Concrete
Improving Operations using AI
Published
2 years agoon
By
admin
Tushar Kulkarni, Business Head – Minerals, Cement & Mining, Siemens Large Drivers India, discusses the role of Artificial Intelligence (AI) and premium efficiency standard products in making cement plant operations more sustainable.
By FY27, cement consumption in India is expected to reach 450.78 million tonnes, driven majorly by expanding demand from housing, commercial construction, national infrastructure projects and industrial construction*. To meet the growing demand, many cement companies are planning or are undertaking capacity expansions. Despite market growth, challenges such as fluctuating raw material prices, energy costs, transportation costs, skill shortages and regulatory complexities continue to persist for cement plants.
Cement plants constantly strive to improve productivity and cost efficiency through sustainable manufacturing and operations. It is imperative for them to maintain continuous and reliable machine operations for producing high-quality cement that comply with industry standards, while also adhering to the environmental emission norms and regulations.
Over the last two decades, various technologies for advanced process control (APC) have been developed for the cement industry, viz fuzzy logic, expert systems and rudimentary approaches of artificial intelligence – these being the most widespread form of technology applied to process control. However, with the changes in technology and increasing use of alternate fuel residual (AFR) and alternative raw materials, the current optimisation systems (APC) have limited performance over process control and require excessive retuning.
In this context, adoption of latest technologies viz digitalisation solutions and use of Artificial Intelligence (AI) will significantly help cement plants in their efforts towards innovation, efficiency and sustainability goals through improved process optimization and increased productivity. Our SICEMENT® Operations Digital solutions portfolio (AI based) is well-positioned to support the cement industry in this endeavor.
*Source: IBEF Aug 23
Transforming Data into Insights
Digitalisation involves the integration of digital technologies, automation and data exchange, which creates large volumes of diverse and continuous data. To leverage such a wealth of data, data science is the catalyst that transforms data into actionable intelligence. Data science involves leveraging advanced techniques and technologies to extract meaningful insights, patterns and knowledge from a large volume of data.
Data science being the backbone of digitalisation process, plays a pivotal role to harness the power of data for strategic decision making, efficiency gains and innovation, such as:
Data-driven decision making: Extracting valuable insights from large datasets for insights driven informed decision making.
Predictive analytics: Forecasting future trends and enhancing operational efficiency.
Process optimisation: Identifying areas of optimisation, which can lead to more efficient production and reduced energy consumption.
Smart maintenance: Predictive maintenance models can forecast potential failures, allowing for proactive interventions and minimising downtime.
Integration of AI in data science increases the capabilities of extracting valuable insights, making predictions and automating various tasks. It empowers data scientists to manage complex problems and extract meaningful information from diverse datasets.
To understand more on applying AI in cement production, let us look at an example of the rotary kiln in cement production. It is known that the different parameters of the kiln react differently to changes in the control parameters – some are sensitive, others do not react at all. In addition, some parameters have linear characteristics, while others behave nonlinearly. These significant differences require a differentiated approach to improve the control strategy. AI technology is designed to manage linear and nonlinear behaviour in a complex environment where numerous dependencies determine the engineering process.
The main difference between a data-centric solution and traditional expert systems is the development of a dedicated machine learning-based kiln model that provides more accurate insights into future kiln process trends than traditional approaches. The latter typically provides insights that are based on a generic mathematical toolbox and a simple aggregation of recent historical data. Advanced Process Control (APC) is widely used to improve kiln and mill control. However, in practice, the limitations of the current APC approach are apparent. For instance, a typical fuzzy logic is not able to cover all operating scenarios and is sensitive to operational changes. A typical Model Predictive Control (MPC) uses linear models in most cases and any change in equipment leads to a completely new setting of the model.
In contrast, by incorporating long-term data sets for AI training, the trained AI models can learn from the past and establish correlations between parameters and time and between actions and outcomes. This knowledge, accumulated in the models, forms the basis for better control performance.
The advantage of the AI-based solution over the previously described APC / MPC solutions is the development of a dedicated machine learning based kiln model that leads to more accurate insights into the future trends of the burning process than conventional approaches, which are usually based on a generic mathematical toolbox and a simple aggregation of recent historical data.
Driving Sustainability through Efficient Products
Industry has to adapt to products that have the highest possible efficiency standards. There is a huge drive by regulatory bodies as well as the manufacturers to scale up efficiencies of products used in process. Let us take an example of Low Voltage Motors. Currently the Minimum Efficiency Performance Standard (MEPS) in India is IE2 efficiency. Motors in IE3 and IE4 efficiency class also are available in the market. Due to the very lucrative ROI and also a concern on carbon emission, the penetration of motors with efficiency standard > IE2 is rapidly increasing and as per the estimation, > 30 per cent by kW of LV Motors produced are with efficiency class > IE2. With this encouraging voluntary shift to motors in efficiency class > IE2, industry is expecting the regulatory body to make IE3 as MEPS soon. Sectors such as the cement industries have already started moving towards IE4 in recent years.
The standards allow tolerance in efficiency declared by manufacturers for the purpose of accommodating manufacturing inconsistencies. However, many motors sold to users are by-design, utilising the negative side tolerances meant for manufacturing inconsistencies. Bearing this in mind, IEC has revised the criteria for CE Compliance w.e.f. 1st July 2022 which are stringent and so users are now assured of minimal utilisation of tolerance on the negative side. This will ensure IE3 and IE4 motors with enhanced operational efficiencies. Further, condition monitoring of motors with the help of cloud-based platforms can enhance the operational efficiencies.
Stringent standards, responded positively by manufacturers and aware users will pave a
path of higher level of sustainability in the cement industry.
ABOUT THE AUTHOR:
Tushar Kulkarni, Business Head – Minerals, Cement & Mining, Siemens Large Drivers India, leads the business verticals of Minerals – Cement & Mining within Innomotics India Pvt Ltd. With over 20 years of experience, he has held positions across business development, customer relationship management and project management amongst others.
Case Study: Retrofitting of lower efficient DC Motor by compact and highly efficient SIMOTICS H-Compact AC motor for Kiln Main Drive at one of India’s largest cement manufacturers. An Innomotics engineer was invited by a customer with an existing motor based on Direct Current Technology and was installed approx. 30 years ago. Based on the customer’s request, the Innomotics engineer visited the site to replace this old motor with a high efficiency AC Motor for Kiln Main Drive application. The customer’s priority was to have a tailor-made solution without disturbing existing mechanical and foundation set-up. After a detailed study during the site visit, the solution was a H-Compact 1PQ4 motor with high efficiency (97.7 per cent @ 75 per cent load) which enabled a reduction in annual energy consumption by 682,000 kWh. This helped in CO2 emission reduction by 440 Tons per annum which approximately would require 17,600 full grown trees to offset. Rating: 1000kW/6P/690V/50Hz/60°C, Application: Kiln Main Drive; Frame: H-Compact, 1PQ4 500 frame.

Concrete
Cement Margins Seen Rising 12–18 per cent in FY26
Healthy demand and GST cut to boost cement profits per tonne.
Published
6 days agoon
September 29, 2025By
admin
Concrete
Adani’s Strategic Emergence in India’s Cement Landscape
Published
3 weeks 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
2 months 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.

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

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