Concrete
Responsible Energy Management
Published
2 years agoon
By
admin
Adani Cement is playing an instrumental role in responsible energy management in the Indian industrial sector. Here’s looking at their comprehensive efforts at sourcing alternative fuel and energy and optimising energy consumption in the cement manufacturing process.
Cement production stands as a prime example of an energy-intensive industry, where the role of energy is paramount in shaping both production costs and sustainability efforts.
One essential application of energy is in the transformation of raw materials, including limestone and additives, into clinker. This heat-intensive process is fundamental to cement production. Electricity plays a critical role in various phases of manufacturing. From grinding raw materials to achieving the final cement product, electricity consumption ranges between 56 to 73 kWh per metric tonne. Notably, the stages of raw material grinding, kiln operation and cement grinding contribute a significant 75-80 per cent to the overall electrical energy consumption.
Our dependence on energy is underscored by the consumption of fuels. For our 3 million tonnes per annum (MTPA) kilns, the daily consumption of fuels fluctuates between 1200 to 1600 tonnes. This sizeable amount of fuel is a prerequisite for sustaining our production operations. The electricity requirements are equally substantial. It surpasses 70 units of electricity per tonne of cement produced, encompassing the entire manufacturing cycle.
However, we are committed to enhancing our energy efficiency. Our efforts include ongoing initiatives to optimise existing installations and systems. Notable investments have been directed toward activities like cooler replacement, burner upgrades, and the incorporation of advanced thin liners in the cement mill. Several of these initiatives have already been implemented, underscoring our dedication to improved energy management.
Diverse Energy Sources
Our organisation employs a diverse array of energy sources to meet its manufacturing requirements, aligning with our commitment to sustainability and responsible energy management. At the heart of our production process, primary heat comes from fossil fuels, which are pivotal in the clinkering stage of cement manufacturing. We are progressively integrating alternative fuels, and we have set a robust roadmap to escalate this figure from present 7 per cent to 25 per cent. In terms of electrical energy, we draw power from both our captive/thermal power plant and the state grid to ensure a reliable supply.
Our emphasis on green energy is a cornerstone of our energy strategy. Solar energy plays a significant role as we harness its power through solar panels to contribute substantially to our electricity requirements. Additionally, wind energy further enriches our energy mix, tapping into wind turbines’ potential. Leveraging waste heat recovery systems (WHRS), we are innovatively converting waste heat from our processes into usable
energy, thereby reducing waste and optimising energy utilisation.
Sourcing Energy Sustainably
Our energy sourcing strategy is a comprehensive blend of primary and secondary sources, underscoring our dedication to both sustainability and efficiency. In the pivotal clinkering phase of cement production, our primary heat source encompasses a mixture of fossil and alternative fuels.
We engage in co-processing alternative fuels in our cement kilns. This includes a diverse spectrum of waste materials, like hazardous and non-hazardous waste from industrial processes, segregated municipal waste sourced from both fresh and legacy sites, as well as biomass like rice husk, soya husk and tuar husk. This innovative stride not only optimises energy use but also significantly contributes to conservation of natural resources and reduction of CO2 emissions.
Currently, around 7 per cent of our total heat requirement is met through alternative fuels, and our roadmap outlines a determined path to elevate this ratio to 25 per cent, aligning seamlessly with our mission to curtail environmental impact and foster sustainable practices. Our energy strategy embraces the robust use of green energy, comprising of solar, wind and WHRS. We are steadfastly working towards elevating both solar and WHRS contributions to at least 40 per cent of our total electricity demand.
All these initiatives serve as a testament to our unwavering commitment to responsible energy management and the stewardship of our environment.
Impact on Cost
The introduction of greener sources of electricity has had a negligible impact on our operations, whereas the influence is more nuanced in the context of our primary energy source, specifically heat generation. For instance, incorporating even a minor proportion of 1 per cent alternative fuel in clinker manufacturing could marginally increase thermal energy by approximately 1-1.5 kcal per kg clinker. It is important to note that this effect might not hold true for alternative fuels like dry biomass due to their distinct characteristics. However, our kiln system is equipped with inherent capabilities designed to mitigate such impacts, ensuring a balanced approach.
