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Use of synthetic bearing lubricant helps increase oil drain interval by more than 2.5 times, thereby resulting in savings of over $27,677/kiln.

India is the second largest producer of cement in the world after China. However due to unfavourable demand-supply scenario, the industry is reeling under the pressure of rising input costs. Today, manufacturers are under tremendous pressure due to reducing profit margins and increased competition.

To combat the continual increase in input costs, and minimise production cost, we need to optimise operations. Cement plants are ‘hot beds’ for equipment problems, as they continuously perform under harsh conditions. A typical process of manufacture consists of three stages:

  • Grinding a mixture of limestone and clay or shale to make a fine "rawmix"
  • Heating the rawmix to temperature up to 1,450?C in a cement kiln
  • Grinding the resulting clinker to make cement

    In the second stage, the rawmix is fed into the kiln and gradually heated by contact with the hot gases from combustion of the kiln fuel. Successive chemical reactions take place as the temperature of the rawmix rises. The objective of kiln operation is to make clinker at the maximum rate that the size of kiln will allow, while meeting environmental standards at the lowest possible operating cost. This creates challenges, which in turn necessitates a careful selection of lubricants as an integral part of the modern processing techniques in cement plants.

    High operating temperatures
    Rajashree Cement (RC), a unit of Grasim Industries Ltd, is an ISO 14001 certified company, and one of the largest cement manufacturing units in India with a gross clinker production capacity of 4.0 MTPA. Catering to the residential and commercial segment of the construction industry, the company manufactures white and grey cement, and operates a opencast mine using state-of-the-art technology and was the winner of the National Award for ‘Quality Excellence In Indian Cement Industry’ by National Council For Cement and Building Materials, for the year 2000-01. At its facility, Rajashree Cement employs three production lines with integrated cement lines and individual kilns of 166 TPH capacity. The support rollers here were typically lubricated by a mineral oil of ISO VG 460 with the bearings running at very high temperatures (78-85?C). Such high temperatures led to frequent tripping of motors. Due to contamination and oxidation that usually occurs at high temperatures, the lube oils required annual replacement. This combination of factors affected the productivity of the plant.

    Faced with the recurring problem of tripping of motors, which in turn affected productivity, the company approached the Field Engineers at Mobil???Industrial Lubricants, who had worked closely with other leading cement producers, to seek expert advice on best-in-class lubrication and maintenance practices for operating kilns.

    Typically, a seamless and uninterrupted operation of the kiln will require stable oils, with demonstrated ability to maintain an appropriate level of thickness at high operating temperatures. Following a thorough analysis of the situation, the Mobil technical experts, recommended that Rajashree Cement use to the new Mobil Industrial Lubricant product – the Mobil SHC???639, a polyalphaolefins based fully synthetic bearing lubricant that demonstrated improved viscometrics at varying high temperatures

    Improving productivity and reliability
    Rajashree Cements was already a customer of ExxonMobil??? They had experienced the benefits of using Planned Engineering Service (PES), under which they used Mobil SHC 639 in one of their PA fans (thermal power plant). The oil exhibited excellent oxidation resistance that occurs at high temperatures and its low traction co-efficient helps save energy and reduce operating temperature. Mobil SHC 639 was the ideal solution for the current problem of operating with high temperature and load from the kiln, thereby ensuring enhanced reliability and reduction in tripping of the machine.

    Developed through extensive research and development, and in-service field testing, the application of Mobil SHC 639 helped to reduce the bearing temperature of the kiln by 10?C, and maintained an appropriate level of viscosity at high operating temperature.

    Though switching to Mobil SHC involved a higher cost outlay for Rajashree Cement, the premium paid was negligible when compared to a 2.5 times increase in the oil drain interval and overall reduction in the tripping of the machinery. This improved productivity led to recovery of the overall cost in no time as the extended oil change also enabled the company to achieve considerable savings through improved productivity and reliability of the kiln. Though Rajashree Cement had been using the ISO VG 460 mineral oil for many years, the significant results provided by Mobil SHC 639 drove the company to take full advantage of the benefits obtained from the newly deployed synthetic oil.

    Following the successful completion of the change, Rajashree Cement team member said, "The change has been seamless. The Mobil Industrial Lubricant product not only enhances the productivity levels of the machine, but also provides increased productivity and higher cost efficiency."

