Humboldt Wedag India celebrated the landmark event at TechConnect 2025 in Goa.

Humboldt Wedag India commemorated a remarkable milestone — 25 years of operations in India — through its flagship event, TechConnect 2025, held over two days in the scenic city of Goa. The event served as both a celebration and a platform for meaningful dialogue on the future of cement manufacturing. The gathering saw participation from nearly 75 delegates representing leading cement groups across the globe. The presence of the management board, founder members, and long-standing partners added to the significance of the occasion, reflecting the company’s enduring relationships and shared journey of growth.
TechConnect 2025 featured a series of panel discussions, interactive sessions and technology-focused presentations, offering valuable insights into emerging trends in the cement industry. The discussions revolved around energy efficiency, process optimisation, Operational Excellence and ‘cement beyond carbon’ — key themes that are shaping the industry’s evolution. Experts from KHD Germany and India along with representatives from partner companies and clients, exchanged perspectives on innovative solutions, operational best practices and successful project outcomes achieved in recent years. A highlight of the event was the release of two special publications: A commemorative book chronicling Humboldt Wedag India’s 25-year journey, capturing milestones, partnerships and contributions to the Indian cement sector. A booklet featuring the company’s recent technical publications, underlining its commitment to knowledge sharing and continuous innovation.
Beyond the formal sessions, TechConnect 2025 offered participants the opportunity to network, share experiences, and explore collaborative possibilities for the future. The event not only celebrated Humboldt Wedag India’s legacy but also reaffirmed its dedication to driving sustainability, efficiency, and innovation in the cement industry.
With the resounding success of TechConnect 2025, Humboldt Wedag India continues to strengthen its position as a trusted technology partner, shaping the next era of smart and sustainable cement manufacturing.

ICR delves into the groundbreaking innovations transforming India’s cement industry — from carbon capture and digitalisation to sustainable engineering and material resilience. Discover how technology and collaboration are shaping a low-carbon, competitive future.

India’s cement industry is at a pivotal turning point—evolving from traditional production methods to an era defined by advanced technology, sustainability, and operational reinvention. According to a report by the India Brand Equity Foundation (IBEF), demand growth of 6 per cent to 7 per cent is projected for FY25, following a robust 7 per cent to 8 per cent YoY increase in the last quarter of FY24. This momentum, driven by urbanisation, infrastructure expansion, and policy pushes like the PM Gati Shakti National Master Plan, underscores the need for the industry to evolve not just in capacity but in how it innovates, optimises, and decarbonises. Meanwhile, a report by ResearchAndMarkets estimates the Indian cement market will reach US $18.39 billion by 2025 at a 6.6 per cent CAGR, while the green-cement segment is expected to grow from US $2.31 billion (2024) to US $3.28 billion (2030)—clear signs that innovation has shifted from aspiration to necessity for competitiveness and carbon compliance. Amid this growth and environmental urgency, path-breaking innovations are transforming every link in the cement value chain—from carbon capture and digitalisation to sustainable packaging, data-driven manufacturing, and energy optimisation. As plants embrace Industry 4.0 and embed sustainable engineering at their core, the industry is transitioning from volume-led expansion to value-led transformation. The trajectory is clear: India’s cement producers are no longer just making cement—they are redefining it, building a low-carbon foundation for the nation’s next phase of infrastructure and sustainable growth.

