Economy & Market

Manpower Development for Indian Cement Industry

Published

8 years ago

October 31, 2018

admin

Indian cement industry is among the best in the world when it comes to energy efficiency. However, specialised training is essential to face and overcome certain unique challenges of the Indian cement industry.

The Indian cement industry is poised for a big growth considering the various infrastructural developments planned by the Government of India and the demand for housing all over the country. The Government of India has planned to invest Rs 5.94 lakh crore in the infrastructural sector with an additional allocation of Rs 2.04 crore for smart cities in the Union Budget of 2017-18. GST, demonetisation and some other factors have affected the growth of the industry temporarily but things are expected to stabilise soon. The Central Government has an ambitious plan to provide housing for all citizens by 2022. Increased allocation to rural housing under Pradhan Mantri Awas Yojna-Gramin scheme and developing smart cities will boost demand. Additional efforts in development of ports under "Sagarmala" and nation-wide road network development under "Bharatmala" will give impetus to cement demand. Nine new airports are on the anvil.

From the chart (next page) it is pertinent that housing sector will play a major role in boosting growth of Indian cement industry. The consumption of cement in agricultural sector is negligible today but as announced in the union budget of 2017-18, this sector is being given due importance.This will contribute to a substantial demand for cement for building warehouses and other logistics in the rural sector. International Monetary Fund (IMF) in its latest update has forecasted a GDP growth of 7.4 per cent next year. If all goes well CLSA expects a volume growth in new home construction to a compounded annual growth rate to about 8 per cent over the next seven years. Cement is a cyclical commodity with good correlation with GDP. With the projected GDP growth of 7.5 to 8.0 per cent in the next few years, cement demand will also increase. The present installed capacity of cement manufacturing is around 435 MT/year. It is estimated that India would need 550 to 600 MT/ annum by 2025. This means an additional capacity of 100 to 150 MTs/ annum need to be installed by 2025. In spite of being the second largest cement producer in the world the per capita consumption in India is only 225 kg, which is much lower than the world average of 500 kg and far behind China where it is more than 1,000 kg. These figures indicate that India has a long way to go to be called a developed nation. However Indian economy is the fifth largest economy as of now and is expected to become third largest very soon. This gives the possibility of huge expansion of the Indian cement industry.

Future technical manpower requirement
Getting skilled manpower for the industry is a challenge. There is a big gap between availability and demand. With the anticipated addition of another 150 MT/annum by 2025, it is estimated that the cement industry will require around 66,000 skilled technical manpower for greenfield projects, brownfield expansion and captive power plant operations.

Need for specialised manpower
Indian cement industry is among the best in the world when it comes to energy efficiency. However specialised training is essential to face and overcome certain unique challenges of the Indian cement industry. The major ones are listed as follows:

Depletion of high-grade limestone. We need to add more capacity with marginal and sub marginal grades of limestone. Also depletion of good quality mineral gypsum and finding large volumes of alternative material is also concerning.
Non availability of good quality cheaper fuel. The plants have to balance their fuel cost without diluting product quality. A rapid stride has to be taken to use alternate fuels and raw materials (AFR). This requires specialised skills.
Further improvements in energy efficiency is necessary by installing WHR systems and retrofitting with energy efficient equipment.
Compliances with stricter environmental and safety norms.
Implementing innovative ideas and methods to keep production cost low in view of the ever increasing cost of inputs like raw materials, fuels, logistics, taxes, etc.

There is shortage of skilled manpower in the industry who can handle such burning issues. There is hue and cry in the country saying that people are not getting employment. On the other hand the manufacturers complain that they do not get the rightly skilled manpower. There is a serious gap between what is wanted and what is available. To address all these issues it is necessary to:

Design training programmes which are practical in nature and completely wedded to the requirement of the construction industry. In this respect, a close co-ordination of industry and academics is the need of the hour.
Enhance skills of the semi-skilled workers to enable them to do their jobs in a scientific manner for better quality and productivity
Make a pool of people ready for the future growth of the cement and construction industry

Initiatives taken by organisations
It is worthwhile to mention that the National Council for Cement and Building Materials (NCCBM) has considerable contribution in this area. They are conducting various programmes to train fresh graduates. They are also regularly conducting short term, customised and contract programmes for improving skills of technical personnel of plants. Few universities and colleges have implemented diploma courses in cement technology but are not doing that well perhaps because their courses are not designed as per industry needs and limitations of cement plant experience in their faculties.With the anticipated rapid growth of the industry all these efforts may not be sufficient.

