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We see a huge potential for VRPM in split grinding locations

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Sanjay Jain, Vice President, AMCL Machinery Ltd, in an exclusive e-interview with Indian Cement Review, elaborates on the company’s offerings to the cement industry and the future plans to serve the industry better with a large number of cement projects in the pipeline.

Brief us about your company and its activities.
AMCL is the 100-per cent subsidiary of Hindusthan National Glass & Industries Ltd (HNGIL) since March 2008. HNGIL is India’s largest glass container manufacturer having six plants across India controlling 55 per cent of the market share and with a turnover of around $400 million. Our major revenue driver is vertical roller pre-grinding mill (VRPM) which is manufactured as per international standard and designed from our technology partner Nihon Cement Co Ltd, Japan (Taiheiyo Engineering Co Ltd, Japan). AMCL also manufactures positive displacement tri-lobe blowers with technology provided by Unozawa-Gumi Iron Works Ltd, Japan.

AMCL also caters to different needs of rubber and tyre industry with technology from Midland Tyre Machinery Co Ltd, UK; Kobe Steel Ltd, Japan; and Leonh Herbert Machinenunlagan, Germany. An ISO 9001: 2008 certified company, AMCL is equipped with highly skilled workforce to exceed customer expectations on quality and timely delivery.

Tell us about your manufacturing facilities.
AMCL is in the business of manufacturing capital goods for more than three decades. We have state-of-the-art facilities for heavy fabrication, CNC machining, assembly, testing, quality control, etc. The quality control department has all the latest instruments for quality assurance. Our design office is well-equipped with latest autoCAD software for adapting to the customer needs. We have our large reputed vendor base for castings, forgings, steel, heat treatment and non-ferrous items.

Can you elaborate on your machinery?
We offer vertical roller pre-grinding mill, tri-lobe blowers, bulk transportation systems and refractory gunning machine to cater the need of the cement industry through advanced solutions sourced from world leaders. VRPM is primarily used for pre-grinding of clinker and limestone for cement manufacturing. The pre-ground clinker is then fed to ball mills. This is a cost-effective solution to reduce energy consumption in cement grinding.

The capacity of existing ball mills/ tube mills can be augmented by 40-50 per cent with reduction in specific power consumption by 15-20 per cent with the installation of VRPM. This is also an ideal application for split location grinding mills.

Tri-lobe blowers are used in cement industy, iron and steel plants, fertiliser plants, chemical plants, textile and paper mills, water and effluent treatment plants, sugar industry, and food processing industry. The tri-lobe blowers have their advantages over twin-lobe blowers such as:

  • Low-pressure pulsation
  • Less noise and vibration levels
  • High volumetric efficiency
  • Low discharge percentage oil-free air
  • Low maintenance.

The refractory gunning machine is an ideal solution for steel, cement, ceramic, refractory and many such user industries. We have designed and manufactured refractory gunning machine where online refractory repair is a critical requirement.

Advantages of these machines are: user-friendly, high productivity, low manpower requirement, short refractory preparation cycles, homogenous mixing, and easy mobility.

Which is the most selling machine?
The major revenue driver (70 per cent) for AMCL is VRPM and we have 27 various installations in India and three installations abroad.

The balance revenue is generated from tri-lobe blowers and special- purpose machines for rubber and tyre industry.

Tell us more about your innovations and R&D activities?
AMCL has developed two new models (Model 180-3 and Model 270-3) VRPM in-house to match different needs of small and large cement plants. These models are well accepted in the market place. Apart from this, AMCL also manufactures bulk transport systems in various capacities to cater to the industry needs of loose cement and fly ash transportation.

What are the services you offer for the cement industry?
AMCL offers engineering and design services to the cement Industry for grinding.

What are your plans on the export front?
Cement machinery has a very large market domestically as well as globally. AMCL is currently focusing on grinding solutions and very soon shall penetrate African and Latin American markets.

Who are your major domestic buyers?
We have leading cement manufacturing companies as our customers. ACC, Ambuja, Jaypee, Century Cement, Maihar Cement, Madras Cements, UltraTech Cement, Birla Corporation, Mangalam and Kesoram Cement are few of them.

What strategies do you adopt to expand your market share?
AMCL is looking forward to technology tie-ups with international companies of repute to manufacture dynamic separators and ball mills. With this addition in product bouquet AMCL will be in a position to offer complete solution for clinker grinding to cement companies.

With more cement projects coming up, what is your perception of future business?
We see a huge potential for VRPM in split grinding locations, where we are gearing up to provide complete solution. Customers prefer AMCL-make tri-lobe blowers over conventional twin-lobe blowers due to lower noise and vibration levels.

Are there any new products or expansions in the offing?
We are aggressively looking forward to prospective technology tie-up for dynamic separators and ball mills. We shall offer complete solution for clinker grinding for split grinding locations. We are expanding our manufacturing facilities to cater to ever increasing demands of the customers.

We are also exploring avenues to enter into industrial process fans market, which is growing in double digits. This business will be synergic to tri-lobe blowers and cement industry and power plants will welcome this as there is a short supply of industrial process fans with huge lead times.

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Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

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Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

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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…

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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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