Technology

Innovation at work

Published

8 years ago

January 31, 2018

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Innovation is driving advancement of technologies and growth of the cement packaging segment globally. India must be able to take part and reap benefits from them.
While innovation is changing the way every work is done in every field of activity, cement packaging cannot be too different. Though there is hardly any change in the material consumed for manufacturing cement packaging, the new technologies and processes are making them high on productivity, safer, quicker to fill, load and re-load, leak-proof and amenable to automation, when compared to yester years when it was dangerous, hazardous and labour-intensive.
Bags are a common way of distribution in the industry, accounting for about 60 per cent of the product shipped to consumers/users. This also holds true for other developing countries, according to industry sources, which put the figure at 45 per cent on an average. Bulk packaging though is yet to catch up on a large scale in India, it is being patronised by some major cement manufacturers and bulk consumers.
Though there are several manufacturers of cement packaging bags in the country, most of the highly advanced automated machinery and systems are being imported from countries like Germany, Italy, Switzerland, the US, Taiwan, etc.
Innovation has been the key for sustained growth of global players like Windm?ller & H?lscher during the recent years, particularly when it has introduced hot air to seal the moisture-proof sacks that used to be closed with adhesives earlier, thereby reducing production costs and technical process limitations. Another global player, FLSmidth offers complete automation solutions by integrating various product types with that of fully automated packing plants, automating even loading and unloading activities.
Packing plants have not only become part of cement production lines, but also grinding stations or cement terminals. A single packing line produces up to 15 to 50 million bags per year based on the material used and the process adopted. That way, packing plants have evolved into complex, fully automated operations, driven by innovation in the recent years.Options
There are three options for cements sacks: Paper, woven and film. "Paper sacks are a comparatively cost-effective form of packaging made from a renewable source," says spokesperson of Windm?ller & H?lscher, which claims to be the market leader in the field of paper sack systems, with over 90 per cent share globally.
Woven polypropylene (PP)/plastic sacks are very lightweight and tear-resistant, which is particularly useful if the sacks are to be used in tougher environments. So, many Indian companies have embraced the option till the regulatory intervention, citing higher loss of cement in wrong handling. But they face a challenge – necessary deaeration of product.
A natural side effect of packing cementitious material into a polypropylene bag is trapped air. In order to make PP packaging a viable option for cement, this air needed to be managed back out of the process to achieve a uniform and stable
pack, which is a crucial ingredient for efficient palletisation. Achieving this, while maintaining the intended waterproof credentials of polypropylene and maintaining process speed is no mean task. However, this has been enabled by the latest technologies.
Film valve sacks, on the other hand, provide excellent moisture protection, and advertising on them is more effective as they hold print well, a factor which is key, particularly in the field of premium packaging.
"Valve sacks have the important benefit of being able to be filled on nozzle packers, which ensure a high filling output. Valve sack concepts are available in all three major materials (paper, pp-woven, PE-film). Important factors regarding filling speed and automated handling are deaeration performance and form stability," says W&H.
Packaging in cement production has to fulfil multiple needs like moisture protection, extended shelf-life, clean appearance and good handling, says W&H, while explaining the prerequisites for a cement bag. "Better stackability, pilfer-resistance, anti-counterfeit solution and better aesthetics are some of the reasons why the hot air sealed woven sacks have been preferred in the Indian market," added the W&H spokesperson. Besides, less flying of packaged product also helps cement users save cost. These benefits also help cement companies create a better brand image in the market-domestic or export.Store appearance
Look and feel of packaging, which was till recently confined to consumer goods packaging, is becoming an important parameter while selecting the medium of packaging even for the cement industry. Their importance is gaining prominence when it comes to product placement and communication to the end-customer, particularly about the sustainability angle of the product and/or its special strengths and features. As such, sacks need to present all marketing messages in an attractive way.
"Currently additional packaging features like carrying handle or easy opening feel an increasing market demand as those features present an added value regarding sack handling for the end-user," says W&H.
