Concrete

“Stop viewing innovation as a cost.”

Published

2 months ago

September 26, 2026

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Rohit Kochar, Promoter, Executive Chairperson and CEO, Bert Labs, challenges cement industry leaders to start investing in AI infrastructure as a strategic imperative.

In a low-margin, volume-driven industry where a single day’s breakdown at an 11,000 TPD integrated plant can cost 2 to 3 crore in operating profit, Rohit Kochar, Promoter, Executive Chairperson and CEO, Bert Labs®, argues that the business case for Foundation AI infrastructure in cement is not a question of ‘if’, but of how quickly manufacturers are willing to act.

How can AI infrastructure be designed into greenfield cement plants to build efficiency, sustainability and decarbonisation into operations from the outset?
AI infrastructure should be designed into greenfield cement plants from the outset to embed efficiency, sustainability and decarbonisation into their operational architecture. For the energy intensive and relatively commoditised instead of low margin – if deemed fit cement industry, end to end efficiency is critical. At Bert Labs®, we address this through Inhouse grown Foundation AI infrastructure developed specifically for industrial applications.
Our infrastructure comprimes Bert Geininus™ and Bert Optimus® together form an AI-driven Digital Twin solution, integrating first-principles models, plant data, simulation, prediction, and optimisation for both plant design and operations., supported by design and operational digital twins. For a greenfield plant, information relating to capacity, whether it is a 10,000, 12,000 or 15,000 TPD facility, along with kiln lines, grinding units, utility sections and other components, can be incorporated into a design digital twin.
Powered by deep neural network algorithms developed by Bert Labs®, the Design Digital Twin can optimise plant architecture before construction begins. This can improve fuel and power consumption, heat efficiency, clinker production and the final cement product. By embedding optimisation at the design stage, companies can reduce later corrective interventions while improving productivity and responsiveness to customer requirements.
Granular data infrastructure is equally important. Many existing plants have decades of operating history, but valuable historical data is often overwritten or not retained. Data relating to machine performance, sensors, production, operating conditions, safety interlocks, process quality and product quality is essential for effective optimisation.
For greenfield plants, this infrastructure can be established through Bert Nova™ is a multi-tenant, microservices-integrated AI platform developed by Bert Labs®. A typical integrated cement plant has more than 10,000 variables across its unit operations, generating structured time series data. The platform enables this information to be captured and stored from at intervals ranging from split seconds to multiple years.
The infrastructure is supported by IoT Systems-on-Chip and the Bert Maximus devices platform, with devices communicating through the BERT Qrious wireless sensor network. BERT Titan acts as a base station, transmitting data to on-premise and cloud servers while enabling edge computing. This allows Foundation AI models to train in real time and enables AI based controls to operate close to the equipment being monitored. The wireless sensor network is designed to deliver 99.99 per cent reliability, with the objective of minimising data loss.
While conventional DCS systems remain important for plant monitoring and control, greenfield facilities can now build an integrated architecture combining IoT platforms, wireless sensor networks, edge computing and AI based enterprise software – “are future-ready and will yield benefits for years to come.”. The system can support distributed and federated computing across on-premise servers, cloud environments and multiple bringing all plants onto a single platform.
The larger objective is to build cement plants that remain relevant five or ten years into the future. By integrating AI, digital twins, IoT, edge computing and intelligent data infrastructure from day one, greenfield plants can become more real time, predictive and increasingly autonomous, embedding efficiency, sustainability and decarbonisation into their operations from the outset.