Considering the inherent volatility of fuel prices, the increased integration of green energy into our processes yields a significant advantage in terms of reducing the overall cost of cement production. By relying more on these sustainable sources, we can potentially mitigate the financial fluctuations associated with traditional fuel sources, leading to more stable and predictable production costs.
Optimising the Use of Energy
Automation and technology play an instrumental role in optimising energy utilisation within cement plants. These advancements contribute to enhanced productivity and heightened system reliability, creating a stable manufacturing environment. The harmonious synergy between automation and technology facilitates the most efficient allocation of energy resources, minimising wastage and enhancing overall energy efficiency. In line with this, we have implemented High-Level Control (HLC) systems for each kiln and cement mill circuit. These technologies not only streamline operations but also empower us to respond proactively to energy consumption patterns, driving us closer to our efficiency and sustainability goals.
Hurdles along the Way
The availability of fuels, particularly coal and petcoke, presents a significant challenge due to factors such as supply constraints and the volatility of their prices. This unpredictability in fuel availability and costs can impact the stability of our operations and cost structures. Additionally, the limited quantity of linkage coal further exacerbates this challenge, necessitating careful resource management and exploring alternative options.
Another notable challenge arises from the non-uniform regulatory procedures governing the utilisation of renewable power sources, namely solar and wind energy. The intricacies of these regulations vary geographically. This disparity introduces complexities in adopting renewable energy solutions consistently across regions, potentially impeding a streamlined transition to cleaner energy sources. Overcoming these regulatory hurdles demands strategic coordination and harmonisation of policies to ensure a more cohesive and efficient integration of renewable energy into our operations.
Compliance and Regulations
Effective energy management is a fundamental aspect of our operations, supported by well-established systems and dedicated professionals. Certified energy managers are stationed at each of our locations, underscoring our commitment to optimal energy utilisation and sustainability. Regular energy audits are a crucial part of our practices, with each site undergoing thorough assessments. The insights derived from
these audits inform actionable plans that are diligently tracked and implemented to enhance energy efficiency.
Furthermore, our commitment to responsible energy management is evident through our collaboration with the Bureau of Energy Efficiency (BEE). We actively share data on both electrical and thermal energy consumption with the BEE, aligning with the regulations and objectives of the Perform Achieve and Trade (PAT) programme. This proactive approach reinforces our dedication to not only internal efficiency but also broader national energy goals.
Adhering to the ‘golden rule’ of energy efficiency improvement, we place stringent monitoring and controls in place. This ensures that our energy management strategies remain dynamic and responsive, adapting to changes and consistently
driving efficiency enhancements. Our comprehensive approach to energy management is a testament to our commitment to sustainable practices, cost optimisation and environmental responsibility.
We employ an internal digital dashboard to meticulously track daily energy consumption encompassing both heat and electricity. However, the benchmarking of thermal and electrical
energy utilisation occurs monthly, both within our organisation and within the broader external context. This practice culminates in the acknowledgment of exceptional accomplishments by the most improved plant team through internal commendations and accolades.
Furthermore, our commitment to optimal energy utilisation is evidenced by annual external energy audits. These audits serve as a comprehensive evaluation of our energy practices, ensuring alignment with stringent standards. The resulting action plan, aimed at continuous enhancement, undergoes a rigorous assessment every three months. This iterative approach underscores our unwavering dedication to refining energy efficiency and reinforcing our sustainable commitments.
Conclusion
In the context of the cement industry, driving advancements in energy consumption is imperative. Regarding heat, it is essential to harness technological progress to curtail energy usage. Shifting the focus to electricity consumption, the installation of green energy sources like solar, wind and WRHS stand out as a promising approach.
Further, by enhancing overall efficiency of individual components, striving to minimise the impact of fluctuations in process parameters collectively hold the potential to revolutionise
energy consumption within the cement industry, driving it towards a more sustainable and
efficient future.
(Communication by the management of the company)
Concrete
Adani’s Strategic Emergence in India’s Cement Landscape
Published
5 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
