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The Indian cement industry is achieving an exemplary performance

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3 years ago

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Jim O’Brien, CSR Consultant and Convenor of Global Aggregates Information Network (GAIN), evaluates how far the industry has come with the efforts to decarbonise cement and to have a positive impact on the environment as he places India’s performance on the spectrum of the international cement industry.

The cement industry is responsible for approximately 8 per cent of emissions globally. What are the key factors the industry must be looking into to reduce this?
Yes, the cement industry is responsible for around 8 per cent of the global CO2 emissions, and it is taking very active steps to reduce that footprint. In parallel, it must be realised that cement is an essential building material for a rapidly-developing modern society like India. Cement, aggregates, and concrete are essential to building the much-needed infrastructure and housing for what is now the most populous and rapidly-developing region in the world. Those concrete structures will gradually absorb much of the CO2 emitted during the cement production, and enable adaptation to whatever changes in climate may occur in the decades ahead. That wider perspective needs to be understood.

What is your outlook about India’s decarbonisation scenario? How is the country faring vis-a-vis other countries in the West?
Even though India pledged to reach Net Zero by 2070, its cement industry is forging ahead on a decarbonisation path to reach that goal by 2050 – or even earlier. In the analysis based on their 2021 sustainability reports, the top Indian players like Ultratech, Shree and Dalmia, demonstrably lead the world in process parameters like:

  • Achieving best kiln thermal efficiencies, approaching as low as 3000MJ/tonne clinker, against an industry average of around 3500MJ/tonne clinker.
  • Achieving best specific net CO2 emissions, now in the region of only 500kgCO2 /tonne cementitious product, against an industry average in the region of 600kg/CO2 /tonne.
  • Achieving reduction in specific net CO2 emissions by over 40 per cent compared to their levels in 1990, which are world-leading performances, of which the Indian cement industry can be truly proud.
  • These world-leading trends witness the major past and ongoing investments in modern kiln technology in India, in turn motivated the rapidly growing market and buoyant economic outlook for at least this decade.

Tell us more about the impact of alternative fuels and raw materials on the energy efficiency of the cement industry.
There are surprisingly contrasting results for the Indian players in this area:

  • The use of alternative fuels in India is amongst the lowest in the world, amounting to only a few per cent of thermal substitution; this is probably because waste legislation is not yet as advanced in India as it is in Europe, where, for example, kilns often use up to nearly 100 per cent of the alternative fuels.
  • These alternative fuels bring two distinct advantages. Firstly, use of these fuels (or at least the biomass component thereof) allows credits in the calculation of net CO2 emissions. Secondly, these fuels are cheaper, the more hazardous ones coming even with a negative cost, with significant commercial benefit.
  • The use of alternative materials in India is, on the other hand, amongst the highest in the world, ranging from 20 per cent to 40 per cent substitution, allowing very low clinker/cement ratios approaching 60 per cent; this is viable through the plentiful availability of puzzolans, slags and fly-ashes in India compared to Europe.
  • The high use of alternative materials and consequent low clinker/cement ratios in India not only greatly reduces the net specific CO2 emissions, but also reduces the volume of limestone needed to produce cement, an important factor in India.

How can technology and automation contribute towards building a sustainable environment?
The leading Indian players are also technology leaders in:

  • Highly efficient electrical energy consumption in the region of 70-80kWh/tonne cement, compared to the international average of around 100kWh/tonne, in India achieved through advanced grinding technology, probably also helped by the less demanding cement fineness required.
  • The extensive investment in waste heat recovery systems, plus the move to renewable energy, in particular through solar installations, all of which help to reduce Scope 2 CO2 emissions.
  • Automation is clearly key to optimising all processes both within and beyond the cement plant, and the latter can help in reducing Scope 3 transport emissions of both incoming raw materials and outgoing products.
  • In the Indian context, what would be the best practices to follow to ensure a sustainable environment?
  • There is much more to sustainability performance than CO2 emissions; the larger Indian players also feature prominently in other aspects.
  • In air emissions, they laudably achieve particulate emissions less than 40g/tonne clinker, NOx less 1000g/tonne clinker and SOx less 100g/tonne clinker, all well below industry averages, but do not yet report on minor air emissions.
  • Because of water scarcity in India, the larger players are highly focused on water use optimisation, achieving as low as 84 litres/tonne of cement, way below the industry average of around 300 litres/tonne; the major players pride themselves in being many times water-positive through rainwater harvesting.
  • The Indian players are highly conscious of waste reduction and re-use, one reporting itself as ‘plastic-positive’, their high use of alternative materials indeed puts them amongst the biggest recyclers in any industry.
  • As part of their ‘licence to operate from society’, the leading players have restoration plans for all their quarries, several with replanting programmes and biodiversity monitoring action plans where appropriate.

How can organisations overcome the challenges of maintaining a healthy and sustainable environment?
A number of relevant social indicators can be cited:
Like the cement industry globally, the Indian industry has a strong focus on occupational health and safety.

  • However, a number of fatalities to employees, contractors and third parties were reported amongst the Indian players in 2021; while the industry has achieved major improvement in fatality reduction over the last decade, the only acceptable figure is zero.
  • Indian employee accident rates are extremely low, as also are contractor rates, bearing witness to the strong operational focus on those key areas.
  • In terms of training, the Indian figures of 10-20 hours of training per employee per year are at or below the industry average of 20 hours, though many international players now have from 30 to 90 hours per employee per year.
  • Employee turnover rates in the Indian companies tend to be in the region of 6 per cent to 8 per cent, below the industry average of 12 per cent, indicating long-term employee loyalty in the Indian companies.
  • The employee age profiles in the Indian companies tend to be about 10 per cent below the age of 30, with 70 per cent between the ages of 30 and 50, with 20 per cent over 50, the average employee age being less than industry average, which bodes well for the future; however, the Indian companies have typically less than 5 per cent female employees, much lower than the industry average of 12 per cent.
  • Indian companies have world-leading programmes in terms of vital support to local communities in education (particularly for women), medical facilities, provision and clean water and sanitation; these witness the Indian cement industry’s huge dedication to the broader social needs of Indian society.

How do you envision the future of a sustainable environment in relation to the cement and building materials sector?
As demonstrated, the Indian cement industry is achieving an exemplary performance within the context of its cement plants and surrounding communities. So far, the Indian industry has in general little downward integration into concrete and aggregates, as is much more common in Europe and other developed regions. Accordingly, both the aggregates and concrete sectors are less developed in India compared to other countries, and could, I suggest, benefit in terms of broader synergistic, sustainability, quality and reputational terms through greater involvement of the cement industry.
The Indian cement industry, in the broadest sense, I believe, is all about delivering the most sustainable solutions in housing, infrastructure, transport and well-being to its society of 1.4 billion people; they deserve and rightly expect a happy, secure, prosperous, and sustainable future in the world’s fastest growing major regional economy. Accordingly, the opportunities for ambitious Indian entrepreneurial companies in further developing its cement, concrete and aggregates industries are immense.

–Kanika Mathur

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Adani’s Strategic Emergence in India’s Cement Landscape

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6 days ago

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September 16, 2025

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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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1 month ago

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August 16, 2025

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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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1 month ago

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August 16, 2025

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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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