CCUS: Cement’s Net-Zero Catalyst
For hard-to-abate process emissions in cement, Carbon Capture, Utilisation and Storage (CCUS) has moved from concept to large-scale implementation. Global first-of-a-kind projects are proving commercial viability: Heidelberg Materials’ Brevik CCS facility in Norway will capture ~400,000 tCO2/year (~50 per cent of the plant’s emissions), with its evoZero cement already pre-sold for 2025, as reported by Reuters. Similarly, Holcim’s GO4ZERO project in Belgium targets ~1.1 MtCO2/year capture by 2029, part of a broader 5 MtCO2/year ambition supported by the EU Innovation Fund. India is preparing to follow this trajectory—Dalmia Cement, in partnership with Carbon Clean, is developing a 500,000 tCO2/year CCUS plant in Tamil Nadu, aligning with its carbon-negative 2040 goal, as mentioned in company releases and an ADB analysis. Policy mechanisms are also emerging: the Global CCS Institute/GCCA policy brief (2024) proposes a Carbon Capture Finance Corporation and innovative funding tools to de-risk early projects, while NITI Aayog’s CCUS roadmap highlights the urgent need for large-scale demonstrations. Together, these moves signal that CCUS is shifting from research to reality, and India aims to be part of this global transformation.
Dr SB Hegde, Global Industry Expert say, “The cement industry’s path to net zero requires a phased and coordinated innovation roadmap. In the near term (2025–2030), emphasis must be on energy efficiency, clinker substitution, AFR, WHR, and digital optimisation, which are already proven and cost-effective. The next decade (2030–2040) will see wider adoption of electrification and carbon capture technologies, supported by renewable energy and green hydrogen. By 2040–2050, advanced low-carbon clinkers, carbon-negative binders, and circular material use will dominate, enabling deep decarbonisation. Together, these phases form a realistic pathway to cut CO2 emissions by over 70 per cent while ensuring competitiveness and resilience.”
Beyond capture, CO2 utilisation is equally vital—turning emissions into economic value through mineral carbonation, CO2-cured concrete, and carbonated aggregates. Europe’s Northern Lights project under Norway’s Longship program has already begun receiving CO2 shipments from Brevik, with plans to scale to ~5 MtCO2/year, as mentioned in the Financial Times. For India, where geological storage mapping and pipeline infrastructure are still evolving, near-site utilisation in construction materials or chemical feedstocks can bridge the economic gap until storage clusters—such as those planned along the west coast—are operational. The strategic path forward involves modular, retrofit-friendly capture systems, integration with energy efficiency and AFR initiatives, and the use of offtake and CFD-style instruments to offset early costs. As a report by TERI emphasises, India’s net-zero pathway by 2070 hinges on CCUS alongside clinker substitution, alternative binders, and renewable integration. The opportunity for Indian cement lies in acting early—turning CCUS from an obligation into a competitive advantage in the race for sustainable manufacturing.

Digital transformation
From quarry to kiln to bagging, Indian cement plants are rapidly shifting from manual set-points to sensor-driven, AI-supervised operations. Advanced Process Control (APC) and machine learning now fine-tune dozens of variables in real time—stabilising the pyroprocess, optimising fuel use, and minimising quality variance. As mentioned in ABB’s Expert Optimiser materials, these systems typically deliver 3 per cent to 5 per cent energy savings and 3 per cent to 5 per cent production gains while cutting emissions—results that have converted skeptics into advocates. For Indian operators navigating volatile fuel mixes and ambitious Thermal Substitution Rate (TSR) goals, such optimisations provide tangible, repeatable ROI. India already holds a global efficiency edge—as reported by the CII–Sohrabji Godrej Green Business Centre (2023), the top 10 plants operate below 70 kWh/t cement and 690 kcal/kg clinker, with best-achieved benchmarks of 56.1 kWh/t and 675 kcal/kg, underscoring the impact of digitisation on sustaining world-class performance.
Tushar Kulkarni, Business Head – Minerals – Cement & Mining, Innomotics India says, “India’s cement industry has long been at the forefront of adopting cutting-edge industrial technologies—ranging from Intelligent MCCs and MV/LV drive systems to full-scale plant DCS automation—placing it among the global leaders in energy-efficient and digitally enabled manufacturing. These initiatives have translated into significant gains in energy reduction and operational efficiency across plants. The sector is now entering a new phase of transformation, embracing innovations like AI-driven process optimisation (AI Pyro, AI Mill), electrification of kilns, and Carbon Capture, Utilisation & Storage (CCUS). Encouragingly, several of these technologies are already under feasibility assessment or pilot implementation, reflecting the industry’s readiness to leverage advanced automation and electrification as key enablers of decarbonisation.”
“However, scaling these innovations industry-wide still faces tangible barriers. Many plants continue to operate with legacy systems that lack seamless data connectivity or structured historians, making AI model training and deployment difficult. Challenges such as non-standardised data formats, limited transparency of AI model performance, and uncertainty in calculating ROI often slow down investment decisions. Strengthening data infrastructure, building trust in AI outcomes, and upskilling teams in digital analytics will be crucial to unlocking the full potential of smart drives, advanced predictive control, and electrification. In the coming years, AI-based optimisation tools and CCUS technologies are poised to become game changers—helping India’s cement sector strike the balance between industrial productivity and its low-carbon future” he adds.
The next leap lies in scaling the digital flywheel—integrating process, maintenance, and logistics data into unified platforms powered by AI and predictive analytics. Plants combining APC, predictive maintenance, and digital twins will achieve steadier clinker quality, lower specific energy, and reduced downtime while preparing for CCUS-ready, low-carbon operations. With six-stage preheaters globally averaging 717–812 kcal/kg, India’s continuous optimisation keeps it at the efficient end of this spectrum. The lesson is clear: Industry 4.0 isn’t a parallel initiative—it’s the operating system of tomorrow’s path-breaking cement plant, where automation, data, and intelligence drive both sustainability and competitiveness.

