Satish Maheshwari, Chief Manufacturing Officer, Shree Cement, discusses how digitalisation and automation are transforming plant performance while strengthening cost efficiency and environmental outcomes.

Across India’s cement industry, modernisation is increasingly shaping the way plants operate, compete and scale. In this conversation, Satish Maheshwari, Chief Manufacturing Officer, explains how Shree Cement is leveraging advanced process control, AI-enabled analytics, waste heat recovery and renewable energy to build smarter, more resilient manufacturing operations.

What are the key drivers pushing cement plants in India to prioritise modernisation?
Our approach to modernisation is firmly anchored in driving long-term cost efficiency and operational excellence. We are making targeted investments in automation, digital systems and advanced process controls to improve energy efficiency, enhance productivity and reduce variability across operations. This allows us to scale responsibly while maintaining strong cost discipline.
At the same time, modernisation supports a more diversified and resilient business model. As customer requirements evolve, there is a growing need for consistent quality, reliability and differentiated products, which modern plants are better equipped to deliver. Equally important is building control and flexibility across the value chain to manage input volatility and regulatory expectations.
Overall, this balanced focus on efficiency, innovation and scalability enables us to remain competitive in a price-sensitive market while preparing the organisation for sustainable growth over the long term.

How is plant modernisation helping you balance cost efficiency, productivity and sustainability targets simultaneously?
Plant modernisation enables us to address cost efficiency, productivity and sustainability through a single, integrated operating framework. By investing in advanced automation, digital process controls and data-led optimisation, we improve plant stability and throughput while reducing energy and fuel consumption per tonne, which strengthens cost efficiency.
At the same time, greater deployment of renewable energy and waste heat recovery reduces dependence on conventional power, improves energy security and lowers emissions, directly supporting our sustainability goals.
Modernised plants allow tighter control over quality and input intensity, ensuring consistent performance as we scale. In effect, modernisation ensures that productivity gains, cost discipline and environmental responsibility move in the same direction, enabling sustainable and competitive growth over the long term.

Which technologies have delivered the most measurable impact in your upgraded facilities?
Automation, AI enabled analytics, digital twins and modernised Waste Heat Recovery Systems (WHRS) have had the most tangible impact across Shree Cement’s upgraded facilities. Advanced Process Control has improved kiln and mill stability, reduced process variability and lowered overall energy consumption. AI based condition monitoring and predictive models have strengthened equipment health visibility, enabling early fault detection and significantly reducing unplanned downtime. Digital twins have supported better optimisation strategies and quicker ramp up after shutdowns by allowing teams to simulate scenarios and refine set points without disturbing live operations.
At the same time, enhanced WHRS have delivered measurable energy savings and reduced dependence on grid electricity, directly contributing to lower carbon intensity. Together, these technologies have improved reliability, elevated operational consistency, and strengthened the company’s sustainability performance. Their combined impact has positioned Shree Cement’s plants to operate with higher efficiency, improved resilience, and a future ready digital approach to manufacturing.

How do you evaluate ROI and payback periods when investing in large-scale plant modernisation projects?
At Shree Cement, ROI evaluation for large scale modernisation projects is built on a rigorous techno economic approach that prioritises efficiency, reliability, and long-term value creation. Each project undergoes a detailed assessment of its impact on key operational parameters such as specific power and heat consumption, throughput improvement, equipment life enhancement, maintenance cost reduction, and process stability. Real time performance data from existing systems is used to benchmark expected gains, ensuring that projections are grounded in actual operating behaviour. Financial metrics, including ROI, IRR, NPV and sensitivity to production variability, are carefully analysed to determine realistic payback periods under different operational scenarios.
Beyond financial returns, Shree Cement places strategic emphasis on sustainability, digitalisation, and regulatory preparedness when evaluating investments. Projects that contribute to lower emissions, improved energy efficiency, enhanced automation, and stronger ESG alignment are given significant weight, even when their payback horizons are moderate. This balanced assessment ensures that capital expenditure not only delivers measurable economic returns but also strengthens long term competitiveness, environmental compliance, and future ready operational resilience.

