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Cement Packaging : A Crucial Step in Getting Cement to End Consumers

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Packaging, across the value chain of cement operations, is a crucial process. ICR explores the various aspects of cement packaging, and its different types, while assessing the challenges and innovations that are expected in the future.

India is one of the largest producers of cement. With the ongoing infrastructural development in the country, the demand is ever rising for cement. Similarly, India also exports a significant amount of cement. Cement from the manufacturers must travel the lengths of the country to reach the users and cross borders during export. This requires strong packaging to avoid coming in contact with moisture and prevent wastage due to leakage. Once cement comes in contact with moisture it turns into concrete and that makes it of no use.


Packaging of cement plays a crucial rule in the process of taking it from the makers to the consumers. Manufacturer’s source highest grade technology and packaging material to protect their product from damage, wastage and to reach the end user in an unharmed manner. Packaging happens at the last leg of the cement manufacturing process. Cement is extracted from the silo bottom by aeration and transported to electronic packing machines by air slides and bucket elevators. Cement is packed in 50 kg packs, and HDPV bags or paper bags are used as per the customers’ requirement. Electronic packing machines are calibrated to deliver the correct weight.


The constant demand of good packaging material for cement gives way to two industries – the technology developers for automation of packaging and packaging material industry. According to a study conducted by the Data Bridge Market Research, the global cement packaging industry is expected to grow at a rate of 3.4 and from 2021 to 2027. This growth shall be credited to the increasing demand from construction industry, surging application of paper bags as it provides ease of printability and replacement of conventional plastic bags. On the other hand, evolution of advanced products will further create new and ample opportunities for the growth of cement packaging market in the above-mentioned forecast period. This will also be seen in the sustainable packaging solutions vertical over the years to come as that demand is growing in most sectors related to cement.

Standards and types of packaging bags for the cement industry
The industry largely uses Polypropylene bags for packaging of cement as it offers protection from moisture and strength to packaging. There are various categories of polypropylene bags available with coatings, linings etc. PP plain woven bags are simple bags made out of plastic and stitched together with to hold cement. The next type is PP lined bags that have an extra lining of plastic in the inside which protects cement from coming in contact with moisture. Next, are the laminated PP bags that have an extra layer of poly film on them. Their strength is higher than simple woven bags and provide greater resistance to air coming in touch with cement. They also give way to bigger branding and storing of cement in uncovered storages.
The higher quality in laminated bags is the BOPP laminated bags. BOPP stands for Biaxially Oriented Polypropylene. It is a layer that is added as an extra layer to the PP woven bags to enhance its strength. BOPP laminated bags have higher durability and are attractive and durable. These bags are primarily used to store and transport multiple contents, including grains, animal feed, and fertilizers.


PP Woven bags have various advantages when put in use for storing cement. They are highly chemical and weather resistant. They have high tear strength, which enables it to carry heavyweight materials. PP woven bags are 100 per cent reusable and have high durability making it the less pollutant product compared to other packaging bags.


Quality control for cement packaging is very important. The BIS (Bureau of Indian Standards) has set norms for cement packaging. As per Cl 9.2 of IS 455: 1989, the average net mass of cement per bag shall be 50 kg. The average net mass of cement per bag may also be 25 kg subject to tolerances and packed in suitable bags as agreed to between the purchaser and the manufacturer. Similarly, as per Cl 10.2 of IS 1489 (Part 1): 1991 and IS 1489 (Part 2): 1991, the average net mass of cement per bag shall be 50 kg. The average net mass of cement per bag may also be 25 kg subject to tolerances and packed in suitable bags as agreed to between the purchaser and the manufacturer. Also, as per IS 8112: 1989, the average net mass of cement per bag may also be 25 kg, 10 kg, 5 kg, 2 kg or 1 kg, subject to tolerances and packed in suitable bag as agreed to between the purchaser and the manufacturer.


The history of cement bags has seen advancement and evolution. Up to 1970s, all cement bags used to be made of jute, which had zero moisture resistance and was prone to high spillage during handling and transportation. Since then, the switchover has been to plain woven polypropylene (PP) sacks. To upgrade PP bags, the concept of lamination was introduced which came with increase in packaging and handling cost. Some manufacturers are also using BOPP laminated bags to enhance brand value.

The technology of cement packaging
The process of cement manufacturing is incomplete till the end product i.e., is packed in bags and is ready to be shipped out. This process takes place with the help of machine and equipment in an automated process. They are mainly used to complete the automatic packing of cement and other powder materials with good fluidity, such as fly ash, gypsum powder, cement additives, etc.


These machines can be classified as a fixed type and rotatory type. The fixed type usually has 1-4 cement discharging nozzles. The rotary type includes 6-14 nozzles and operates in a rotating way to realize the automatic cement bag filling.


With this machinery, cement bags are filled continuously through the discharging mouth by the impeller running at high speed. A weight is set for the filling and when the cement reached that set weight, a signal is transmitted to the main system and the filling is stopped. This process is electronically controlled; however, bags of the desired size are manually fed to the machine.


Automation of the bag filling process has various advantages like having a stable operation, giving uniformity and structure to the bags, clean and hygienic filling of cement bags, ease of maintenance and lesser mechanical faults.