Data-driven decisions
Across Indian cement plants, production is becoming data-rich and model-driven, with IoT sensor networks, AI models, and APC systems working in tandem to optimise kiln stability, fuel mix, and quality in real time. As mentioned in Holcim’s program page and a Global Cement report, the company’s Plants of Tomorrow initiative has deployed 2,100+ digital applications across 40+ countries, with AI software expected in ~100 plants by 2028. Indian leaders already operate at world-class efficiency, achieving ~56.1 kWh/t cement (electrical) and ~675 kcal/kg clinker (thermal), benchmarks maintained through data analytics and condition-based maintenance, as reported by the CII–Sohrabji Godrej Green Business Centre (2023). Downstream, digital control towers and route analytics have helped UltraTech cut average lead distance to ~400 km and logistics costs by ~2 per cent YoY. As mentioned in reports by the GCCA (2024/25) and the World Economic Forum (2024), digitalisation is now a central pillar of the global net-zero cement strategy, proving essential for an industry that contributes ~6 per cent of global CO2 emissions to maximise efficiency from kiln to dispatch.

Sustainable engineering
Sustainable engineering in India’s cement sector is advancing beyond efficiency gains toward holistic life-cycle design, where plant layout, raw materials, and product use all align with low-carbon goals. As mentioned in TERI’s roadmap, the industry must cut CO2 intensity to ~0.35 tCO2/t cement by 2050, down from 0.62 in 2010, while as per the OECD report, new plants should target ˜70 kWh/t (electrical) and ˜680 kcal/kg clinker (thermal). On the materials front, Limestone Calcined Clay Cement (LC³) and similar low-carbon binders can reduce emissions by 30 per cent to 40 per cent versus OPC. According to the Department of Science and Technology, cement and brick production currently emit 200–250 MtCO2 annually, underscoring vast decarbonisation potential. Sustainable engineering is thus no longer conceptual—it’s materialising through plant retrofits, alternative binders, and integrated design strategies that link sourcing, production, and construction into a single, optimised low-carbon chain.
Utssav Gupta, Director, Supertech Fabrics says, “India’s cement industry, as the second-largest producer globally, has made remarkable progress in adopting advanced filtration and emission control technologies. The country now enforces some of the most stringent environmental norms among developing economies, and new plants are being commissioned with state-of-the-art filtration systems that rival international benchmarks. More importantly, there is a visible intent among manufacturers to retrofit and upgrade older units, reflecting a strong national commitment to sustainability. As a material-producing nation, India’s openness to embracing innovation has allowed advanced filtration solutions to gain acceptance swiftly. This mindset shift—where manufacturers and end-users alike are eager to align with global best practices—positions India not as a follower but as a fast-rising leader in environmental performance and technological adaptability within the cement sector.”
“When it comes to modernising emission control systems, the challenge is not the lack of technology but the need for stronger instrumentation and data transparency. Real-time monitoring and consistent data sharing between OEMs, operators, and material suppliers remain critical to fine-tuning systems and achieving peak efficiency. Broader adoption of connected instrumentation could help perform deeper root cause analyses, enabling more precise optimisation and accountability. On the technology front, filtration science itself is undergoing a transformation—driven by material innovation that enhances both performance and longevity of filters. The next wave of filtration technologies will not only reduce particulate emissions but also improve plant sustainability and energy efficiency—marking another leap forward in India’s journey toward cleaner, smarter, and more resilient cement production” he adds.