What operational challenges do you face while upgrading brownfield plants without disrupting ongoing production?
Upgrading a brownfield cement plant without disrupting ongoing production presents significant operational and managerial challenges. The constraints of highly restricted shutdown periods necessitate the completion of critical tie ins and modifications within compressed timelines, while ensuring uninterrupted supply commitments. To meet the tight timelines, we prepare necessary assemblies and tasks in advance, which are then quickly connected and executed during the shutdown period to minimise downtime.
Existing plant layouts, often characterised by limited space and legacy structural configurations, make the installation of additional equipment and the rerouting of ducts, cables, and utilities a complex undertaking. Execution activities are frequently carried out in proximity to live, high temperature equipment, demanding stringent safety controls and coordinated planning. Integrating new systems
with aging control architectures, instrumentation networks, and mechanical interfaces introduces further technical complexity.
Even minor disturbances during execution can adversely impact kiln draft control, cyclone separation efficiency and grinding system stability, requiring continuous coordination between execution teams and operations. The involvement of multiple contractors in confined working zones raises supervisory and interface management requirements, while temporary emission variations during tie in activities heighten environmental compliance obligations.
Ultimately, the core challenge lies in delivering modernisation initiatives that enhance plant efficiency and sustainability, while fully maintaining production performance and operational reliability.

How is modernisation reshaping workforce skills, safety standards, and day-to-day plant management practices?
Modernisation is significantly reshaping workforce skills, safety standards, and day to day plant management at Shree Cement, driving a shift toward more advanced, data centric and safety focused operations. With increasing adoption of digital tools, automated control systems, and high efficiency equipment, workforce capabilities are evolving from conventional plant operation to expertise in analytics, digital monitoring, remote diagnostics, and predictive maintenance. Training now emphasises technical upskilling, process optimisation and multi-disciplinary knowledge, enabling teams to operate more intelligent and interconnected systems.
Safety standards have also strengthened, supported by automation, continuous monitoring, and digitised safety management systems. Real time alerts, automated interlocks, safety by design equipment and digital permit to work systems are reducing manual exposure and enhancing overall workplace safety.
In day-to-day management, operations are becoming more proactive and technology driven. Supervisors and CCR teams increasingly rely on dashboards, performance analytics, and AI assisted insights to make faster, data backed decisions. Routine activities, such as equipment inspections, energy tracking, and process audits, are now supported by mobile apps, digital logs, and online reporting platforms, improving accuracy and accountability.
Modernisation has therefore transformed Shree Cement’s plants into more efficient, safer and knowledge-driven workplaces, where employees operate with greater precision, stronger safety culture, and enhanced decision-making capabilities

In what ways are modernised plants contributing to lower carbon emissions and alignment with ESG commitments?
Modernised plants are significantly reducing carbon emissions and strengthening ESG alignment at Shree Cement. High efficiency kilns, advanced grinding systems, and upgraded fans have lowered specific power and heat consumption, directly cutting CO2 intensity. Improved AFR feeding and combustion technologies enable higher alternative fuel usage, reducing reliance on fossil fuels.
WHRS expansions further convert waste heat into clean power, shrinking the overall carbon footprint. Digital tools, such as real time emissions monitoring and AI based process control, ensure continuous compliance with environmental norms. Through these modern upgrades, Shree Cement is advancing towards a more energy efficient, low carbon, and ESG aligned manufacturing ecosystem.

What role do partnerships with technology providers play in ensuring long-term efficiency and future readiness of your plants?
Partnerships with technology providers are critical for securing long term efficiency and future readiness in modern cement plants. Such collaborations enable access to advanced automation systems, high efficiency equipment, and data driven optimisation platforms that enhance reliability, reduce energy consumption, and strengthen process control.
Technology partners also contribute through specialised training, remote diagnostics, and performance benchmarking, ensuring that operational teams remain aligned with evolving industry standards and sustainability expectations. Examples include high efficiency grinding technologies, intelligent process control systems, real time emissions monitoring and predictive maintenance platforms.
Modernisation at Shree Cement is centred on real time, data driven operations that enhance efficiency, reliability and sustainability. With advanced automation, integrated digital platforms and intelligent controls across our plants, decision making has become faster, more accurate and predictive. These technologies stabilise core processes, improve safety and reduce energy intensity, enabling a smarter and more resilient manufacturing ecosystem that is ready for the industry’s future demands.

• – Kanika Mathur