Initiatives taken by AKS University
Keeping all these requirements in mind it is worthwhile to mention an innovative University called AKS University in Satna, Madhya Pradesh. This university had the foresight of this future demand of India and started conducting degree anddiploma courses in cement technology from the year 2012 after getting UGC approval. The visionary of AKS University is Er Anant Kumar Soni who started this humble journey to impart quality education at affordable price to the rural masses. He sensed long back that being located in a cement hub, it will be a great service to the rural poor if they are trained to take up employment in cement plants in this limestone rich belt of Satna. He vowed to make education affordablewithout any capitation fees. His objective is to raise the level of rural education and bring it at par with urban levels and trainthe poor students for employment.

AKS University is spread over an area of more than 100 acres of land in the Satna town of Madhya Pradesh, adjacent to NH-7. It has developed 4.5 lakh sqft of lecture rooms, workshops, state of the art laboratories, agriculture research farms, incubation center etc. At present the AKS University is offering 52 courses under 12 faculties and more than 7,500 students are enrolled for the session 2017-18.

AKS University credentials Within a short duration of five years, AKS University has been awarded various credentials for its achievements, this are listed below.

Best University in IT infrastructure for the year 2018 awarded by ASSOCHAM.
Best Private Innovative University for the Year 2017.
Excellent Private University in rural sector awarded by ASSOCHAM in 2016
Excellent Private University in Rural sector for the year 2015, awarded by Dr. RS Katheriya, Hon?ble State Higher Education Minister, Ministry of HRD, Govt of India.
Excellent Private University in Madhya Pradesh by CMAI, Madhya Pradesh Technical Excellence Education Summit Bhopal in the year 2014.
Indo Nepal Sadbhavna award in the year 2014 from Govt of Nepal, Kathmandu, Nepal.
Best University in IT infrastructure for the year 2014 by CCI Technology Excellency Award, Bhopal.

AKS University, in addition to cement technology, offers various Diploma, B. Tech., M. Tech andPh. D programmes in most of the courses. While many private universities are reporting shortfall in the intake of students in the engineering streams, AKS University is experiencing higher intakes especially in the agriculture and mining departments. Mention must be made of the innovative approaches carried out in the mining department which is bringing laurels to the university. Students are sent to present technical papers in internationals seminars. The department organises various seminars in the country where well known persons from the Indian mining industry are felicitated and givenlife time achievement awards. This department has eight professors who are ex general managers from Coal India Limited.

Considerable efforts are taken to ensure good attendance among students as well as professors. The administration ensures that all courses are actually taken and completed in time inclusive of revision classes. Industry academic coordination and networking is given the topmost priority.

Why Cement Technology (CT) from AKS University?