How can AI infrastructure help brownfield plants modernise legacy systems and improve process efficiency without requiring extensive replacement of existing assets?
One of the key strengths of the Bert Labs® Foundation AI Infrastructure and Bert platform solution is its ability to deliver up to 10 per cent fuel savings and up to 20 per cent power savings through annual year-on-year commitments. The foundation of this impact is a 360-degree view of data.
For brownfield plants, our approach begins by integrating IT and OT systems. IT infrastructure, including ERP, CRM, HRMS and other enterprise software platforms, is integrated with Bert Nova™, our multi-tenant AI distributed and federated computing enterprise software platform. Operational technology, including the DCS, energy management, production management and quality management systems, is integrated into the same platform.
Another important capability is bringing multiple facilities onto one common platform. A cement company may operate 15, 20, 30, 40 or even 100 plants, each with its own DCS and operational systems. Bert Nova™ can integrate these facilities, including those across different geographies, onto a common enterprise platform, which is particularly relevant as Indian cement companies expand globally.
This integration also enables greater centralisation of basic plant operations. Instead of each of 20 or 30 plants requiring large teams to independently manage operations, a significantly smaller central team can monitor multiple facilities through Bert Nova™ dashboards, covering safety, production, process management and product quality.

How can AI-driven optimisation reduce specific energy and raw material consumption while improving productivity and lowering the carbon intensity of cement production?
Our major focus in the cement sector is energy because it represents a significant cost and operational challenge. Through the Bert Labs® Foundation AI Infrastructure, we help cement manufacturers reduce specific energy consumption while improving productivity, optimising raw material use and lowering carbon emissions.
Our approach involves creating Foundation AI agents for the integrated cement plant. These models establish correlations across the entire process, from limestone particle size and moisture at the crusher to raw meal fineness, fuel characteristics, kiln feed and rotary kiln operations. Real time control of these variables can directly influence heat consumption and overall process efficiency. Cement plants may use seven, eight or more fuel sources, including waste streams from other businesses within diversified industrial groups, making intelligent optimisation particularly important.
An integrated cement plant can have approximately 10,000 independently measured parameters captured through digital and analogue sensors, alongside tens of thousands of dependent and latent variables that are not directly measured. Bert Labs® uses physics and chemical engineering-based simulations to model processes in grinding units and kilns. These models create soft sensors, which are integrated with physical sensors and deep neural networks to provide the Foundation AI with a more comprehensive understanding of plant operations.
Bert Labs® reports potential reductions of up to 20 per cent in power consumption and up to 10 per cent in fuel consumption on an annual and year on year basis. Reduced energy consumption directly lowers carbon dioxide and other greenhouse gas emissions, supporting progress towards net zero. According to the company, its work could help clients accelerate net zero targets, including a European client’s 2035 target and an Indian company’s 2040 target.
Improved heat efficiency also reduces the energy intensity of clinker production. Bert Labs® reports reducing specific heat consumption from 720 kilocalories per kg of clinker to 691 kilocalories per kg at one cement plant, and from 711 kilocalories per kg of clinker to 662 kilocalories per kg at another.
Raw material optimisation is enabled by integrating plant operations with supply chain and enterprise data through Bert Nova™. Information on incoming materials can be connected with the real time requirements of the raw mill, pyro section and cement mill, as well as changing customer requirements. This enables the system to optimise the raw mix, including limestone, gypsum and other materials, in real time.

