not a technology problem.
The adoption of alternative fuels and raw materials (AFR) in Indian cement plants has increased significantly in recent years. However, despite this progress, many facilities continue to face a common challenge: achieving consistent and reliable performance in day-to-day operations. Through extensive engagement with cement manufacturers and AFR stakeholders across India, including technical assessments and visits to various cement plants by Fornnax, a clear pattern has emerged. Many facilities deal with inconsistent feedstock quality, high moisture levels, contamination, fluctuating output quality and unexpected maintenance issues. These challenges are not isolated incidents. They reflect the complex realities of AFR operations.
The root cause is simple because there is no universal AFR process that works equally well for every facility. Waste composition varies across regions. Kiln configurations differ from plant to plant. Operational priorities, whether related to fuel substitution, production targets, or infrastructure limitations, are rarely the same. Yet many AFR projects still rely on standardised equipment and process layouts. As a result, solutions designed for one operating environment are often expected to perform equally well in another. This disconnects between standardised systems and local operating conditions can lead to underperformance, higher costs, and delayed project outcomes.
The cost of getting AFR wrong
AFR is no longer viewed solely as a sustainability initiative. It has become a strategic business priority for cement manufacturers. Rising fuel costs, stricter environmental regulations and growing pressure to reduce dependence on conventional fuels are accelerating AFR adoption across the industry. However, the success of an AFR project depends heavily on how effectively waste is processed before it reaches the kiln. Poor preprocessing can negatively impact kiln performance, fuel efficiency and emission control systems. Inconsistent fuel quality often forces operators to make frequent adjustments, reducing throughput and increasing energy consumption.
Equipment failures and unplanned downtime can disrupt production schedules and increase maintenance costs. When operational challenges persist, plants may lose confidence in AFR as a reliable solution and return to conventional fuels, undermining both sustainability goals and investment returns. The industry’s most successful operators have learned that AFR success is not determined by equipment alone. It requires the right combination of process design, material understanding, operational flexibility, and long-term support.
Engineering-led customisation
At Fornnax, we believe successful AFR implementation starts with understanding the challenge before selecting the solution. Rather than taking an equipment-first approach, we focus on engineering-led customisation that aligns with each plant’s unique operating conditions.
Understanding the material first: Every AFR project begins with a detailed assessment of the waste stream. Factors such as material composition, moisture content, contamination levels, seasonal variations and output requirements are carefully analysed. This understanding forms the foundation for process design, equipment selection, automation requirements, and operational flexibility.
Designing around real plant conditions: No two cement plants operate under identical conditions. Our process designs take into account actual waste characteristics, kiln requirements, available infrastructure, maintenance capabilities, and future expansion plans. Instead of forcing facilities into a standardised model, we develop solutions that fit their operating reality.
Creating integrated systems: A successful AFR plant is not simply a collection of machines. It is an integrated system where every component works together to maintain stable throughput and consistent fuel quality despite changing feedstock conditions. Drawing on insights gained from working with more than 70 cement facilities, we focus on identifying and eliminating potential bottlenecks during the design stage, when they are easier and more cost-effective to address.
Supporting performance beyond commissioning
As AFR operations mature, plant operators increasingly require more than equipment performance. They need responsive service support, spare parts availability, process optimisation guidance, performance monitoring and long-term reliability. Fornnax incorporates these lifecycle considerations into every project from the outset. Our goal is not simply to supply equipment, but to support sustained operational success. For us, innovation is not defined by complexity. It is measured by the ability to improve reliability, simplify operations, and deliver consistent results under real-world conditions.
Next phase of AFR growth
As AFR adoption continues to expand, the industry’s competitive advantage will increasingly belong to companies that combine technical expertise with a deep understanding of operational realities. This shift creates a significant opportunity for Indian engineering companies that understand local conditions, can adapt quickly, and are committed to long-term customer success, helping cement manufacturers achieve their targeted thermal substitution rate (TSR) while maintaining operational efficiency and process stability.
About the author
Jignesh Kundaria is the Director and CEO of Fornnax Technology. He has established himself as one of India’s foremost voices on waste-to-fuel technology and alternative fuel infrastructure. He has contributed to policy formulation in association with NITI Aayog across two critical areas: waste processing and tyre recycling, bringing an operator’s ground-level perspective to national-level conversations on industrial decarbonisation.
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