W&H is also seeing acceptance in India of high-end Biaxially-Oriented Polypropylene (BOPP) laminated hot air sealed block bottom bags, which are much more expensive than the conventional sewn bags, and are amenable for printing very high quality photographic images. New automatic range
Automation is catching up with packaging processes of cement industry, of late. The technique of making an apparatus, a process, or a system operate automatically as it is described is being opted for by the industry for taking advantage of its well-known attributes – increased productivity, more efficient use of materials, better product quality, improved safety and reduced factory lead times. The packaging automation has extended to loading of closed top and open top trucks or containers by now.
"In India, hot air sealed block bottom bags are the most used for high automation production. The benefit for bag producers is lower manpower requirement for producing as these bags are produced with high speeds and advance automation," says the W&H spokesperson.
AD PROTEX valve bags produced on CONVERTEX platform by W&H ideally combine minimum raw material usage, adhesive-free sack production and unequalled functionality of their box-shaped design. As a result, they are made in a particularly economical way, but can also be filled and palletized similarly as the conventional pasted valve bags. "Our new production line for cement valve packaging ensures the production of paper sacks which fulfil the requirements for automated high speed filling," the company said.
Packaging for dry powdered materials like cement has changed little in the last 40 years leaving the end user to cope with the problems associated with the industry standard paper valve sack. As a result problems such as dust, spillage and a relatively high wastage return rate caused by the ingress of water brought about by poor storage conditions have largely remained unchallenged.
However, domestic packaging manufacturer, Arodo has introduced it brand of vacuum bagging system that produces fully deaerated plastic packs that don’t feature perforations of any kind, addressing the concerns of cement manufacturers and their customers. It is projected as a waterproof and tamper-proof cement pack.
"The absence of perforations allows each individual pack to be stored or placed in the most arduous of weather conditions without risk of spoiling the product through water ingress," says Vikas Marwaha, Director, Arodo India Pvt Ltd. These packs have been placed outside and completely underwater for weeks before retrieving and using the product as if it had been freshly packed, Marwaha claims.
Windm?ller & H?lscher has developed CONVERTEX, which heat seals woven PP cross bottom bags and thus eliminates the need of glue for this type of bags. "During the last 10 years the output of the bottomer was more than doubled: from 60 bags per minute to 140 in the last model. This speed represents the technological leadership in this type of equipment," W&H said, stating that today, CONVERTEX forms the backbone of its extensive portfolio of the woven PP business.
High-quality PP tapes with tenacity up to 7 g/den and indexed micro-perforation provide the technological tools to be able to produce e.g. cement bags with a weight of 65 grams instead of the current global market standard of 80 grams. Drop tests with the LS Bags are done – with the result that LS bags easily excel conventional bags, W&H claims.
The AD proFilm MP sack, launched in 2015, is unusual in the sense that it uses hot air to seal the sacks. This means that it does not require adhesives, which can be the source of significant production costs and technical process limitations. It is manufactured on the AD PLASTIC 2 valve bottomer.
When the company was developing the new AD proFilm MP film valve sack, it chose to focus on two key factors: high moisture protection (MP = moisture-proof), and extending the product’s shelf life. It achieved these through the use of its innovative Breathing Chamber Technology – a ventilation chamber along the longitudinal seam of the sack. "This technology means that effective ventilation and high moisture protection are no longer mutually exclusive", explains Uwe K?hn, Head of Processing Products at W&H.
In a presentation made on June 21, 2017, Francesco Ferrandico, President-FLSmidth Ventomatic Cement Packaging said that the company’s automation systems range extends beyond filling of sacks to loading into trucks – open or closed. "FLSmidth Ventomatic provides the key product types and integrates them for fully automated packing plants," Ferrandico said while explaining about different packaging processes that include electronic rotary and inline packers; empty bag applicators; palletizing systems; loaders for closed trucks/containers; and loaders for open top trucks.
FLSmidth claims that its loaders for closed trucks/containers were the first full automatic pallet loading system in the market. Truck/container loaders significantly increase safety level and productivity and they do not use forklifts and relevant operators, it said. Its electronic rotary and inline packer’s equipment for filling bulk cement from silos into bags have an output from 60 tons/h up to 250 tons/h.
