Concrete

Lubricant in a machine is like blood in a human body

Published

3 years ago

June 12, 2023

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Gaurav K Mathur, Chief Executive, Global Technical Services, discusses the importance of contamination-free lubrication to keep machinery working at optimum capacities.

What is Total Lubrication Management System.
Cement plants are process plants, with thousands of rotating machines operating 24×7, 365 days. Availability of these machines are critical and plant reliability is vital; operating conditions of cement plants are highly dusty; lubricants can get contaminated before being filled in machines; if not stored according to the well-established system. Therefore, system-oriented approach for contamination-free lubrication is the foremost requirement of the cement industry.
Our Total Lubrication Management (TLM) is implemented at the plants as per Standard Operating Procedures (SOP), for uniform adaptation of best lubrication practices to ensure clean lubricants are fed to machines. Good lubricants storage, handling and dispensing of lubricants is essential for good lubrication programme in any industry.
The important aspects of the SOP are:

Roles and responsibilities of all responsible for implementing TLM at every site.
Good housekeeping: clean environment in Central Lubrication Cell.
Storage of oil and grease barrels: to ensure feed clean lubricants to machines.
Colour Coding system: to eliminate contamination.

In-house laboratory and testing procedures:
to establish condition base oil change and oil conservation.

Online filtration: to keep oil clean in service at all times
Management of spillage and leakages
Management of minor and major leakage
Regeneration of drained oil and its usage

after lube-testing – a must for oil conservation. Lubricating oil is expensive and needs to be saved.
Some of the largest cement plants in the country have outsourced their lubrication activities on a single window basis to us (GTS), entrusting the responsibility of storage, handling, dispensing, regeneration, and condition monitoring of lubricants for the plants and mines. All resources required for world class lubrication are deployed by GTS including dedicated manpower and a well-equipped oil testing laboratory at each site, beside lubrication equipment, and fifth generation oil filtration systems (they can remove water/moisture besides suspended dust, and wear particles).

How often do you audit or review your implemented systems?
The team of engineers from our Mumbai office visit each site regularly and review our site team work, and discuss with the plant’s mechanical maintenance team for their feedback and further improvement required. Then we make a time bound schedule and implement the same. This is our ongoing process for all sites.
The frequency of reviewing or auditing TLM is a continuous process, quality service requires various yardsticks to identify gaps for continuous improvement. We are pleased to convey that our customers are quite satisfied with our working. We make every effort to achieve world class lubrication management at our sites. We are now in the process of implementing software-based TLM System at some of our sites. Once it is established properly, we will be doing the same at all our sites.
Each cement plant has thousands of lubrication points and each and all points have their lubrication frequency monitoring of lubrication, etc. has been incorporated in the software. Thousands of lubrication points are generating a very large quantum of data and once this software with artificial intelligence (AI) is developed shall a great boon for us and the industry. One of the key challenges today is contamination free lubrication and condition-based oil change system, with the assistance of the site laboratory leading to oil conservation (this shall also be integral part of the AI-based software).
We have developed fifth generation oil filtration system and we have been able to conserve approximately 18 to 20 per cent lubricants at our site, on yearly basis. ‘Oil never dies – it only gets contaminated.’ Once these contaminations are removed, oil is fit for further use. And yes, laboratory test report is important.

How do you maintain quality for the lubricant products provided to the cement manufacturers?
Lubricants are manufactured by well-established oil companies with extensive R&D, high value lubricants are handed over to the industry, however if not stored properly at the industry’s site the high-quality lubricants can get contaminated. Since oil in a machine is like blood in human body, the contaminated lube oil can be damaged the machine. We store the oil very carefully to ensure no dust, dirt or moisture go into the oil barrel and therefore we adopt covered indoor storage and keep the barrels in our Central Lubrication Cell (CLC), which is provided by the site management to us and we develop it to our operating requirements. We do all lubrication activities for the site from CLC. We also establish Oil Test Laboratory at this location (Central Lubrication Cell.)
How do lubricants improve functionality at cement plants?
Cement manufacturing plants work under highly dusty environment. They are located in remote areas away from the major towns. Keeping the oil as clean as possible within the machine is extremely important. This helps improve machine condition, production reliability and ultimately profitability of our customers.

How do you incorporate sustainability in your process and operations?
One of the pillars of TLM regeneration of lubricants. These tested oils are crafted to match the performance of fresh oil, resulting in conservation of lubricants leading to sustainability.

What is the role of automation and technology?
Modern day manufacturing is a lot more demanding, with advancement in technology, data becomes vital and customised software is not developed enough to track assets parameters. There has been a need for software for route planning and execution of lubrication activities – these activities are so many in numbers to monitor them without an AI based software leaves enough room for error.
We are implementing TLM software at plants where TLM is being implemented by us. This software helps micro level operational ease and counter check of activities. All activities data is logged through secured servers. Bringing meaningful, actionable data on the palm top is the key, and all modern technologies are being adopted for the same, including industrial internet of things (IIOT) and autonomous monitoring. We are implementing a mix of technology to have a robust system in the plant, while implementing TLM.

Which innovations are in the pipeline?
It is important that we adopt a system- and AI-based TLM at all the plants. We have established a world class oil testing laboratory at site and a mother oil testing laboratory with modern equipment such as Inductively Coupled Plasma (ICP), covering 5-6 plants and with test results available within 48 hours for oil condition monitoring.
We are developing technologies involving AI, drones, robotics, software and sensors coupled with robust databases, all specifically for machine monitoring, to attain the dream of ‘Machine
for Life’.