Challenges faced by users of cement due to cement packaging
Karan Sabhlok, Director, Kamdhenu Realities says, “one of the major challenges we face is when the labour unloads the packages of cement using hooks which leads to tearing of the packages and further lead to spillage of cement. We buy 50 kg packs and while loading and unloading the cement falls from packages and the rest in the pack gets hard and due to coming in contact with air, the strength of cement also decreases”.


He suggests that, “Cement should be packed in 2 bags, outer bag on which we will attach the hook and the inner bag which should be of at least 50 microns so that it keeps the cement safe from air. Also, the hook on the outer bag should be attached near the stitching so that there is least amount of damage to the bag”.


Some of the common challenges that users of cement like construction workers and builders face are wastage, leakage and tearing of cement bags while handling them. They are looking for cement manufacturers to provide stronger packaging materials or provisions where hooks can work without causing damage.


Throwing some more light on the challenges faced by builders Raj Kamal Yadav, General Manager – Strategy, Lodha Group says, “Cement industry uses unlaminated polypropylene bags with valves which allows them to pack cement very easily and fast, Since the bags are without lamination so cost of bags is low. However, the use of hooks in their logistics during the loading and unloading of cement causes tearage and leakage. These bags also have lower UV resistance and when placed in sunlight leads to cement losing its strength”.


These issues direct the cement packing industry to strive for innovation in packaging that can lead to lesser wastage and more ease of use.


Cement packaging taking a sustainable route
Cement manufacturers are moving towards paper packaging and makers of packaging are trying everyday to make cement packing material better for the environment and sustainable. While innovations are on the way, it is imperative that the environment is protected from the waste that may happen with used plastic bags.


Alpesh Patel, Managing Director, Knack Packaging says, “Every cement manufacturing company must ensure that used cement bags must be collected and either sent back for recycling or must be used as fuel in their kilns. This way they prevent waste accumulation in the ground and reduce the usage of natural resources for fuel supporting the environment.”
It is a question to dwell upon if the industry shall lean towards paper packaging that is recyclable, better in aesthetics, supports branding and is cost effective but does not protect cement well enough from environmental factors like moisture or they shall lean towards plastic sacks that do protect cement from moisture but produce larger amount of dust and are more prone to leakages.

Kanika Mathur

Concrete

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

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FORNNAX TECHNOLOGY has appointed industry veteran Dieter Jerschl as its new sales partner in Germany to strengthen its presence across Central Europe. The partnership aims to accelerate the adoption of FORNNAX’s high-capacity, sustainable recycling solutions while building long-term regional capabilities.

FORNNAX TECHNOLOGY, one of the leading advanced recycling equipment manufacturers, has announced the appointment of a new sales partner in Germany as part of its strategic expansion into Central Europe. The company has entered into a collaborative agreement with Mr. Dieter Jerschl, a seasoned industry professional with over 20 years of experience in the shredding and recycling sector, to represent and promote FORNNAX’s solutions across key European markets.

Mr. Jerschl brings extensive expertise from his work with renowned companies such as BHS, Eldan, Vecoplan, and others. Over the course of his career, he has successfully led the deployment of both single machines and complete turnkey installations for a wide range of applications, including tyre recycling, cable recycling, municipal solid waste, e-waste, and industrial waste processing.

Speaking about the partnership, Mr. Jerschl said,
“I’ve known FORNNAX for over a decade and have followed their growth closely. What attracted me to this collaboration is their state-of-the-art & high-capacity technology, it is powerful, sustainable, and economically viable. There is great potential to introduce FORNNAX’s innovative systems to more markets across Europe, and I am excited to be part of that journey.”

The partnership will primarily focus on Central Europe, including Germany, Austria, and neighbouring countries, with the flexibility to extend the geographical scope based on project requirements and mutual agreement. The collaboration is structured to evolve over time, with performance-driven expansion and ongoing strategic discussions with FORNNAX’s management. The immediate priority is to build a strong project pipeline and enhance FORNNAX’s brand presence across the region.

FORNNAX’s portfolio of high-performance shredding and pre-processing solutions is well aligned with Europe’s growing demand for sustainable and efficient waste treatment technologies. By partnering with Mr. Jerschl—who brings deep market insight and established industry relationships—FORNNAX aims to accelerate adoption of its solutions and participate in upcoming recycling projects across the region.

As part of the partnership, Mr. Jerschl will also deliver value-added services, including equipment installation, maintenance, and spare parts support through a dedicated technical team. This local service capability is expected to ensure faster project execution, minimise downtime, and enhance overall customer experience.

Commenting on the long-term vision, Mr. Jerschl added,
“We are committed to increasing market awareness and establishing new reference projects across the region. My goal is not only to generate business but to lay the foundation for long-term growth. Ideally, we aim to establish a dedicated FORNNAX legal entity or operational site in Germany over the next five to ten years.”

For FORNNAX, this partnership aligns closely with its global strategy of expanding into key markets through strong regional representation. The company believes that local partnerships are critical for navigating complex market dynamics and delivering solutions tailored to region-specific waste management challenges.