Depending on level of automation, packing plants consist of 2 – 8 packing lines, and at full automation, reduces required manpower per shift from 12 to 2 when going from complete manual to automation packing, but with the same output, FLSmidth added.Cementing growth
W&H has seen a huge growth in consumption of hot air sealed woven sacks in Indian market with several plants running already and more on order. It has also seen a trend in the market of use of high-end Biaxially-Oriented Polypropylene (BOPP) laminated hot air sealed Block Bottom bags. "These bags are much more expensive than the conventional sewn bags, but are finding good acceptance in the Indian market. These bags can be printed with very high quality photographic images," W&H spokesperson said. We also expect increase in consumption of multiwall paper bags in the Indian market. The reasons are very interesting, innovations like high strength paper and water soluble paper done by paper industries.
As packaging industry’s growth is tied to the Indian economy and demand for cement and cement products, growth in these two elements are of critical importance for sustainability and growth of packaging industry in the country. Though the current trends in cement demand do not augur well for the packaging industry, the Union Budget released recently have some good news to bask under.
During the first eight months of FY2018 (2017-18), cement production witnessed a marginal growth of 0.6 per cent at 190.0 million MT compared to 188.8 million MT during the same period the previous year, leading rating agency ICRA said, citing various factors like weak real-estate activity, sand shortage and issues related to implementation of GST as reasons. Based on the current trend, it projected that cement demand is likely to report a modest demand growth of around 2 percent in FY2018.
In a pre-budget (January 31, 2018) analysis, Sabyasachi Majumdar, Senior Vice President & Group Head, ICRA Ratings, said "Going forward, the demand growth is likely to be driven by a pick-up in the housing segment – primarily affordable and rural housing, and infrastructure segment – primarily road and irrigation projects. However, new project announcements from the private sector continue to remain weak and revival of public-private partnership is crucial to improve the pace of infrastructure development."
"ICRA expects the capacity overhang and moderate demand growth to continue to keep the industry’s capacity utilisation level between 60-65 per cent over the medium term," Majumdar added.
However, the Union Budget 2018-19 released on February 1, 2018, has some good news for the cement industry. The move to boost the capital outlay of Pradhan Mantri Awas Yojana (housing scheme) -Urban (PMAY-U) five-fold to Rs 31,500 crore, will aid some recovery in the otherwise muted urban-housing demand, which accounts for 30 per cent of cement demand, said leading rating firm, CRISIL in a post-budget report. Besides, increase in outlays for the Ministry of Road Transport and Highways (MoRTH) and Railways by 11 per and 22 per cent respectively are expected to impact cement demand positively.
However, CRISIL had added a word of caution, when it said, "Healthy budget outlay for cement-intensive infrastructure segments like roadways, irrigation and railways should cement growth (infrastructure share estimated at 20 per cent). However, achievement of budgeted outlay to be key monitorable as some shortfall was observed in the previous fiscal."
There is a marginal negative stroke for the sector from the budget in the form of social welfare surcharge of 10 per cent on customs duty, which replaces the earlier 3 per cent education cess on custom duty of all imports. This will particularly affect the advanced packaging equipment imports.Looking ahead
Innovations are driving advancement of technologies and growth of the cement packaging segment globally over the recent years. India being one of the major producers of cement has to make inroads into the top echelons of the sector by increasing spending on research and development and entering into joint ventures with major global manufacturers to lower our import dependency in the long run.
Major cement manufacturers like UltraTech Cement, ACC, India Cement and Ambuja have to take the lead in this initiative. This is an imperative when all the major manufacturers have to take advantage of latest technologies and improve their global competitiveness. Full automation may come in handy in this regard by boosting productivity and quality. Reduction of manpower may not be as important for India as it is for many other countries. Labour being cheaper in the country, the companies have to weigh the social impact of full automation in comparison with social benefit of utilising the cheap manpower, if other parameters like quality and productivity are not affected.
Adoption of advanced technologies also means guarding against health hazards for employees and stakeholders, which will lead to attraction and retention of talent, a critical resource for success of any business. It will also lead to optimisation of costs and leads to higher competitiveness, which are essential for the prosperity of companies and the country.– BS SRINIVASALU REDDY
Factors to be considered for best packaging
The factors one should consider while searching for the best packaging production are:

