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Reduce use of mineral-based lubricants

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Gopalkrishna Murthy, Vice President, Zuari Cement, discusses the importance of lubricants in maintaining the heavy machinery at cement plants and ensuring its smooth operation and cost savings.

What is the role of lubricants in maintaining the machinery of cement plants?
The main role of lubricants used in the machinery of a cement plant rotating. A lubricant is bought to help in the cement manufacturing process. They lubricate the bearings, rollers, engines or whatever is used in operations is lubricated to ensure smooth functioning of the plant.

How often are quality checks and maintenance functions performed in a cement plant?
All manufacturers of the equipment of the cement plant give manuals along with it that have time intervals like 100 hours, 500 hours or 5000 hours depending on the equipment application for the replacement or for quality checking. There is a compliance guideline and a laboratory for checking, examination and replacement of lubricants. Viscosity, total base number, contamination and wear depreciation are all examined based on the compliance guidelines. Other frequently conducted tests like checking for water contamination, exhaustion of the life of the lubricant, requirement of filtering of the lubricant for reuse etc., are checked. Generally, the number of hours, be it 500 hours, 5000 hours or 10,000 hours, depends on the equipment.
The general maintenance of a cement plant is usually done once in six months when there is a shutdown for refractory maintenance, mill maintenance etc. It is then when the condition of the lubricants like oil for the kiln, grease for the bearings is also checked. In any cement plant they have open gear systems for the mills which are regularly checked for spray patterns and application of lubricants if it is going in as instructed or not.
In rare cases when there is excess stock or if the plant stops for any reason, even then the lubricants are checked.


What are the types of lubricants used in a cement plant? Tell us about their applications.
In a cement plant, right from the beginning at the mining site, where shovels, extractors etc. are used, we use engine oils for the engines, hydraulic oils for the hydraulic systems and transmission oils for the transmission process.
In the plant, where there are multiple gear boxes, oils are used as lubricants. In kilns and open gears or spur gears, grease is used with a grease spray. This grease is also used for bearings throughout the plant. There are multiple motors in the plant, even though they are lubricated across the plant. Some of the motors have lubrication oil circulating systems also depending on the size of the motors. Circulating oils, lubricating oil and greases are used in a cement plant.

Does the external environment impact the choice of lubricants made for the plant?
One of the major considerations while selecting lubricants for equipment is to look at its working conditions. We look at the temperature in the area of function, exposure to dust, if the lubricant will work with the seal etc. All these factors are monitored and then a lubricant is selected for the application. Hence, the external environment plays a major role in selecting the lubricant for the cement plant.

How do you select your provider for lubricants and plant maintenance?
Ready availability is one of the key parameters we consider while selecting the lubricant provider for the plants. Other parameters like cost and quality certifications are what we look into while selecting the provider.
If any lubricant by a provider is certified or showed confidence in by our machinery supplier or equipment supplier, we consider them. If other players in the industry are using the lubricant, it shows a trust in their quality, then we consider them. If a lubricant provider has special application and certifications from member companies, appreciation and experience of their product in the market is looked at while selecting them. Another consideration is their viscosity grade and national or international certification of quality by recognised bodies.
After sales service is also an important aspect we look into for this selection, such as collecting samples, taking materials for testing and feedback, maintaining a data bank of the organisation and then the lubricant providers update it and share it with the concerned department. These become important considerations while selecting our
lubricant provider.

What are the standards you look for in a product before shortlisting them for your brand?
Generally, all the lubricants used in the cement plants have an ISO certified viscosity grade. Greases used are certified by the National Lubricating Grease Institute (NLGI) grades; oils used are certified by American Petroleum grades and military oil grades. They also have quality certifications from the original manufacturers. Sometimes, when the manufacturer makes an oil especially for their equipment, we consider that quality as well.

Does using lubricants for the plant have an impact on the environment? Can it be made more eco-friendly?
We ensure that whichever lubricant we use does not contaminate the environment. The lubricants should be made in such a manner that they can be re-filtered, recycled and reused. The plants usually push for longer drain intervals so that it reduces the impact on the environment when discarded. The lubricants should also be made in such a manner that they can be used as a source of energy or can be burned in the kilns without causing pollution to the environment. We consider these factors when we choose them for our plant.
Bio lubricants are now coming up in a big way and the industry is slowly reducing the use of mineral-based lubricants. Now there are multiple synthetic lubricants being formulated that are environment friendly. Their drain intervals are longer and hence, they can be used for a longer time, which means they are discarded at much longer intervals than other oils reducing the contamination of the environment and stay longer in the plants.

What innovative products do you suggest should be in the market for efficient cement plant lubrication?
There are two major requirements of the cement industry at this given time. Synthetic lubricants should be made for all kinds of applications and the cost should be in moderation that will allow more manufacturers to make the switch.
The cement industry consumes multiple lubricants and in large quantities. A scientific innovation should be made in the formulation to allow longer drainage intervals. Today the available synthetic lubricants are much costlier as compared to other type of lubricants and their drain intervals are also shorter.
The lubricants should also be energy efficient. If an organisation decides to invest in a higher costing lubricant, it should provide energy efficiency that will help them reduce their costs in other arenas. This would in turn make these lubricants environment friendly.

How do you foresee the collaboration of the lubricant industry and cement industry in the future?
Lubricant banks are developed by multiple oil industries, which they place in cement industries. This facility is not for all but cement plants do buy lubrication from the oil industry. However, this causes lack of availability. If all the lubricant manufacturers develop a banking type of structure in the plant campus itself, that will help in better interaction between the plant personnel and the lubricant makers and easy availability of the lubricants.
It will also help us recognise the many varieties of lubricants available in any category of lubricants which will help us make better informed choices and thus, improve the plant efficiency. The lubricant manufacturers will also have the opportunity to sell their best products and having these lubricants readily available on the plant campus will reduce lead time as well.
This development will make a better collaboration and interaction between the lubricant industry and cement industry.

-Kanika Mathur

Concrete

Adani’s Strategic Emergence in India’s Cement Landscape

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Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.

India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.

Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:

  • September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
  • December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
  • August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
  • April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
  • Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
  • Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
  • Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
  • Orient Cement: It would serve as a principal manufacturing facility following the merger.

Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:

  • By FY 2026: Reach 118 MTPA
  • By FY 2028: Target 140 MTPA

These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).

Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.

Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.

Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.

Challenges potentially include:

  • Integration challenges across systems, corporate cultures, and plant operations
  • Regulatory sanctions for pending mergers and new capacity additions
  • Environmental clearances in environmentally sensitive areas and debt management with input price volatility

When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.

Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.

About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.

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Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

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PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.

Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

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Driving Measurable Gains

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Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.

Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.

Beyond energy efficiency, the retrofit significantly improved operational parameters:

  • Lower thermal stress on equipment
  • Extended lubricant drain intervals
  • Reduction in CO2 emissions and operational costs

These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.

Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:

  • Enhanced component protection
  • Extended oil life under high loads
  • Stable performance across fluctuating temperatures

By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.

Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.

A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

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