Energy optimisation
Indian plants are squeesing megawatts from every °C of kiln heat while hard-wiring renewables into their grids. Waste-heat recovery (WHR) has scaled rapidly—installed capacity in India rose from ~240 MW to ~1,289 MW over the last decade, with leaders adding triple-digit megawatts in just a few years; UltraTech reports 351 MW of WHR capacity in FY 2024–25, while Ramco commissioned a new 10 MW WHRS in September 2025, signalling steady brownfield gains, as mentioned in a report by the CII–Sohrabji Godrej Green Business Centre and as mentioned in company/press updates. On the consumption side, global pathways raise the bar: the IEA’s NZE trajectory targets average kiln thermal intensity < 3.4 GJ/t clinker and electricity < 90 kWh/t cement by 2030—benchmarks that Indian best-performers are already approaching or beating, as mentioned in a report by the IEA.
The fuel and power mix is tilting greener at scale. UltraTech has publicly set 85 per cent “green energy” in the total energy mix by 2030 (with an interim 60 per cent by FY26) and surpassed 1 GW of installed renewable capacity—tying energy optimisation directly to cost and carbon, as mentioned in company disclosures. Shree Cement lifted green power to ~56 per cent to 66 per cent with ~582–586 MW of RE capacity (solar, wind, WHR), as mentioned in broker/market reports. Meanwhile, the switch to alternative fuels remains a major lever: industry assessments show Thermal Substitution Rate (TSR) adoption is rising but uneven across firms, with availability and pre-processing still the bottlenecks—yet TSR is pivotal to hitting sector targets, as mentioned in a report by CARE Edge ESG.

Reinventing packaging and storage
Moisture remains the silent enemy of bagged cement, driving a shift from stitched sacks to block-bottom, valve bags made of coated polypropylene (PP) that resist humidity, burst less, and run seamlessly on automated lines. Designs like AD*STAR® offer higher strength, moisture protection, and recyclability within PP streams, as mentioned in Starlinger’s overview, while Indian brands such as Bharathi Cement highlight tear resistance, micro-perforation, and near-zero bursting. Recycling infrastructure is expanding too—as mentioned in a report by the India Plastics Pact (2023), 819 mechanical recycling units now process recovered PP, supporting EPR-linked sack take-back programs under CPCB’s 2023–24 inventory. On the dispatch front, plants are deploying automatic bagging, robotic palletising, and warehouse control systems to reduce breakage and boost loading efficiency, as reported in automation case studies. With bulk loading, silo telemetry, and RFID-enabled yards improving traceability, India’s cement logistics are evolving toward moisture-resistant, recyclable packaging and end-to-end automation, ensuring every bag reaches the site intact—with its strength and brand promise preserved.
Frank Ormeloh, Business Unit Manager – Cement, Haver & Boecker says, India’s cement industry presents a fascinating paradox when it comes to integrated digital and hardware adoption. Despite the country’s global reputation for software excellence, the current level of integration between digital and mechanical systems in cement plants remains modest. Most investments still lean toward mechanical upgrades—from material handling to process machinery—while digital adoption lags behind. Yet, the potential for digital transformation is immense. Digital tools, from AI-based control systems to predictive analytics and smart mesh technologies, often come with lower cost thresholds and higher ROI compared to conventional mechanical retrofits. The industry’s growing openness to innovation, combined with India’s strong IT foundation, suggests a major opportunity to elevate operational intelligence through integrated digital-hardware ecosystems.”
“The true obstacles, however, are not technological but commercial and cultural. The prevalent “lowest price possible” mindset still overshadows the “maximum profit possible” philosophy needed to scale advanced mesh, AI, and robotic systems. To accelerate adoption, pioneers within the sector must step forward—those willing to demonstrate that smart, data-integrated plants are not only more efficient but also more sustainable, safe, and investor-attractive. HAVER & BOECKER envisions this transformation through Operation & Maintenance (O&M) partnerships, where experts co-manage packing facilities alongside customers, aligning technical excellence with business value. Proven in India’s chemical sector, this service-driven model aims to bring cement producers closer to “Perfect Flow,” redefining the material not as a low-cost commodity but as a high-value, innovation-driven product that embodies efficiency, sustainability, and long-term profitability” he adds.