    Mobil SHC 639 reduces costs, maximises productivity
    For Rajashree Cement, the results from the new Mobil SHC 639 were outstanding, and the company saw its machine efficiency double. In addition, the durability of Mobil SHC 639 delivered increased equipment availability, enabling the Rajashree Cement to maximise its productivity, and save more than S$30,000/kiln annually by reducing the number of oil changes, and creating less waste oil.
    The company has been using Mobil SHC 639 since Q4 2008 and there has been no incident of kiln tripping, oil drain, contamination or oxidation, etc. The composite benefits achieved by using Mobil SHC 639 are as follows:

  • Improved productivity and reliability of Kiln
  • The bearing temperature reduced by 10?C
  • Oil drain interval increased by more than 2.5 times
  • Speaking on MIL’s success in providing a solution to Rajashree Cement requirements, Shankar Karnik, General Manager – Industrial, ExxonMobil Lubricants Private Limited, said, "Mobil Industrial Lubricants has partnered with all the leading companies across sectors, and has a long tradition of providing innovative solutions to all its customers after understanding the core issue. The results delivered by Mobil SHC 639 for Rajashree Cement are perfect examples of how ExxonMobil’s technology leadership and exceptional application expertise can deliver significant financial value and help companies increase their productivity."

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    Price hikes, drop in input costs help cement industry to post positive margins: Care Ratings

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    Region-wise,the southern region comprises 35% of the total cement capacity, followed by thenorthern, eastern, western and central region comprising 20%, 18%, 14% and 13%of the capacity, respectively.

    The cement industry is expected to post positive margins on decent price hikes over the months, falling raw material prices and marked drop in overall production costs, said an analysis of Care Ratings.

    Wholesale and retail prices of cement have increased 11.9% and 12.4%, respectively, in the current financial year. As whole prices have remained elevated in most of the markets in the months of FY20, against the corresponding period of the previous year.

    Similarly, electricity and fuel cost have declined 11.9% during 9M FY20 due to drop in crude oil prices. Logistics costs, the biggest cost for cement industry, has also dropped 7.7% (selling and distribution) as the Railways extended the benefit of exemption from busy season surcharge. Moreover, the cost of raw materials, too, declined 5.1% given the price of limestone had fallen 11.3% in the same aforementioned period, the analysis said.

    According to Care Ratings, though the overall sales revenue has increased only 1.3%, against 16% growth in the year-ago period, the overall expenditure has declined 3.2% which has benefited the industry largely given the moderation in sales.

    Even though FY20 has been subdued in terms of production and demand, the fall in cost of production has still supported the cement industry by clocking in positive margins, the rating agency said.

    Cement demand is closely linked to the overall economic growth, particularly the housing and infrastructure sector. The cement sector will be seeing a sharp growth in volumes mainly due to increasing demand from affordable housing and other government infrastructure projects like roads, metros, airports, irrigation.

    The government’s newly introduced National Infrastructure Pipeline (NIP), with its target of becoming a $5-trillion economy by 2025, is a detailed road map focused on economic revival through infrastructure development.

    The NIP covers a gamut of sectors; rural and urban infrastructure and entails investments of Rs.102 lakh crore to be undertaken by the central government, state governments and the private sector. Of the total projects of the NIP, 42% are under implementation while 19% are under development, 31% are at the conceptual stage and 8% are yet to be classified.

    The sectors that will be of focus will be roads, railways, power (renewable and conventional), irrigation and urban infrastructure. These sectors together account for 79% of the proposed investments in six years to 2025. Given the government’s thrust on infrastructure creation, it is likely to benefit the cement industry going forward.

    Similarly, the Pradhan Mantri Awaas Yojana, aimed at providing affordable housing, will be a strong driver to lift cement demand. Prices have started correcting Q4 FY20 onwards due to revival in demand of the commodity, the agency said in its analysis.

    Industry’s sales revenue has grown at a CAGR of 7.3% during FY15-19 but has grown only 1.3% in the current financial year. Tepid demand throughout the country in the first half of the year has led to the contraction of sales revenue. Fall in the total expenditure of cement firms had aided in improving the operating profit and net profit margins of the industry (OPM was 15.2 during 9M FY19 and NPM was 3.1 during 9M FY19). Interest coverage ratio, too, has improved on an overall basis (ICR was 3.3 during 9M FY19).

    According to Cement Manufacturers Association, India accounts for over 8% of the overall global installed capacity. Region-wise, the southern region comprises 35% of the total cement capacity, followed by the northern, eastern, western and central region comprising 20%, 18%, 14% and 13% of the capacity, respectively.

    Installed capacity of domestic cement makers has increased at a CAGR of 4.9% during FY16-20. Manufacturers have been able to maintain a capacity utilisation rate above 65% in the past quinquennium. In the current financial year due to the prolonged rains in many parts of the country, the capacity utilisation rate has fallen from 70% during FY19 to 66% currently (YTD).

    Source:moneycontrol.com

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    Wonder Cement shows journey of cement with new campaign

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    The campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV…

    ETBrandEquity

    Cement manufacturing company Wonder Cement, has announced the launch of a digital campaign ‘Har Raah Mein Wonder Hai’. The campaign has been designed specifically to run on platforms such as Instagram, Facebook and YouTube.