“We see tremendous potential in the Central European market,” said Mr. Jignesh Kundaria, Director and CEO of FORNNAX.
“Partnering with someone as experienced and well-established as Mr. Jerschl gives us a strong foothold and allows us to better serve our customers. This marks a major milestone in our efforts to promote reliable, efficient and future-ready recycling solutions globally,” he added.

This collaboration further strengthens FORNNAX’s commitment to environmental stewardship, innovation, and sustainable waste management, supporting the transition toward a greener and more circular future.

 

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Budget 2026–27 infra thrust and CCUS outlay to lift cement sector outlook

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Higher capex, city-led growth and CCUS funding improve demand visibility and decarbonisation prospects for cement

Mumbai

Cement manufacturers have welcomed the Union Budget 2026–27’s strong infrastructure thrust, with public capital expenditure increased to Rs 12.2 trillion, saying it reinforces infrastructure as the central engine of economic growth and strengthens medium-term prospects for the cement sector. In a statement, the Cement Manufacturers’ Association (CMA) has welcomed the Union budget 2026-27 for reinforcing the ambitions for the nation’s growth balancing the aspirations of the people through inclusivity inspired by the vision of Narendra Modi, Prime Minister of India, for a Viksit Bharat by 2047 and Atmanirbharta.

The budget underscores India’s steady economic trajectory over the past 12 years, marked by fiscal discipline, sustained growth and moderate inflation, and offers strong demand visibility for infrastructure linked sectors such as cement.

The Budget’s strong infrastructure push, with public capital expenditure rising from Rs 11.2 trillion in fiscal year 2025–26 to Rs 12.2 trillion in fiscal year 2026–27, recognises infrastructure as the primary anchor for economic growth creating positive prospects for the Indian cement industry and improving long term visibility for the cement sector. The emphasis on Tier 2 and Tier 3 cities with populations above 5 lakh and the creation of City Economic Regions (CERs) with an allocation of Rs 50 billion per CER over five years, should accelerate construction activity across housing, transport and urban services, supporting broad based cement consumption.

Logistics and connectivity measures announced in the budget are particularly significant for the cement industry. The announcement of new dedicated freight corridors, the operationalisation of 20 additional National Waterways over the next five years, the launch of the Coastal Cargo Promotion Scheme to raise the modal share of waterways and coastal shipping from 6 per cent to 12 per cent by 2047, and the development of ship repair ecosystems should enhance multimodal freight efficiency, reduce logistics costs and improve the sector’s carbon footprint. The announcement of seven high speed rail corridors as growth corridors can be expected to further stimulate regional development and construction demand.

Commenting on the budget, Parth Jindal, President, Cement Manufacturers’ Association (CMA), said, “As India advances towards a Viksit Bharat, the three kartavya articulated in the Union Budget provide a clear context for the Nation’s growth and aspirations, combining economic momentum with capacity building and inclusive progress. The Cement Manufacturers’ Association (CMA) appreciates the Union Budget 2026-27 for the continued emphasis on manufacturing competitiveness, urban development and infrastructure modernisation, supported by over 350 reforms spanning GST simplification, labour codes, quality control rationalisation and coordinated deregulation with States. These reforms, alongside the Budget’s focus on Youth Power and domestic manufacturing capacity under Atmanirbharta, stand to strengthen the investment environment for capital intensive sectors such as Cement. The Union Budget 2026-27 reflects the Government’s focus on infrastructure led development emerging as a structural pillar of India’s growth strategy.”

He added, “The Rs 200 billion CCUS outlay for various sectors, including Cement, fundamentally alters the decarbonisation landscape for India’s emissions intensive industries. CCUS is a significant enabler for large scale decarbonisation of industries such as Cement and this intervention directly addresses the technology and cost requirements of the Cement sector in context. The Cement Industry, fully aligned with the Government of India’s Net Zero commitment by 2070, views this support as critical to enabling the adoption and scale up of CCUS technologies while continuing to meet the Country’s long term infrastructure needs.”

Dr Raghavpat Singhania, Vice President, CMA, said, “The government’s sustained infrastructure push supports employment, regional development and stronger local supply chains. Cement manufacturing clusters act as economic anchors across regions, generating livelihoods in construction, logistics and allied sectors. The budget’s focus on inclusive growth, execution and system level enablers creates a supportive environment for responsible and efficient expansion offering opportunities for economic growth and lending momentum to the cement sector. The increase in public capex to Rs 12.2 trillion, the focus on Tier 2 and Tier 3 cities, and the creation of City Economic Regions stand to strengthen the growth of the cement sector. We welcome the budget’s emphasis on tourism, cultural and social infrastructure, which should broaden construction activity across regions. Investments in tourism facilities, heritage and Buddhist circuits, regional connectivity in Purvodaya and North Eastern States, and the strengthening of emergency and trauma care infrastructure in district hospitals reinforce the cement sector’s role in enabling inclusive growth.”

CMA also noted the Government’s continued commitment to fiscal discipline, with the fiscal deficit estimated at 4.3 per cent of GDP in FY27, reinforcing macroeconomic stability and investor confidence.

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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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