It is the first university in the country offering both Diploma and B.Tech courses in cement technology recognised by MP Board of Technical Education and UGC respectively.
Being an autonomous institution, technical courses are designed and constantly upgraded keeping in view the latest technological developments in Indian cement industry. Frontier areas relevant to Indian cement industry like alternate fuels and raw materials (AFR), waste heat recovery systems (WHR), energy efficiency, composite and geo-polymeric cements, belitic cements, etc. A great thrust is given on concrete technology with emphasis on application aspects. Management aspects like marketing, operations management, safety and environment management etc. from an integral part of the course. Mechanical, electrical, instrumentation, mining, geology, chemical engineering aspects are covered extensively with examples and case studies from Indian cement industry.
Industrial training and doing project work on frontier areas which challenges the Indian cement Industry is compulsory for all students.
Experienced industry faculty is a special feature at AKS and so in CT Department.There is blend of 50 per cent full time professors from industry with more than 35-year experience and remaining 50 per cent comprising of seasoned academicians specialising in chemical, mining, electrical and instrumentation, mechanical engineering, geology etc.Most of them are from IITs, NITs, and other reputed universities.
State of the art infrastructure and laboratories for hands on training and research.
Group discussions, role plays, mock interview sessions, Saturday departmental seminars are regularly conducted to improve the personality aspects of students
Research opportunities including real-time industry projects.
With the approval of Board of Apprenticeship Training (BOAT) Mumbai, the B.Tech students undergo a Sandwich Apprenticeship (in plant training) for 150 days in VIII Semester.
Simulator based training at National Council for Cement and Building Materials(NCCBM), Ballabgarh, Haryana is compulsory in semester VI in B. Tech programme. These full time degree courses have a practical component of 40% and theoretical component of 60 per cent.
AKS University is connected with many cement plants through Cement Manufacturing Association of India (CMA)
AKS University is a "University with difference" where the courses are modified on a regular basis involving industry professionals. Management is deeply inclined to establish strong relationship with industry. Most of the senior staff in Engineering and Technology departments’ are stalwards in their own fields from institutions like ACC, NCCBM, Lafarge, Coal India, Indian Oil etc. Quite a few of them have foreign degrees and one professor in Cement Technology department is a Canadian national. This helps the students to network with professionals of industry right from early stages of their courses.
A good number of students have been placed and are workingwith Star Cement, Sanghi Cement, Amrit Cement, Ultratech Cement, Gorahi Cement(Nepal), Prism cement, KJS cement, etc.

Achievements of AKS University

1.First batch of B.Tech students passed out in 2015
2.More the 50per cent students placed in cement plants
3.Carrying out short term courses (three to six months) for enhancing skills of plant personnel (workers and staff) on cement technology. Completed two programmes for Prism Cement Ltd. Satna and further programmes are in offing.

Negotiation with UltraTech are on to train masons on a regular basis. These masons will be picked out by them.
4.Established a name in imparting high quality training programmes for techno-marketing professionals of cement industry. This is a well established popular training programme highly appreciated by industry.
Application engineering is an area that needs a lot of manpower. Now-a-days, this has emerged as a necessary activity of cement marketing. These engineers are responsible for technical marketing of cement and assist the customers throughout the construction process. They also handle quality complaints. TheAKS three-year diploma course, which is being renamed as diploma in cement and concrete technology, is perhaps the best fit degree for techno marketing personnel in rural areas as they know both sides of the game (cement and concrete ). They can do all the dirty work better as compared to a B.Tech/Diploma in civil engineering.

AKS University has conducted numerous short-term courses for techno marketing professionals for companies like UltraTech, KJS Cement, etc. with grand success. These are residential programmes with certification from Centre of Continuing Education, Department of Cement Technology, AKS University, Satna.

Training scheme
The department can train fresh personnel selected by cement manufacturers and make them industry ready either with the Diploma or B.Tech programme in cement technology which are on campus programmes. Short term customised courses are also feasible.New cement companies who have started their greenfield projects can send their entire team of fresh recruits to AKS so that they get professionally trained by the time the plant is ready for commissioning. Good hostel facilities are available in Satna town. Local people from surroundings of Cement plants located in rural areas have been found to be assets for the industry both in the past and present. These people show lot of dedication and loyalty compared to people from urban areas Moreover creating local employment is also compulsory as part of CSR schemes. AKS University has all the expertise to nurture these poor people from rural areas and make them industry ready.