Sack geometry
Sack converting
Sack design
Appearance
Stack design

Each aspect can be more or less important depending on the region and market the customer is looking for. Furthermore, different applications, availability of the respective materials, or even regional differences, sometimes with historical root causes may influence the decision. The supplier must be able to provide machines for the production of each sack type and after installation service.
Windm?ller & H?lscherCritical success factors in India
The following are the critical success factors (CSFs) that determine the future of a company or business, particularly for a player in the packaging equipment industry in India:

Technology
Price
Delivery
Performance standards
Cost of equipment, and
Low running cost
Possible upgrades to the product and
Aftersales/installation service
Compiled from different sources

Growth through productivity: FLSmidth CARICATECHTM automatic truck loader

Innovative development for loading all type of bags on all kind of trucks
Bag layers are picked up by a fork with a special roller way (no vacuum system required) while maintaining the traditional loading from the top Addresses trend of productivity improvements through automation in developing markets
CARICATECHTM replaces existing loading equipment without major process changes or rebuilds – targeting upgrades of existing packing lines

Economy & Market

RAHSTA Roundtable Sets Agenda for Smarter, Safer Highways

Published

1 week ago

March 16, 2026

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Roundtable discussions focus on innovation for safer highways.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the RAHSTA Roundtable brought together stakeholders from across the highways and infrastructure ecosystem to shape the agenda for the 16th RAHSTA 2026, scheduled for 8–9 July 2026 at the Jio Convention Centre, Mumbai. The session focused on key industry themes including road construction, technology, safety and long-term sustainability.

Opening the discussion, Pratap Padode, Founder, FIRST Construction Council, said the roundtable marked the beginning of a broader consultative process leading up to the July event. The aim, he noted, is to bring together industry stakeholders to refine the agenda for discussions on the future of roads, bridges, tunnels and allied infrastructure.

Padode noted that while central road project awards have slowed in recent years, states are increasingly driving the next phase of infrastructure growth. Maharashtra, with its long-term road development plans and agencies such as MSRDC and MSIDC, is expected to play a significant role in this expansion.

RAHSTA Expo 2026 as a specialised platform dedicated to road infrastructure, covering highways, tunnels, bridges and flyovers along with construction technologies, safety systems and maintenance solutions. He also highlighted the growing importance of rural connectivity and said the organisers are engaging with government bodies to highlight rural road development initiatives.

Tanveer Padode, CIO, ASAPP Info Group, presented insights from IMPACCT, the group’s infrastructure intelligence platform. He pointed to a strong project pipeline despite slower highway awards earlier in the year, noting that states such as Maharashtra, Odisha and Arunachal Pradesh are emerging as key drivers of new projects. The data also revealed that only a small group of contractors participates in large-value infrastructure bids.

Lt Gen Rajeev Chaudhary, former Director General, Border Roads Organisation and Chairman of the RAHSTA Expo Committee, emphasised the need for stronger collaboration across the ecosystem, including policymakers, contractors, technology providers and financiers. He also called for addressing systemic issues within the sector and encouraged greater participation of women in infrastructure leadership.

The discussion also explored the evolving economics of road development. Phani Prasad Mandalaparthy, Associate Director, CRISIL Intelligence, noted that the slowdown in project awards reflects a shift towards higher-value logistics corridors rather than simple road widening projects. However, private participation through BOT and TOT models remains limited.

From the contractors’ perspective, Sudhir Hoshing, Whole-Time Director, Ceigall, said companies are becoming more selective in bidding, favouring projects with clearer payment mechanisms and efficient processes. While NHAI continues to offer greater operational clarity, states such as Uttar Pradesh and Bihar were cited as relatively supportive environments for project execution.

Durability and sustainability also emerged as key themes. Himanshu Agarwal, COO – Road & Infrastructure, Zydex Group India, highlighted the need to prioritise lifecycle performance and resilient pavements, while participants discussed the potential of alternative materials such as plastic waste, steel slag and industrial by-products in road construction.