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Concrete

JSW Cement Commissions 1 MTPA Unit in Rajasthan

Rajasthan grinding capacity rises to 3.50 MTPA after commissioning

Published

2 days ago

October 9, 2026

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JSW Cement has commissioned an additional 1 MTPA cement grinding unit in Nagaur, Rajasthan, taking the company’s total cement grinding capacity to 25.1 MTPA. The commissioning was announced on Tuesday, October 6.

The company said the new unit had increased the total cement grinding capacity at its Rajasthan plant to 3.50 MTPA. The expansion adds to JSW Cement’s production infrastructure as it continues to build capacity across its operating network.

The company’s total clinker manufacturing capacity, including capacity at its joint venture JSW Cement FZC, stands at 9.74 MTPA. Clinker is an intermediate material used in cement production, and its availability supports the company’s grinding operations.

JSW Cement is also pursuing a proposed merger of its listed subsidiary Shiva Cement with the company. The scheme, approved by the boards of the respective companies, involves issuing five fully paid-up JSW Cement equity shares for every 41 shares held by Shiva Cement shareholders other than JSW Cement.

The arrangement remains subject to shareholder and regulatory approvals. JSW Cement currently holds 66.23 per cent of Shiva Cement’s paid-up equity share capital, and the shares held by JSW Cement in the subsidiary will be cancelled under the proposal without any issue of JSW Cement shares against that holding.

The scheme has an appointed date of April 1, 2026, and the company has indicated that completion could take 12 to 14 months, depending on the receipt of approvals. These include clearances from stock exchanges, the Securities and Exchange Board of India, the National Company Law Tribunal and other applicable authorities, along with approvals from shareholders and creditors where required. JSW Cement shares closed at Rs. 113.15 on the BSE, up Rs. 2.05, or 1.85 per cent.

Concrete

Wonder Cement appoints Mahesh Singh as VP Corporate Brand Communication

Published

2 days ago

October 9, 2026

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Singh brings 20+ years of brand and marketing experience, and will lead integrated corporate brand communication initiatives at Wonder Cement

New Delhi

Wonder Cement, a leading cement manufacturer, has appointed Mahesh Singh as Vice President – Corporate Brand Communication. In his new role, he will oversee corporate brand strategy and communication, including digital and performance marketing, public relations, trade, events, exhibitions, sports and experiential marketing.

Singh brings over two decades of experience across marketing and communications, with roles spanning the automotive industry, agencies and entrepreneurship. He spent more than a decade with Honda Motorcycle & Scooter India, working across integrated communication, media, digital, retail and consumer engagement. His stint also included helping build the company’s digital marketing capabilities.

He moved to dentsu X India as Vice President – Strategy & Planning, working across categories such as automotive, auto components, electric vehicles, FMCG, consumer electronics, BFSI, apparel and brand consulting. His responsibilities included media and marketing strategy, product launches, content, performance marketing and consumer activations.

Singh subsequently took an entrepreneurial route with Radiant Brands before joining Shriram Ltd (SPR Autotech) as Head – Marketing & Communications. There, his remit included brand and corporate strategy, communications, PR and ORM, retail identity, loyalty programmes and events.

At Wonder Cement, Singh will be responsible for bringing together the company’s corporate brand communication initiatives across digital, performance marketing, PR, trade, sports and experiential platforms. The role will focus on creating an integrated approach to communication across consumers, trade partners and other key stakeholders.

The appointment brings to Wonder Cement a marketer whose career has spanned the brand, agency and entrepreneurial sides of the communications ecosystem.

Wonder Cement, part of the RK Group, is a cement manufacturer with roots in Rajasthan and a focus on quality, trust and transparency. The company has grown to six manufacturing plants, and a cement capacity of 21.5 MTPA. With more than 2,000 employees and a network of over 5,000 dealers, its operations span manufacturing, distribution and customer engagement, with a focus on consistent product quality and efficient execution.

Concrete

JSW Cement commissions additional 1 MTPA grinding unit in Rajasthan

The Nagaur expansion takes JSW Cement’s total grinding capacity to 25.10 MTPA.

Published

3 days ago

October 8, 2026

admin

JSW Cement has commissioned an additional 1 million tonne per annum (MTPA) cement grinding unit at its Nagaur Integrated Plant in Rajasthan. The commissioning takes the company’s total cement grinding capacity to 25.10 MTPA.

JSW Cement’s total clinker manufacturing capacity, including its joint venture JSW Cement FZC, now stands at 9.74 MTPA.

The company began operations in North India in March 2026 with the Nagaur Integrated Plant, comprising a 3.30 MTPA clinkerisation unit and a 2.50 MTPA cement grinding unit. With the latest expansion, the plant’s total grinding capacity has increased to 3.50 MTPA.

The additional capacity will cater to cement demand across Rajasthan, Haryana, Punjab and the National Capital Region (NCR). The expansion has been funded through a combination of equity and long-term debt.

During the quarter ended September 30, 2026, JSW Cement also commissioned an Alternate Fuel Handling System and a Waste Heat Recovery System (WHRS) at the Nagaur plant.

Nilesh Narwekar, CEO, JSW Cement, said the additional grinding capacity was a strategic priority for the company’s expansion in North India. He added that the Alternate Fuel Handling System and WHRS were expected to reduce production costs.