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Right design of the transportation system is critical

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Vinod Agrawal, Executive Vice President – Logistics, Wonder Cement, discusses the varied factors affecting the material handling equipment and their maintenance, as well as the role of automation and technology in the material handling process.

Tell us about the key material handling equipment used in a cement plant. At what stage of manufacturing are these equipment most functional?
Cement manufacturing is a process driven industry where various types of ore, raw materials, semifinished and finished products are handled in various forms at various stages. Efficiency and productivity of the material handling equipment is vital to produce the best quality of cement at the most economic cost. Modern cement plants use following material handling equipment:

From limestone mines to crusher: Hydraulic high-capacity dumpers/tippers, poclains, belt conveyors/pipe conveyors. Some of these belt conveyors are even spread cross-country panning at a length of 17 km, carrying limestone from mines in India for cement plants located in Bangladesh. The longest conveyor belt in the world measures to 98 km and is operational to transport at the ore in Western Sahara, Africa. Since belt conveyors are a very efficient mode of transportation, there are various projects ongoing for manufacturing even longer belt conveyors not only in cement industries but also in other manufacturing sectors.

From crusher to raw mill: Belt conveyors, stacker and reclaimers are used to maintain uniformity of quality. In the mines from pit to pit based on the horizontal and vertical location there is some variation in quality. Stacker and reclaimer are a two-step material handling, storage as well as homogenisation process equipment to maintain uniformity of the raw material of limestone, ores like gypsum, raw materials and fuels like coal, petcoke etc. Here, the wagon tipplers and truck tipplers are used to receive and unload raw materials “Right design of the transportation system is critical.”Vinod Agrawal, Executive Vice President – Logistics, Wonder Cement faster throughout the chain of operation.

From raw mill output to clinkerisation: Heat resistant belt conveyors, bucket elevators (belt and chain type), air lifters/air slides, pneumatic conveying system, screw conveyors and overhead cranes are used to carry materials in this stage of cement manufacturing.

From post clinkerisation to grinding: Belt conveyors, bucket elevators, air slides, screw conveyors are used to carry clinker to grinding units.

From cement packaging to dispatch: Automatic ROTO packers, wagon loading machines for covered wagons for 50kg cement bags, truck loading machines, bulk cement conveying and loading system for bulkers/tank Container wagons, clinker loading system for open wagons.

Finished goods (cement) – end transportation to customers: Various type of railway wagons like covered wagons (BCN/BCNA), Open Type Wagons (BOXN), bulk cement transportation wagons like (BCCW, BTAP), various types of trucks with a capacity of 10 MT to 45 MT, bulkers for transportation of bulk cement by road, container wagons by road as well as rail.For material handling, storage and onwards, the transportation at the depot is done by using conveyors, cranes or manually

What is the maintenance procedure of the material handling equipment at your organisation?
In our organisation, we maintain the highest level of reliability of all equipment by adhering to Preventive Maintenance (PM) Frequency as given by the suppliers (Original Equipment Manufacturers) recommendation. The preventive maintenance is a very structured and well-designed maintenance system, where each part of the equipment has a defined frequency of inspection, repairing and replacement of the parts. Since cement manufacturing is a continuous process industry, reliability on each and every equipment is equally important as negligence or deviation in any material handling equipment even if it may be of smallest value. Negligence can cause a complete stoppage of the entire production cycle. We are following a 100 per cent adherence on the preventive measure schedule given by OEM. Apart from this we are continuously innovating better systems for superior operation in each stage of material handling.

Tell us about the role of automation and technology in the material handling process?
Today’s digitisation and technological upgradation has changed the shape of material handling equipment.

There are inbuilt quality checks installed in the equipment that conduct an hourly check at each stage of material handling where the equipment functions. Every equipment in our units are equipped with automatic sensors, safety interlock switches for material high level, low level, cross belt analyser, belt conveyors material conveying rate Ton Per Hour (TPH) on real time basis, speed variable drives to increase or decrease the speed on automatic basis to cite some examples. Our quality testing laboratory, we use world class robotic technology to handle the samples of raw materials, semi-finished and finished products for quality assurance.

Every equipment at our packaging plants is equipped to monitor the exact weight of each bag of cement. An automatic bag counter is installed at various stages of the packing and loading operation unit, which helps reduce manual work load and ensure higher rate of accuracy in the system

What are the key differences in handling raw material versus handling end products at the cement plant?
Raw materials are normally handled in bulk form in larger structures like stone shapes, granules, fine powder and mainly handled by equipment like belt conveyors, belt bucket elevators, air slides, air lifters, pneumatic conveying system. For the finished goods, till the packing operation, almost similar equipment is used to carry the load through different units.

However, after the packaging is done, there are customised material handling equipment like wagon loading machine, truck loading machine etc. The belt conveyor is most commonly used equipment and is functional throughout the process till loading is done inside the wagons and trucks. The design, capacity and size of the belt conveyors changes as per each stage of operation.

Tell us about the various conveyors used in the manufacturing unit?
There are various types of conveyors like, belt conveyor, which is most commonly used. There are other types of conveyors used for transportation of material like pipe type conveyors, heat resistant belt conveyors, bucket elevators, screw conveyors etc., through different processes of the cement manufacturing process.

What role do gates play in the transportation of material in and out of the plant?
Gates or valves are an integral part of the material handling equipment. These ensure controlled flow of materials and avoid any overflow, jamming or bottlenecks in the process of transfer of materials. They also are of help during maintenance work as they can stop material from flowing while the maintenance job is being completed.

How does the manufacturing unit ensure efficiency in the material transportation process?
Efficiency of the material transportation process can be ensured by adhering to the best operation practices and maintenance standards enlisted according to individual system guidelines. This not only ensures efficiency; it increases the machinery reliability and impacts productivity of the unit as a whole.

How can material handling or transportation impact the profitability of the organisation?
Selection of the right design of transportation system is critical for long term sustainability and profitability of any organisation. For example, if we do not install belt conveyors for ore transportation from mines to crushers and instead use road transportation, then the operating cost of the function will be almost five times higher than the use of conveyors.

Similarly, installation of rail handling systems or rail siding is key for long term viability and ease of operation compared to road transportation. Also, as a responsible corporate each organisation has the responsibility of conserving and protecting the environment, which is only possible with right designing, installation as well as operation of the material handling equipment.

What are the technological advancements required to enhance the productivity of material handling equipment?
There is a continuous cycle of innovation in the technology provided by prominent suppliers of material handling equipment. They are offering advancement in terms of automation and digitisation of the equipment, they are making them more environment friendly, safer for operation, providing a higher output while consuming less operating cost and giving higher number of runs before a scheduled maintenance is needed as per industry standards.

All this has been achieved with technological advancements and the same can be further improved and enhanced for higher productivity levels.

How do you foresee the future of material transportation at your manufacturing unit?
Earlier, most of the key material handling equipment for cement plants were imported. However, with the industrial development in India, we are gradually seeing a reduction of imported equipment and a lot of industries being set up locally for this sector that can provide the same technology of equipment at a much lower price while maintaining international standards. We foresee many more such industries being set up in India, where equipment delivery time will be reduced significantly and the cost will be competitive in the market. The lead time will be significantly reduced with this move as suppliers will be available across the country.

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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Concrete

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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