Dr LR Manjunatha, Vice President, JSW Cement, emphasised that India has abundant fly ash, slag and other industrial materials that can improve durability and sustainability if integrated into specifications and policy frameworks.

Technology and equipment challenges were also discussed. Dr Lakshmana Rao Mantri, Dy General Manager, Afcons Infrastructure, highlighted the shortage of tunnel boring machines (TBMs), which is delaying several underground infrastructure projects. Participants agreed that developing domestic TBM manufacturing capabilities will be critical for future infrastructure expansion.

The future of concrete pavements was another area of discussion. Dr V Ramachandra, President, Indian Concrete Institute, stressed that the debate should focus on lifecycle performance rather than material choice alone, noting that evolving design standards are improving the feasibility of concrete roads.

Prof Dharamveer Singh of IIT Bombay added that while India has made significant progress in infrastructure development, stronger capacity building and better execution practices are essential to ensure consistent road quality.

The discussion also touched upon technology adoption in the sector. Rushabh Mamania, Partner & CBO, Roadvision, highlighted the growing role of AI in road infrastructure, noting that AI-driven monitoring systems are already being deployed across large stretches of national highways.

Overall, the roundtable underscored that the future of highway infrastructure will depend not only on the pace of construction but also on durability, safety, technology integration and sustainable materials. The discussions offered valuable insights that will help shape the agenda for RAHSTA 2026 and guide future collaboration within the industry.

Economy & Market

CTS Roundtable Charts Tech-Led Roadmap for Construction

Published

1 week ago

March 16, 2026

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CTS Roundtable Maps Technology Roadmap for Construction

Ahead of the Construction Technology Show (Con Tech Show) 2026, industry leaders, technology innovators and academia came together in Mumbai to deliberate on how digitalisation, automation and industrialised construction can reshape the sector. The discussion made one thing clear: construction can no longer afford to treat technology as optional.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the CTS Roundtable served as a precursor to the Construction Technology Show 2026, scheduled for 19–20 August 2026 at NESCO, Mumbai.

A platform to move from discussion to deployment

Opening the session, Pratap Padode, Founder and Editor-in-Chief, ASAPP Info Global Group, said construction technology has long remained close to his heart, especially given the sector’s traditionally slow pace of technology adoption. He noted that over the years, the Construction Technology Summit had steadily built interest, and the next step was now to expand it into a larger, more meaningful platform that could bring together technology providers, users, startups and innovators under one roof.

Padode said the vision for CTS is not limited to software alone. The platform aims to embrace all forms of technology that can improve construction efficiency, quality and execution—from digital tools and project management systems to lean construction, off-site fabrication and startup-led innovation. He also highlighted plans to deepen startup participation and create space for young companies to showcase emerging construction solutions.

Industry at a turning point

Moderating the roundtable, Naushad Panjwani, Chairman, Mandarus Partners, set the context by pointing out that the global construction industry, despite being a multi-trillion-dollar sector, continues to lag in productivity. He noted that while manufacturing has consistently improved efficiency, construction has remained slow to modernise.

Referring to both global and Indian trends, Panjwani underlined that the industry is now at a decisive moment. India, he said, is entering a major build cycle, and delivering the next phase of infrastructure and real estate growth through traditional methods alone is no longer viable. The goal of the roundtable, therefore, was not to debate technology in isolation, but to identify the most critical conversations that would bridge the gap between innovation and implementation.

His central message was clear: CTS 2026 must be shaped around themes that make CEOs, CIOs and CTOs feel they cannot afford to miss the event.

From BIM to AI, data to governance

A major theme that emerged through the discussion was the need for better data, better visibility and better decision-making. Dr Venkata Santosh Kumar of IIT Bombay echoed this, saying that the underlying data infrastructure itself needs attention. Construction projects, particularly remote ones, often face issues around connectivity, data collection and data use. Without this foundation, more advanced technologies cannot deliver their full value.

Chandra Vasireddy, CEO & Co-founder, Inncircles, expanded the discussion to governance, arguing that technology must help connect the many moving parts of a construction business. For him, the real value of digital transformation lies in creating better governance, clearer visibility and stronger business outcomes.

