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Lubricant in a machine is like blood in a human body

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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’.

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

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