Concrete
We focus on delivering ‘solutions’ rather than ‘products’
Published
2 years agoon
By
admin
Anant Pokharna, CEO, Unisol Inc, speaks at length about bespoke grinding aid formulations that are helping cement companies meet their carbon emissions targets.
Tell us about the cement additives,grinding aids and construction chemicals provided by your organisation to the cement industry.
Our product range includes bespoke grinding aid formulations, quality improvers and other relevant high-impact chemical additives that find application in cement manufacturing. Our products help cement producers in a range of applications including:
- Increased cement mill throughput and reduced specific power consumption
- Reduced clinker factor (content) in blended cements and corresponding increment in ecologically friendly and cheaper substitutes such as fly ash, slag, pond ash etc.
- Increased cement quality and strengths
- Special application premium cements
- Hydrophobic cements
- Increased raw mill throughput and reduction on power consumption
- Substitution of mineral gypsum with chemical / phosphor gypsum
Leveraging our extensive research and domain expertise, we design products that precisely meet our customers’ strategic and technical objectives.
How does your bespoke approach help your clients bring efficiency in their operations?
Every cement plant is a unique case, when it comes to its requirement for grinding aids and/or chemical additives. Before proposing the right chemical additive / grinding-aid, we comprehensively understand specific needs of each plant covering aspects
such as:
- Strategic and business needs
- Mineralogy, chemical, and physical properties of input materials such as clinker, gypsum, fly ash, slag etc.
- Baseline quality parameters such as compressive strengths, setting times, PSD, blaines and residues
- Process parameters and underlying process equipment etc.
Subsequently, an initial hypothesis is developed and multi-component blends (grinding-aid formulations) are prepared. Extensive trials and iterations are undertaken for assessing the impact of these formulations.
The best formulation(s) is/are tested at plant scale and validated for the impact in a full scale environment. Optimisations and fine-tuning efforts are undertaken to ensure maximum value delivery at plant scale. In a nutshell, we focus on delivering ‘solutions’ rather than ‘products’.
Why does your organisation pioneer the concept of open-sourcing of chemicals and on-site blending?
On-site blending is a leaner, better and more flexible approach to delivering grinding-aids and such chemical additives to remote cement factories.
Most legacy grinding aids (commercially available chemical additives typically supplied to cement producers) contain > 50 per cent water. Such high content of a low-value, high-volume ingredient, as water, leads to significantly higher costs associated with freight, duties and handling of pre-blended liquid solutions.
In addition, such pre-blended, ready-to-use chemical additives offer considerably diminished possibility of modifying concentration and formulation for different cement grades or for different objectives or for different process conditions.
The concept of on-site blending allows for a significantly improved model that involves:
- Delivery of chemical components of grinding-aid formulations to the cement factories in concentrated form (zero to very low water content)
- Addition of water on-site (at the cement factory)
- On-site blending of chemical components and water using mixing tanks
- Dosing of blended solutions into cement (or raw) mills
The above model allows for:
- Reduced costs of freight, packaging and handling
- Lower carbon footprint
- Higher transparency
- Greater flexibility in modifying products and formulations for mapping to different needs and objectives
What are the key factors of your products that help the cement industry reduce their carbon emission?
The most significant and primary contributor to CO2 and GreenHouse Gas (GHG) emissions during the cement manufacturing process is clinker production. Each tonne of clinker emits 800-890 kg of CO2 during the production process.
Clinker content in cements varies from 98 per cent in pure OPC (ordinary portland cement or pure cement) to 30 per cent in PSC (portland slag cement or blended slag cement).
Our grinding-aids and high-impact-strength-enhancers can help reduce clinker content in cement by 3 per cent to 10 per cent (depending on the compatibility and conditions). This reduction can therefore help lowering CO2 emissions between 30 kg to 80 kg per tonne of cement.
Assuming a total cement production of 400 million tonnes in India and about 4 billion tonnes worldwide, bespoke grinding aids with the right impact can help reduce carbon footprint by >10 million tonnes of CO2 emissions in India alone and >100 million tonnes per annum worldwide.
What role does technology play in providing better solutions to your clients?
Technology underpins our entire approach to design, delivery, and deployment of solutions for cement producers. Designing of these products is undertaken at our cutting-edge research centre in Noida, where we focus on developing advanced and bespoke products for our customers. Our dedicated team of cement scientists, engineers and chemists are conducting >100 trials (lab and plant scale) every year, in the process developing an in-depth domain and technology know-how.
Further, the deployment of these products / solutions at the cement plants in an optimised manner involves extensive experience in cement manufacturing process as well as the know-how around interaction of various chemical additives with the regular input materials and cement plant equipment.
How can your product help in achieving cost efficiency in the cement manufacturing process?
Our products help cement manufacturers in achieving greater cost efficiency through one or more of the following ways.
a) Reducing clinker factor in blended cements: Clinker contributes most significantly to the variable cost of cement production. One tonne of clinker ranges between Rs 2,200 to 3,500 in variable costs. Our products can help reduce clinker content in blended cements by 3 per cent to 10 per cent without affecting the strength and quality of final cement. The more expensive clinker can be replaced with cheaper ingredients such as fly ash (Rs 400-1200 per tonne) and slag (Rs 600-1500 per tonne).
b) Reducing specific power consumption: Our grinding aids help increase cement mill throughput with the same power consumption, in turn delivering reduced specific power consumption per tonne of cement. This helps reduce 2-3 KWH/tonne of cement production, leading to significant cost savings in the long run.
c) Replacement of expensive mineral gypsums with cheaper chemical / phospho gypsums: By increasing cement compressive strengths and accelerating setting times, our products allow for reducing / eliminating usage of mineral gypsums while increasing / replacing with chemical / phosphor gypsums that are much cheaper.
What are the major challenges you face while providing solutions to the Indian cement industry?
- Remote locations of the cement plant sites: Involves extensive travel by our team and
- associated hardships.
- Constantly changing quality of input materials, leading to a possible change in impact of our products and subsequent modification of the formulations to keep aligned with the objectives of the customer.
- Ever evolving needs of the customers: Strategic objectives keep changing and it is imperative for us to keep evolving with the needs of the customers.
- Cost-value trade-off: Not all cement plants have a direct use case of deployment of premium chemical additives. In such instances we have to ensure that the trade-off between cost and value delivery is appropriately balanced.
Tell us about ongoing innovations and research that the Indian Cement industry can look forward to?
One of the most significant research exercises that we are undertaking currently is development of high impact chemical additives, which would eventually help reduce clinker factor by up to 15 per cent in certain blended cements (such as PSC and PCC) without any reduction in final cement quality. The work is being undertaken not just for the Indian cement industry but for the global industry and we are keen on taking these solutions to our
clients worldwide.
How do you envision your contribution to the cement industry in the years to come?
We envision ourselves as a significant player in the cement manufacturing ecosystem, where all stakeholders would aggressively work towards a more sustainable and carbon neutral industry. Our products, solutions and approach will help the cement industry in producing leaner, greener and better cements, sustainably.
As the limestone reserves across the country face sustained pressure in terms of both life of the deposits as well as the quality of limestone being mined, there would be an ever-increasing role that we would need to play in deriving more cements with limited resources. Sustainability in cement production would be driven by increasing usage and deployment of chemical additives.
Additionally, pressure on cement producers will continue to grow exponentially to reduce their CO2 and GHG emissions. This in turn, would also enhance the potential contribution of our products and solutions in the ecosystem.
-Kanika Mathur
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