Summary
With the expected spurt in demand for technical personnel in cement industry, which is imminent, it is worthwhile to have a serious thought on manpower development and skill enhancement of existing manpower. Actions need to be taken right now so that the industry is not starved of skilled personnel. It is worthwhile if cement manufacturers recruit cement technologists who are already trained by institutes like AKS University. Such trained personnel with degree or diploma in cement technology are industry ready and only need to be customised to the working of individual cement manufacturers who recruit them. This will reduce the gestation period to take up independent supervisory and other roles. There are very few institutions in India imparting quality cement technology programmes in India. AKS University, Satna is already in this field for past five years and has matured enough to be a partner to generate competent manpower for the Indian cement industry at affordable cost. Customised short-term courses are also feasible as per requirement of individual cement manufacturers.

About the authors:
Prof KN Bhattacharjee and Prof GC Mishra of Department of Cement Technology AKS University Satna. Prof KN Bhattacharjee is the corresponding author. He can be contacted on: Email: karuna.bhattacharjee3@gmail.com| Mob: 91-9340898824.

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

5 days ago

June 5, 2026

admin

World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

Concrete

Building a Greener Future Together

Published

6 days ago

June 4, 2026

admin

Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

Concrete

Dalmia Bharat Acquires Jaiprakash Associates Cement Assets for ₹2,850 Crore

Published

2 weeks ago

May 25, 2026

admin

Dalmia Cement executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra, to acquire 5.2 MnTPA of cement capacity across Madhya Pradesh and Uttar Pradesh.

Dalmia Cement (Bharat) announced on May 22, 2026 that it had signed a Business Transfer Agreement with Jaiprakash Associates Limited and Adani Infra (India) Limited for the acquisition of cement plants located at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh. The deal was struck at an enterprise value of ₹2,850 crore and is expected to close within two weeks of execution.

The acquired assets from Jaiprakash Associates include 5.2 MnTPA of cement capacity and 3.3 MnTPA of clinker capacity. The package also covers 99 MW of thermal power capacity and railway sidings at Rewa, Chunar, and a common siding at Churk. This infrastructure gives the acquisition immediate operational utility beyond just production tonnage.

The transaction has a long backstory. Dalmia Cement had originally entered into a framework agreement with Jaiprakash Associates in December 2022, covering the sale of these business assets along with a long-term clinker supply arrangement. However, before the deal could be completed, Jaiprakash Associates was admitted to insolvency proceedings under the Insolvency and Bankruptcy Code. The earlier agreements could not be consummated as a result.

In an official statement, Puneet Dalmia, Managing Director & CEO, Dalmia Bharat, said, “I am very excited about addition of these assets in our portfolio. This serves as a great strategic fit for Dalmia. It helps us move forward in our journey to be a pan India player and provide a strong head start to serve the high potential markets in Central region. I am optimistic that the expansion potential of these assets along with close proximity with Dalmia’s captive mines will help us create a capacity hub for the future”.

Following the approval of Adani Group’s resolution plan for Jaiprakash Associates under the IBC framework, Dalmia approached the new management to revive discussions. The fresh Business Transfer Agreement was executed to settle all pending disputes, legal proceedings, and arbitration matters arising from the original framework agreement with Jaiprakash Associates.

Expanding market reach

Dalmia added, “Our familiarity with these assets under the earlier tolling arrangement gives us a deep understanding of the facilities and helps us establish strong connect with channel partners and vendors. We believe that this will help us in faster ramp up of capacities and quicker inroads into the market. As we look forward, I am very confident that we will be able to leverage the strengths of Dalmia to operate these assets in a manner where we can maximise value creation for all our stakeholders.”

With the addition of these plants, Dalmia Bharat’s total installed cement capacity will rise to 54.7 MnTPA upon consummation. The company has further expansion projects underway at Belgaum, Pune, and Kadapa, which are expected to take overall capacity to 66.7 MnTPA by Q2 to Q3 FY28.

The Central India location of the Jaiprakash Associates plants gives Dalmia Bharat faster access to markets in Madhya Pradesh and Uttar Pradesh than a greenfield build would have allowed. The company also cited debottlenecking and brownfield expansion as near-term opportunities at the acquired sites. Dalmia Bharat said the assets were expected to contribute positively to EBITDA and overall returns, given the pricing environment in the region and the company’s cost structure.