Tejas Vara of Inncircles stressed the importance of timely site data for leadership teams, especially in large and remote projects where decisions on materials, machinery and manpower often get delayed because information does not reach headquarters in time.

The role of AI also featured prominently. Rushabh Mamania, Partner and CBO, Roadvision said that while AI and machine learning are now common terms, vision intelligence and language intelligence have still not deeply penetrated the construction sector. He emphasised that startups in India are building relevant AI-led solutions and are already attracting international interest, showing that innovation need not be imported—it can be built locally and scaled globally.

Industrialised construction gains ground

The roundtable also placed strong emphasis on industrialised construction methods. Kalyan Vaidyanathan, CTO – Construction & R&D, Tvasta, called for greater focus on off-site fabrication and the broader industrialisation of construction. Bhargav Jog, General Manager, Dextra, highlighted precast technology and alternative sustainable materials as areas with immediate relevance.

Several participants agreed that modular, precast and pre-engineered approaches are no longer niche ideas. They are increasingly becoming practical responses to the sector’s challenges around labour shortage, timelines, quality control and predictability.

Anup Mathew, Sr VP & Business Head, Godrej, argued that the industry needs a fully integrated approach—from design and procurement to execution and asset management. Unless these are connected, technology adoption will remain fragmented and sub-optimal. He pointed to pre-engineered and modular systems as examples of how industrial thinking can compress timelines, improve quality and reduce dependence on difficult on-site conditions.

Adoption remains the biggest hurdle

While there was broad agreement on the promise of technology, the discussion repeatedly returned to one fundamental challenge: adoption.

Abhishek Kumar, COO, LivSYT, observed that the market is crowded with solutions, but many buyers still struggle to evaluate which technology suits which use case. According to him, the industry needs clearer frameworks to help users select, compare and adopt solutions, rather than expecting a single platform to solve every problem.

Dr Tenepalli JaiSai, Associate Professor, School of Construction(SoC), NICMAR University, noted that isolated technologies will not solve the productivity problem by themselves. What is required is an integrated Construction 4.0 approach, where digital, physical and cyber-physical systems work together rather than in silos.

That concern around silos was reinforced by Subodh Dixit, former Director, Shapoorji Pallonji, who said the issue is not just that technologies are disconnected, but that stakeholders are as well. Clients, consultants, contractors and partners often operate with different priorities. Unless these silos are broken, technology will struggle to percolate across the full project value chain.

Harleen Oberoi, Project Management, Tata Realty shared a practical perspective from the client side, saying that successful BIM implementation requires investment across the ecosystem, not just within one organisation. Trade partners, vendors and other stakeholders must also be trained and aligned if the technology is to deliver its intended results.

Beyond buzzwords

A notable takeaway from the session was that the industry is moving past the phase of treating technology as a buzzword. Participants repeatedly stressed that the real question is not whether technology should be used, but where it creates measurable value and how that value can be scaled.

The conversation also expanded beyond mainstream themes to include repairs and rehabilitation, construction and demolition waste, sustainability, circular economy, green sourcing, carbon measurement, design interoperability, generative design, robotics, and the role of horticulture and greener built environments.

Setting the agenda for CTS 2026

By the close of the session, the roundtable had surfaced a strong set of themes for the upcoming show: BIM and digital twins, AI and data platforms, industrialised construction, startup innovation, governance-led technology adoption, robotics, sustainable materials, and integrated project delivery.

More importantly, the session established CTS 2026 as more than an exhibition. It is shaping up to be a serious industry platform where users, technology providers, researchers and policymakers can collectively define the future of construction.

As Padode noted in his closing remarks, the conversation will continue through further consultations and possibly webinars in the run-up to the show. If the roundtable is any indication, CTS 2026 will aim not merely to showcase technology, but to push the industry towards meaningful adoption at scale.

Concrete

Human Factor in Grinding Optimisation

Published

1 month ago

February 20, 2026

admin

Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, discusses the role of skilled operators as the decisive link between advanced additives, digital control and world-class mill performance.