How should cement manufacturers evaluate the business case for AI infrastructure in terms of energy savings, resource efficiency, emissions reduction and long-term progress towards net zero?
My first advice to cement industry leaders is to stop viewing innovation as a cost and learn to invest in it. Innovation should become the norm in the cement industry, which is a low margin and highly volume driven business. While India’s infrastructure and construction growth provides significant opportunities, industry consolidation will also continue, making innovation essential to maintaining competitiveness.
Cement companies should evaluate AI infrastructure through conventional metrics such as payback period, return on investment and internal rate of return, while also recognising its wider operational value. According to Bert Labs®, the payback period for its Foundation AI Infrastructure and Bert Platform Solution® can be as short as one month for a single integrated plant, with an internal rate of return running into several hundred per cent.
The scale of the opportunity becomes clear when energy consumption is considered. If the annual power and fuel cost of a pyro section, from the preheater to the cooler, is 60 crore and AI driven optimisation reduces this by approximately 23 crore to 24 crore annually on a year-on-year basis, the savings can become substantial across multiple lines. For a company operating nine or 20 lines, along with additional grinding units, energy expenditure can run into 700 crore, 800 crore or even 1,000 crore.
Resource efficiency is another important consideration. Industry leaders note that a cement plant that required around 500 people to operate 35 to 40 years ago may today operate with approximately 55 to 60 people. With automation and centralised
AI enabled operations, basic operations across
multiple plants could potentially be managed by much smaller teams, significantly reducing the human resources required.
Reduced human intervention can reduce bias and also improve productivity, operating margins and safety. An 11,000 TPD integrated cement plant can reportedly face an operating profit impact of 2 crore to 3 crore per day during a major breakdown. AI enabled monitoring and optimisation can help reduce such disruptions while lowering the management bandwidth required to address operational and workforce challenges.
Ultimately, cement manufacturers should not wait for innovation to become risk free. They can begin with smaller deployments, learn from the outcomes and continue investing in technologies that demonstrate value. The business case for AI infrastructure should therefore extend beyond immediate financial returns to include energy savings, resource efficiency, improved productivity, reduced operational risk, emissions reduction and a more sustainable future.

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Concrete

ABB Extends Drive Lifespan at ACC Cement Plant Without Production Shutdown

Published

3 hours ago

November 12, 2026

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ABB reconditions 25 drives at ACC’s Jamul cement plant, avoiding 16 tonnes of CO₂ emissions while improving reliability through predictive maintenance.
Chhattisgarh

ABB has signed a multi-year Motion OneCare service agreement with ACC Limited, part of the Adani Group, to modernise ageing industrial drives at its Jamul cement plant in Chhattisgarh, improving operational reliability while avoiding approximately 16 tonnes of carbon dioxide (CO₂) emissions without disrupting production.

Announced on 27 October 2026, the agreement combines scheduled drive reconditioning, digital condition monitoring and energy appraisals to extend equipment lifespan, improve plant uptime and optimise maintenance costs. The initiative marks a shift from conventional equipment replacement towards a more resource-efficient approach to industrial asset management.

The first phase, completed in April 2026, involved the on-site reconditioning of 25 ABB ACS800 variable speed drives without a major plant shutdown. By retaining the existing cabinets and restoring the drive modules rather than replacing entire panels, ABB helped ACC preserve capital investment, minimise material consumption and avoid approximately 16 tonnes of CO₂ emissions.

A second phase, covering an additional 25 ACS800 drive modules, is scheduled for the fourth quarter of 2026. The programme is designed to improve long-term equipment reliability while allowing maintenance activities to be aligned with the plant’s operational schedules.

The ACS800 drives, installed at Jamul in 2010, had delivered more than a decade of near-continuous service in demanding cement manufacturing conditions. However, ageing electrical components and changing fault patterns had begun to affect their ability to meet the plant’s reliability requirements.

Rather than opting for complete equipment replacement, ACC engaged ABB’s certified engineers to conduct a comprehensive asset health assessment. The evaluation found that the existing cabinets and enclosures remained structurally sound, making targeted reconditioning a technically viable and cost-effective alternative to full replacement.

Drawing on nearly two decades of experience with ACC’s equipment and operating requirements, ABB developed a maintenance framework tailored to the plant’s shutdown windows, budget cycles and production priorities.

The Motion OneCare agreement incorporates planned equipment restoration, condition-based monitoring and energy assessments, enabling ACC to adopt a more systematic approach to maintaining critical electrical infrastructure.

As part of the programme, ACC has implemented ABB Ability™ Digital Powertrain Insights to monitor drive performance and identify emerging operational issues before they result in equipment failures.

The digital platform provides continuous visibility into parameters such as temperature, current, vibration and fault patterns. These insights allow maintenance teams to detect early signs of equipment deterioration, schedule interventions more effectively and reduce the likelihood of unexpected downtime.

