Economy & Market

Local equipment makers could do with govt boost

Published

8 years ago

December 31, 2017

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Rakesh Sharma, Director, AMCL Machinery Ltd

Rajesh Pathak, Director, Sales & Operations, Raymond Bartlett Snow

Do you foresee any paradigm shift?
Rakesh Sharma (RS): As far as the Indian cement industry is concerned, it proactively factored in the advancements in technology a decade ago. That’s why plants with 10,000 tonne per day capacity continue to operate with the same number of personnel as earlier. However, NOx, SOx and carbon dioxide emissions might pose a challenge and cement plants, and the industry is trying to cope up with that. This provides an opportunity to Indian equipment manufacturers to work out cost-effective emission control technologies. Apart from that, the industry is continuously striving to reduce consumption of power and fuel. Equipment manufacturers like us are undertaking retrofit jobs to not only reduce power and fuel consumption but also release of polluting elements.

Rajesh Pathak (RP): I would say that there is no paradigm shift per se. No major capacity expansion took place in the cement segment after 2008. But with the government impetus to infrastructure projects from 2014, most cement, power and steel plants are again expanding capacity. I, therefore, don’t see any threat in terms of redundancies. But I do agree that there is a need for pollution control norms. For example, in the cement sector, wherein there is an application of coal grinding mills, most cement plants use pet coke as it’s cheaper. A recent Supreme Court judgment has asked states and union territories to consider banning the fuel. Avoiding pet coke is certainly going to help in reducing emission levels, but it is also going to put pressure on pockets of cement manufacturers.

So, what’s your outlook for the Indian cement business?
RS: I am very positive. Although things might not look very bright for equipment manufacturers at the moment, but growth is certain going forward. Today, we are talking about 7 per cent growth, but it’s my guess that in the next 3-4 years it might touch 9 per cent. Normally cement consumption is one-and-a-half times GDP growth. The earlier high was around 8 per cent. Once the economy picks up pace, this might exceed 10 per cent! And, most definitely, by 2030 the per capita consumption of cement would reach 400 kg, which will help double the capacity of cement plants. RP: The cement industry will register further growth. If you look at the outlook for the next five years, there is a lot of talk about slag cement. This waste material from steel plants can be used for cement application. The talk is now about Portland Slag Cement (PSC). I also agree with Mr. Sharma’s view on cement equipment manufacturers. They face a major challenge from their Chinese counterparts. Therefore, when we talk about ‘Make in India’, all equipment suppliers should have terms in their contract to either manufacturing or source only India-made equipment. This will ensure that local suppliers also get a chance to grow. The government could also mull levying extra import duty on equipment that are outsourced from countries like China and South Korea.

What can be done at the government level?
RS: Unlike Chinese equipment manufacturers, where there is always a question mark on product quality, Indian manufacturers enjoy a favourable reputation. Leading global players like FLSmidth, KHD Humboldt Wedag and others have set up bases here, and are doing quite a bit of engineering and local sourcing. India will definitely acquire an edge over competition over the next few years and might become an exporter of machinery to countries that prefer quality. It’s like in the automobiles industry, where we are today reckoned an important exporter of automotive components and automobiles.

RP: India is presently the second largest producer of cement in the world. Since we are now talking about smart cities, dedicated freight corridors and new roads & highways, there is undoubtedly good potential for the growth of the sector. In the Indian Subcontinent, we have favourable business treaties with countries like Nepal and Bhutan, and the government can incentivise Indian companies to set-up cement plants there. This would help expand the industry’s footprint overseas.

Economy & Market

TSR Will Define Which Cement Companies Win India’s Net-Zero Race

Published

3 days ago

April 27, 2026

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Jignesh Kundaria, Director and CEO, Fornnax Technology

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.

Concrete

WCA Welcomes SiloConnect as associate corporate member

Published

2 weeks ago

April 13, 2026

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The World Cement Association (WCA) has announced SiloConnect as its newest associate corporate member, expanding its network of technology providers supporting digitalisation in the cement industry. SiloConnect offers smart sensor technology that provides real-time visibility of cement inventory levels at customer silos, enabling producers to monitor stock remotely and plan deliveries more efficiently. The solution helps companies move from reactive to proactive logistics, improving delivery planning, operational efficiency and safety by reducing manual inspections. The technology is already used by major cement producers such as Holcim, Cemex and Heidelberg Materials and is deployed across more than 30 countries worldwide.

Concrete

TotalEnergies and Holcim Launch Floating Solar Plant in Belgium

Published

2 weeks ago

April 13, 2026

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TotalEnergies and Holcim have commissioned a floating solar power plant in Obourg, Belgium, built on a rehabilitated former chalk quarry that has been converted into a lake. The project has a generation capacity of 31 MW and produces around 30 GWh of renewable electricity annually, which will be used to power Holcim’s nearby industrial operations. The project is currently the largest floating solar installation in Europe dedicated entirely to industrial self-consumption. To ensure minimal impact on the surrounding landscape, more than 700 metres of horizontal directional drilling were used to connect the solar installation to the electrical substation. The project reflects ongoing collaboration between the two companies to support industrial decarbonisation through renewable energy solutions and innovative infrastructure development.