    #HarRaahMeinWonderHai is a one-minute video, designed and conceptualised by its digital media partner Triature Digital Marketing and Technologies Pvt Ltd. The entire journey of the cement brand from leaving the factory, going through various weather conditions and witnessing the beauty of nature and wonders through the way until it reaches the destination i.e., to the consumer is very intriguing and the brand has tried to showcase the same with the film.

    Sanjay Joshi, executive director, Wonder Cement, said, "Cement as a product poses a unique marketing challenge. Most consumers will build their homes once and therefore buy cement once in a lifetime. It is critical for a cement company to connect with their consumers emotionally. As a part of our communication strategy, it is our endeavor to reach out to a large audience of this country through digital. Wonder Cement always a pioneer in digital, with the launch of our IGTV campaign #HarRahMeinWonderHai, is the first brand in the cement category to venture into this space. Through this campaign, we have captured the emotional journey of a cement bag through its own perspective and depicted what it takes to lay the foundation of one’s dreams and turn them into reality."

    The story begins with a family performing the bhoomi poojan of their new plot. It is the place where they are investing their life-long earnings; and planning to build a dream house for the family and children. The family believes in the tradition of having a ‘perfect shuruaat’ (perfect beginning) for their future dream house. The video later highlights the process of construction and in sequence it is emphasising the value of ‘Perfect Shuruaat’ through the eyes of a cement bag.

    Tarun Singh Chauhan, management advisor and brand consultant, Wonder Cement, said, "Our objective with this campaign was to show that the cement produced at the Wonder Cement plant speaks for itself, its quality, trust and most of all perfection. The only way this was possible was to take the perspective of a cement bag and showing its journey of perfection from beginning till the end."

    According to the company, the campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV. No other brand in this category has created content specific to the platform.

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    In spite of company’s optimism, demand weakness in cement is seen in the 4% y-o-y drop in sales volume. (Reuters)

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    Cost cuts and better realizations save? the ?day ?for ?UltraTech Cement, Updated: 27 Jan 2020, Vatsala Kamat from Live Mint

    Lower cost of energy and logistics helped Ebitda per tonne rise by about 29% in Q3
    Premiumization of acquired brands, synergistic?operations hold promise for future profit growth Topics

    UltraTech Cement
    India’s largest cement producer UltraTech Cement Ltd turned out a bittersweet show in the December quarter. A sharp drop in fuel costs and higher realizations helped drive profit growth. But the inherent demand weakness was evident in the sales volumes drop during the quarter.

    Better realizations during the December quarter, in spite of the 4% year-on-year volume decline, minimized the pain. Net stand-alone revenue fell by 2.6% to ?9,981.8 crore.

    But as pointed out earlier, lower costs on most fronts helped profitability. The chart alongside shows the sharp drop in energy costs led by lower petcoke prices, lower fuel consumption and higher use of green power. Logistics costs, too, fell due to lower railway freight charges and synergies from the acquired assets. These savings helped offset the increase in raw material costs.

    The upshot: Q3 Ebitda (earnings before interest, tax, depreciation and amortization) of about ?990 per tonne was 29% higher from a year ago. The jump in profit on a per tonne basis was more or less along expected lines, given the increase in realizations. "Besides, the reduction in net debt by about ?2,000 crore is a key positive," said Binod Modi, analyst at Reliance Securities Ltd.

    Graphic by Santosh Sharma/Mint
    What also impressed analysts is the nimble-footed integration of the recently merged cement assets of Nathdwara and Century, which was a concern on the Street.

    Kunal Shah, analyst (institutional equities) at Yes Securities (India) Ltd, said: "The company has proved its ability of asset integration. Century’s cement assets were ramped up to 79% capacity utilization in December, even as they operated Nathdwara generating an Ebitda of ?1,500 per tonne."

    Looks like the demand weakness mirrored in weak sales during the quarter was masked by the deft integration and synergies derived from these acquired assets. This drove UltraTech’s stock up by 2.6% to ?4,643 after the Q3 results were declared on Friday.

    Brand transition from Century to UltraTech, which is 55% complete, is likely to touch 80% by September 2020. A report by Jefferies India Pvt. Ltd highlights that the Ebitda per tonne for premium brands is about ?5-10 higher per bag than the average (A cement bag weighs 50kg). Of course, with competition increasing in the arena, it remains to be seen how brand premiumization in the cement industry will pan out. UltraTech Cement scores well among peers here.

    However, there are road bumps ahead for the cement sector and for UltraTech. Falling gross domestic product growth, fiscal slippages and lower budgetary allocation to infrastructure sector are making industry houses jittery on growth. Although UltraTech’s management is confident that cement demand is looking up, sustainability and pricing power remains a worry for the near term.

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