Amit Gupta, Local Division Manager, Motion Services, ABB India, said: “We know what unchecked wear costs over time: a small inefficiency that eats away at ROI for years. At Jamul, the evidence pointed clearly to assets with productive life still in them.”

“Our job was to restore them properly and give the team the tools to stay ahead of the next problem. At ABB, we don’t just fix what fails. We want to protect what works.”

The initiative also demonstrates the growing relevance of circular economy principles in cement manufacturing, where extending the service life of existing industrial equipment can reduce capital expenditure, material consumption and the environmental impact associated with manufacturing replacement components.

According to ABB, drive reconditioning can reduce lifecycle emissions by 50 to 80 per cent compared with complete equipment replacement. By preserving functional components and restoring critical modules, the process helps retain the economic and material value of existing industrial assets.

The addition of energy appraisals in subsequent phases will further expand the programme beyond equipment restoration, enabling ACC to assess drive performance, identify energy-saving opportunities and improve operating efficiency.

For cement manufacturers, variable speed drives play an important role in controlling motors and optimising energy consumption across production processes. Maintaining their reliability and efficiency is essential for minimising operational disruptions and managing electricity costs.

Vinod Bahety, CEO – Cement Business, Adani Group, said: “Moving from reactive firefighting to a structured maintenance plan was exactly what this operation needed. That kind of peace of mind doesn’t come easily. It comes from a partner that understands how your business runs.”

“We didn’t need a full system overhaul; we needed expert support, actionable insights, and a plan we could execute around our schedule. That’s what we got.”

The project supports ACC’s broader strategy to improve manufacturing efficiency through digital transformation, preventive maintenance and sustainable asset management.

ACC, a subsidiary of Ambuja Cements and part of the Adani Group, operates 20 cement manufacturing facilities and 119 ready-mix concrete plants across India. The company has been advancing initiatives focused on renewable energy, circular economy practices and technology-driven operational improvements.

Alongside Ambuja Cements, ACC is part of a large-scale building materials business committed to achieving net-zero emissions by 2050, with near-term and net-zero targets validated by the Science Based Targets initiative (SBTi).

The Jamul initiative aligns with these sustainability objectives by demonstrating how equipment life extension and digital monitoring can contribute to resource efficiency without requiring large-scale replacement of existing infrastructure.

ABB, a global technology company specialising in electrification and automation, brings more than 140 years of industrial expertise and employs approximately 110,000 people worldwide. Its Motion Services business supports industrial customers through equipment maintenance, modernisation, digital monitoring and lifecycle management solutions.

The agreement also reflects a wider shift in industrial maintenance practices, with manufacturers increasingly adopting predictive technologies to improve equipment availability, manage costs and reduce unplanned shutdowns.

With 25 drives already reconditioned and another 25 scheduled for restoration, ABB’s collaboration with ACC illustrates how targeted modernisation, digital monitoring and circular maintenance practices can extend the operational life of critical equipment while supporting more efficient and sustainable cement production.

Concrete

ABB Drives Digital Transformation at TCI MAX Cement Plant in J&K

Published

4 hours ago

November 12, 2026

admin

ABB deploys advanced process control at TCI MAX’s Srinagar cement plant to improve clinker quality, energy efficiency and sustainable manufacturing.

Kashmir

ABB has deployed its advanced process control technology at TCI MAX Cement’s Srinagar facility in Jammu and Kashmir, marking the region’s first reported implementation of advanced process control (APC) in cement manufacturing and strengthening efforts towards more efficient, digitally enabled production.

Announced on 5 November 2026, the deployment of ABB Ability™ Expert Optimizer at the facility, operated by Trumboo Industries Pvt. Ltd., aims to improve process stability, clinker quality, energy efficiency and overall plant productivity. The implementation forms part of TCI MAX’s strategy to modernise its manufacturing operations through automation and digital technologies.

