Concrete
Decarbonising Cement
Published
2 years agoon
By
admin
S K Rathore, Head Manufacturing – Grey Cement, J K Cement, gives a 360-degree overview of making cement manufacturing a sustainable activity and resolving environmental issues arising out of it.
The Indian cement industry is the second largest producer of cement with around 8 per cent of global cement capacity. It is one of the major contributors to the GDP of the country. The Indian cement sector is one of the most energy-efficient sectors in our country. It has adopted various new practices for improving energy efficiency, environmental performance and cost competitiveness but still has a long way to go to achieve the global targets on carbon footprint reduction.
At JK Cement Ltd (JKCL), they are at the forefront of their sustainability journey. Their progress is on the right speed to achieve their alignment with cement sectors Sustainable Development Goals (SDG). To meet global SDG, they are working on various levels, which include improving energy efficiency, green power, circular economy, clinker factor/blended cement, water footprint and biodiversity.
For the circular economy, JKCL has adopted an environmentally friendly way by disposing of the waste and hazardous waste in cement kilns to replace fossil fuel. For conservation of natural resources, JKCL is using various industrial waste such as fly ash and slag as alternative raw materials.
Circular Economy
A circular economy is a suitable and environmentally friendly way to dispose of the waste and hazardous waste in cement kilns, which replaces fossil fuel.
All their cement kilns are equipped with state-of-the-art pre-processing and feeding of a wide range of liquid and solid waste materials in the calciner. They have increased their Thermal Substitution Rate (TSR) from 6 per cent 2017-18 to 12.9 per cent till YTD FY 2023 and aim to reach 35 per cent by FY30. One of their plants in the state of Karnataka is currently using around 18 per cent Alternative Fuel and Raw Materials (AFR). Recently the company has signed a MoU with PRESPL for the supply of biofuel, biomass to achieve the TSR target.
To strengthen the existing AFR feeding system and to overcome the process challenges, the company is investing in advanced pre-processing and feeding facilities, and in chloride bypass systems to utilise all types of waste including hazardous waste. The company has installed a state-of-the-art R&D lab across all the sites to check the compatibility of waste and
process stabilisation.

They are increasing the share of blended cement by the use of industrial waste such as fly ash and slag as alternative raw materials. As of now the company has achieved a clinker factor of 65 per cent by Q2 FY23, and achieved the target set for FY 2030 under SBTi by company.

Advanced processes are the key to manufacturing green cement as a carbon-negative approach is required to achieve this.
Reducing the Carbon Footprint
Cement being an energy-intensive sector and major contributor to CO2 emissions needs to take major steps to reduce its carbon footprint.
The major GHG emissions are released during clinker production. To achieve their targets, the company is closely monitoring and putting efforts to decarbonise their operations according to the United Nations Framework Convention on Climate Change (UNFCC) campaign’s Race to Zero pledged by the company under the egis of GCCA. In their 2030 agenda, they have targeted to reduce gross carbon emissions from 680 kg CO2/t cement to 532 kg CO2/t cement and net carbon emissions (Scope 1) from base year FY20 level of 580 to 465 kg CO2/t cement.
In the last three years, JKCL has reduced gross GHG emission by 16.62 per cent to 567 kgCO2/t cementitious material and net Scope-1 emission by 10 per cent to 522 kgCO2/t cementitious material till FY2023 Q3.
Role of Automation
JK Cement’s primary focus is on improving energy efficiency and lowering fuel consumption and emissions. By optimising the performance of process control loops, significant energy efficiency can be achieved at a minimal cost, to start with. A process loop optimiser with an AI-based module also helps to optimise fuel use by minimising operational disturbances resulting in decreased carbon emissions. The future bucket list of decarbonisation phases includes AFR gasification, CO2 capturing and upcycling.

Business sustainability is directly linked to automating the cement process and so is the same for JK Cement, too. They have recently developed an AI-based WHRS efficiency enhancement model, and the AI module predicts and makes suggestions to optimise cooler operation for effective and economic solutions for WHRs.
Spreading Awareness
Structured programmes and awareness campaigns for increasing awareness on sustainability are offered to the employees in order to help build world-class competencies and skills. Corporate Sustainability Council is formed, with representation from plant and functional heads, which is working for implementation of sustainability initiatives across the organisation. It plays a major role in developing sustainability awareness and is responsible for communication, reporting and alignment with the global best practices. The Council also facilitates sustainability audits, participating in environmental and social events, while providing relevant information and disclosures to the stakeholders as well as sustainability rating bodies.
The corporate sustainability team monitors climate-related interventions across the organisation, collects and monitors sustainability data and reports to the Corporate Sustainability Council.
Cement is a key ingredient for the development of our cities and societies: construction material is responsible for putting roofs over the heads of billions. As the backbone of the housing and infrastructure sector, it also fuels widespread economic growth but at same time produces a lot of CO2 and it is a hard-to-abate sector from an environmental point of view as the main process itself generates CO2 apart from use of energy in other forms.

India’s infrastructure and urban growth will bring the necessary impetus for innovation in green cement and related technologies
About 40 percent of the emissions come from fossil-fuel combustion and the rest from chemical reactions inherent to the cement making process. It’s a challenge to 100 per cent replacement of fossil fuel by AFR as the quality of AFR available in India is inconsistent.
Scarcity of good quality Secondary Cementitious Material (SCM) due to global switching to renewable energy from fossil fuel based power plants is going to be a major challenge to reduce clinker factor. It is resulting in the need to explore alternative SCMs like good quality clay sources to produce the under development LC3 cement in future and acceptance in the market.
The Future of ‘Green Cement’
India is a growing country with a plethora of construction prospects, which drives cement consumption. Green cement has a promising future in India, if the supply-demand cycle is balanced while maintaining environmental standards.

It is estimated that the cement industry contributes 8 per cent of the total CO2 emissions. To cut down on future emissions, green cement is one such innovation in the cement industry. The green cement is manufactured with a net carbon-negative, technologically advanced process. It is environmentally friendly since it recycles industrial waste and decreases carbon dioxide emissions in total. At the moment, blended cements account for 73 per cent of total cement production, while ordinary Portland cement accounts for 27 per cent. There are several BIS standards under development related to green cement, e.g., Portland limestone cement (PLC), Limestone Calcined Clay Cement (LC3), and Portland Composite Cement (limestone-based), which will be great alternatives to eliminate production of Ordinary Portland Cement.
By using green cement and concrete, CO2 emissions can be reduced further. Also, it reduces the use of freshwater in ready-mix concrete. Eco-friendly products are the need of the hour and will help the cement industry resolve environmental issues.
ABOUT THE AUTHOR:
S K Rathore, BE(Mech), PGDM, has been associated with JKCement for almost 40 years. Throughout his stint with the organisation, he has worked in all technical and operational areas of manufacturing plants. He has contributed immensely to plant operations for stabilisation and improvements with consistent efficient performance.
Concrete
Adani’s Strategic Emergence in India’s Cement Landscape
Published
3 days agoon
September 16, 2025By
admin
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.
Concrete
Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series
Published
1 month agoon
August 16, 2025By
admin
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.

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.

Adani’s Strategic Emergence in India’s Cement Landscape

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

Driving Measurable Gains

Reshaping the Competitive Landscape

CCU testbeds in Tamil Nadu

Adani’s Strategic Emergence in India’s Cement Landscape

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

Driving Measurable Gains

Reshaping the Competitive Landscape