The industry always tries to reduce the number of operators in the Centre Control Room. (CCR) Though the concept was succeeded to certain extent, still we need a skilled person in the CCR.
In an era where artificial intelligence (AI) grinding aids, performance enhancers, and digital optimisation tools are becoming increasingly sophisticated, it’s tempting to believe that chemistry alone can solve the challenges of mill efficiency. Yet plants that consistently outperform their peers share one common trait: highly skilled operators who understand the mill as a living system, not just a machine.
Additives can improve flowability, reduce agglomeration, and enhance separator efficiency, but they cannot replace the nuanced judgement that comes from experience. Grinding is a dynamic process influenced by raw material variability, moisture, liner wear, ball charge distribution, ventilation, and separator loading. No additive can fully compensate for poor control of these fundamentals.

Operators see what additives cannot
When I joined the cement industry in 1981, not much modernisation was available then. Mostly the equipment was run from the local panel. Once I was visiting the cement mills section. The cement mills were water sprayed over the shell to reduce the temperature to avoid the gypsum disintegration.
The operator stopped the feeding for one of the mills. When I asked the reason, he replied that mill was getting jammed, and he added that he could understand the mill condition by its sound. I also learned that and it was useful throughout my career. In another plant I saw the ‘Electronic Ear,’ which checked the sound of the mill and the signal was looped with feed control!
Whatever modernisation we achieve, it is from the human factor that the development starts.
Additives respond to conditions; operators interpret them.
A skilled operator can detect subtle shifts, like a change in mill sound, a slight variation in circulating load, or a drift in separator cut point. It’s long before instrumentation flags a problem. These micro-observations often prevent major efficiency losses.
Additives work best when the process is stable
I would like to share one real time incident. The mill was running on auto mode looped with the mill outlet bucket elevator kilowatt. (KW)There was a decrease in the KW, and the mill feed was increased by the auto control (PID). After a while, the operator stopped both the feed and the mill. He asked the local operator to check the airslide between mill outlet and the elevator. They found the airslide was jammed and no material flow to the elevator!
The operator deduced the abnormality by his experience by seeing the conditions and the rate of increase of the feed by the auto control.
It’s always the human factor that adds value to the optimisation.

Grinding aids are multipliers,
not magicians.
They deliver maximum benefit only when:
• Mill ventilation is correct
• Ball charge is balanced
• Feed moisture is controlled
• Separator speed and loading are improved
• Blaine targets are realistic
Without these fundamentals, even advanced additives may become costly investments. The operator is responsible for ensuring process stability, whether using a ball mill or a vertical mill. After ensuring the system is stable, the operator observes it briefly before transitioning to automatic control. If there is any anomaly in the system the operator at once takes control of the system, stabilises and bring back to auto control.

Skilled operators adapt in real time
It will be interesting to note that the operators who operate from local panel start to operate from DCS also. They have the experience and the ability to adapt the changes. Operator checks each parameter deeply. Any meagre change in the parameters is also visible to him.
Raw materials change. Weather changes. Wear patterns change.
A skilled operator adjusts:
• Feed rate
• Water injection
• Separator speed
• Grinding pressure (in VRMs)
• Mill load distribution.
These adjustments require intuition built from years of experience, something no additive can replicate.

Human insight prevents over reliance on additives
Plants sometimes increase additive dosage to mask deeper issues like:
• Poor clinker quality
• Inadequate drying capacity
• Incorrect ball gradation
• High residue due to worn separator internals.

A knowledgeable operator finds root causes instead of chasing temporary chemical fixes.
The real optimisation sweet spot is reached when:
• Operators understand how additives interact with their specific mill.
• Additive suppliers collaborate with plant teams.
• Process data is interpreted by humans who know the mill’s behaviour.
This constructive collaboration consistently delivers:
• Lower kWh/t
• Higher throughput
• Better product consistency
• Optimum standard deviation.

Advanced additives are powerful tools, but they are not substitutes for human ability. Grinding optimisation is ultimately a human driven discipline, where skilled operators make the difference between average performance and world class efficiency. Additives enhance the process but operators
control it.

About the author:
Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, is a seasoned cement process consultant with 43+ years of global experience in plant operations, process optimisation, refractory management, safety systems and training multicultural teams across international cement plants.