Following the integration of ABB’s advanced process control solution and supporting IT infrastructure, TCI MAX has reported improvements in operational productivity, product quality and sustainability-related performance indicators. The technology focuses on optimising the cement pyro process, a critical stage of production involving high-temperature processing and clinker formation.

Waseem Ahmed Trumboo, Director, Trumboo Industries Pvt. Ltd., said: “Introducing advanced process control at TCI MAX is an important step in how we are evolving our operations. Our focus is on improving the stability and efficiency of our processes while maintaining consistent clinker quality. We have been encouraged by the performance of the solution during commissioning and by the support from the ABB team, and we look forward to realizing its full potential.”

ABB Ability™ Expert Optimizer combines advanced process control, model predictive control (MPC) and artificial intelligence (AI) to continuously monitor and optimise manufacturing operations. By analysing process conditions, predicting operational behaviour and automatically adjusting key parameters, the system enables more consistent production while reducing process variability.

In cement manufacturing, maintaining stable pyro-processing conditions is essential for achieving uniform clinker quality and optimising thermal energy consumption. Fluctuations in operating parameters can affect fuel efficiency, production output and product consistency.

The deployment is designed to address these challenges through real-time process optimisation, helping operators maintain more stable kiln operations while improving the utilisation of fuel, electricity and raw materials.

Kapil Agarwal, Senior Vice President and Local Division Manager, Process Industries Division, ABB India, said: “Cement producers are increasingly looking to adopt digital technologies to achieve greater consistency and efficiency while addressing their sustainability priorities. ABB Ability™ Expert Optimizer brings advanced process control and deep cement process expertise together to help operators make their processes more stable and efficient. We are pleased to support TCI MAX as it takes this important step in its digital transformation.”

The technology also supports sustainability objectives by optimising fuel consumption, improving electrical energy efficiency and minimising process waste. More stable operations can contribute to lower energy intensity and reduced emissions associated with cement production.

For TCI MAX, the investment represents a move towards data-driven manufacturing, where automated control systems complement operator expertise to improve production performance and operational reliability.

The implementation is particularly significant for Jammu and Kashmir’s cement industry, as it introduces advanced process optimisation technology to a regional manufacturing facility. Its deployment could demonstrate the potential for wider adoption of digital automation across cement plants seeking to modernise their operations.

The project builds on ABB’s experience in delivering advanced process control solutions to cement manufacturers worldwide. Through the integration of industrial automation, predictive technologies and process engineering expertise, the company supports manufacturers in improving resource efficiency and maintaining consistent production quality.

As cement producers face increasing pressure to manage energy costs, improve productivity and reduce their environmental footprint, technologies such as AI-enabled process control and predictive optimisation are becoming important components of plant modernisation strategies.

ABB’s Expert Optimizer provides a platform for addressing these priorities by enabling automated adjustments based on changing process conditions, reducing reliance on manual intervention and supporting more efficient plant operation.

ABB, a global technology company specialising in electrification and automation, has more than 140 years of industrial experience and approximately 110,000 employees worldwide. Its Automation business employs around 26,000 people and provides technologies and services across process, hybrid and maritime industries.

The TCI MAX deployment reinforces ABB’s growing role in the digital transformation of cement manufacturing in India, where improving process efficiency and reducing energy consumption remain critical to the industry’s long-term sustainability.

With the advanced process control system now implemented at its Srinagar facility, TCI MAX aims to build on the initial operational improvements and further optimise production efficiency, clinker consistency and environmental performance.

Concrete

Ramco Cements’ Hard Worker Wins Eight Awards at ‘Love of Advertising Awards 2026’

Published

4 hours ago

November 12, 2026

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Ramco Cements’ Hard Worker brand wins eight awards for excellence in advertising, packaging and brand identity at the Love of Advertising Awards 2026.

Hyderabad

The Ramco Cements Limited’s construction chemicals brand, Hard Worker, has secured eight awards at the Love of Advertising Awards 2026, recognising its creative excellence across television, digital advertising, packaging design and brand identity.

Organised by the Advertising Club of Trivandrum, the awards were presented at a ceremony held at The Leela Raviz, Kovalam, on 24 October 2026. The recognition highlights Hard Worker’s integrated marketing strategy and its efforts to establish a distinctive presence in India’s competitive construction chemicals market.

The eight awards span multiple creative categories, reflecting the brand’s approach to combining product-focused communication with engaging storytelling, humour and innovative design. Through its campaigns, Hard Worker has sought to simplify technical product benefits and make construction chemicals more accessible and relatable to consumers and construction professionals.

Built around the philosophy of “Hard-working products for hardworking people”, the brand focuses on communicating practical product advantages through memorable advertising narratives while maintaining a consistent identity across different marketing platforms.

Its campaigns for Ramco Hard Worker Eco Plaster and Tile Fix have been central to this approach. The Eco Plaster campaign highlights water conservation through the product’s self-curing properties, positioning it as a solution that supports more efficient construction practices. Meanwhile, Tile Fix promotes specialised tile-fixing solutions by presenting their practical benefits through relatable situations and creative storytelling.

Beyond advertising, Hard Worker has invested in distinctive packaging and brand identity development to improve product recognition and maintain consistency across customer touchpoints. This integrated approach has helped the brand differentiate itself in a category where marketing communication has traditionally focused on technical specifications and functional performance.

A V Dharmakrishnan, CEO, Ramco Cements, said, “Winning eight awards at the Love of Advertising Awards is a proud moment for Ramco Cements and the Hard Worker team. We believe that building a strong brand requires not only quality products but also the ability to communicate their value in a compelling and differentiated manner. Hard Worker’s journey reflects our commitment to combining product performance with innovative marketing to create meaningful connections with our customers and strengthen our presence in the construction chemicals market.”

The recognition comes as building materials manufacturers increasingly focus on brand differentiation, product awareness and customer engagement to strengthen their position in the construction chemicals segment.

By using humour and storytelling to explain product applications and benefits, Hard Worker aims to bridge the communication gap between technical construction solutions and the practical requirements of contractors, applicators and end-users.

Balaji K. Moorthy, Executive Director – Marketing, Ramco Cements, said, “Hard Worker was conceived to bring a fresh perspective to the construction chemicals category, where product communication has traditionally been functional and technical. Our endeavour has been to break through the clutter with distinctive ideas, humour and storytelling, while keeping the product proposition at the heart of every campaign. The recognition across TV and digital advertising, packaging design and brand identity design demonstrates our integrated approach to building the brand. These eight awards are an encouraging recognition of the creative thinking and collaborative effort behind Hard Worker’s marketing initiatives.”

The awards add to Hard Worker’s growing portfolio of creative recognitions and reinforce Ramco Cements’ emphasis on integrating product innovation with strategic marketing.

The brand’s communication initiatives also reflect a wider shift in the construction materials industry, where manufacturers are increasingly adopting consumer-focused marketing strategies to improve product understanding and strengthen relationships with construction professionals.

With its portfolio of construction chemicals, Hard Worker aims to address evolving requirements for durability, application efficiency and construction quality. Its marketing efforts seek to complement these product attributes by building stronger awareness and encouraging the adoption of specialised construction solutions.

Ramco Cements, one of India’s established cement manufacturers, operates across cement and allied building solutions. Through Hard Worker, the company is expanding its presence in the construction chemicals segment with products designed to enhance performance, quality and durability in modern construction applications.

The latest recognition strengthens Hard Worker’s brand visibility and underscores the growing importance of creative communication in promoting technical building materials. Ramco Cements intends to continue combining product development with distinctive marketing initiatives to support the brand’s growth in India’s construction chemicals market.