Material resilience
A new generation of low-carbon binders is redefining cement’s material resilience by cutting emissions without compromising performance. Limestone Calcined Clay Cement (LC3) reduces CO2 by ~40 per cent while matching or exceeding OPC strength, lowering the clinker factor to ~50 per cent or less, as mentioned in or a report by RMI’s 2024 “Business Case for LC3” and the LC3 Global Assessment. Composition-level innovations such as Calcium Silicate Cement (CSC) further show up to 45.5 per cent energy and 35.1 per cent CO2 reductions versus OPC, owing to reduced limestone demand and lower sintering temperatures, as mentioned in or a report by Williams and Yang (2024). Beyond emissions, alkali-activated concretes (AAC) deliver ~54 per cent to 61 per cent lower CO2 and ~39 per cent to 70 per cent lower embodied energy, while maintaining high strength under thermal stress, as noted in peer-reviewed studies (2024–2025). For India, reducing the clinker factor through high-quality SCMs and alternative binders remains central, as mentioned in or a report by the GCCA Net Zero Progress Report (2024/25) and CII–GBC benchmarking data. The message is clear: material resilience now means lower embodied carbon, longer service life, and regionally optimised composites tailored to India’s diverse heat, moisture, and chloride conditions.
Jignesh Kundaria, CEO and Director, Fornnax says, “India’s cement industry has made significant progress in adopting IoT and predictive analytics, though maturity remains uneven across the sector. Leading manufacturers are integrating digital tools for process optimisation, equipment health monitoring, and real-time insights, but adoption is still in the early-to-mid stage compared to Europe, where digital ecosystems are more advanced. Encouragingly, Indian plants increasingly recognise that data drives efficiency, sustainability, and competitiveness, marking a cultural shift toward digitisation. The main barriers lie in infrastructure: many plants still use legacy systems incompatible with modern automation, making integration complex and costly. A shortage of digital talent and high upfront costs further slow progress. Yet the outlook is strong—modular, interoperable, and retrofit-friendly solutions are steadily lowering adoption barriers and enabling a scalable, cost-effective transition toward intelligent, data-driven cement operations across India..”

Human–tech synergy
The cement industry’s digital transformation is as much about people as it is about technology—where human expertise evolves alongside AI, digital twins, and robotics. As plants automate and adopt AI-based process control, job roles are shifting from manual operation to analytical decision-making. According to a report by Deloitte (2024), over 60 per cent of global manufacturers now prioritise reskilling in data analytics, IoT, and automation. India mirrors this trend—as mentioned in CII’s 2024 Future of Work in Manufacturing study, cement and heavy industry players are allocating up to 3 per cent of annual operational budgets to digital training, with UltraTech and ACC establishing in-house digital academies for process engineers and maintenance teams.
Dijam Panigrahi, Co-founder and COO, GridRaster says “The core of Industry 5.0 is the human operator. By having Spatial AI systems safely take over repetitive, monotonous, or highly dangerous tasks, plant personnel are liberated to focus on the highest-value work: complex process management, troubleshooting, and continuous process optimisation. This fosters a human-machine collaboration that drives innovation, enhances safety and ensures sustainability. Spatial AI is not merely a theoretical leap in digital twin technology; it is a concrete, actionable technology that is delivering immediate, impactful change on the plant floor. By simplifying complexity and driving setup time down to minutes, this technology is the essential accelerator that makes advanced industrial automation truly accessible to all cement manufacturers, marking the definitive arrival of the human-centric, high-efficiency world of Industry 5.0.”
As mentioned in a report by the NSDC (2025), over 75,000 workers in India’s materials and infrastructure sectors will require advanced digital skills by 2030. The GCCA calls this “digital sustainability”—training workers to manage systems that cut emissions and energy use, not just boost output. In practice, kiln engineers interpret AI dashboards, maintenance teams conduct predictive analytics, and logistics managers optimise CO2-efficient routes. The cement plant of the future is, therefore, a human–machine collaboration hub, where workforce adaptability is as critical as the algorithms driving efficiency and sustainability.

Conclusion
As India’s cement sector enters its next growth phase, the challenge is no longer scale but sustainability at scale. The nation already leads in energy efficiency and alternative fuels, yet the next leap demands embedding innovation into every tonne of cement—through CCUS, low-clinker blends like LC3, AI-driven process control, and green logistics. Supported by the National Green Hydrogen Mission, PAT scheme, and 2030 renewable targets, India’s ecosystem is aligning toward low-carbon, globally competitive manufacturing that exports not just cement but expertise. Achieving this will require deep collaboration among industry, academia, and policymakers, focusing on scalable CCUS, mineral carbonation, and regionally suited binders. As led by the GCCA and CMA, shared R&D platforms and policy-backed decarbonisation clusters—akin to Europe’s CCS hubs—can fast-track progress, while green bonds, blended finance, and carbon credits can de-risk early adoption. Ultimately, path-breaking innovation is India’s passport to a net-zero construction future—where digital intelligence, sustainable engineering, and circular materials converge to make every plant a lab for efficiency and every engineer an innovator. With bold collaboration and steadfast execution, India can transform its cement industry from a top emitter into a cornerstone of global green growth.

– Kanika Mathur

Vikram Gulliani, Business Line Manager, Air and Gas Applications, Compressor Technique, Atlas Copco (India), explores how intelligent, energy-efficient and digitally connected compressor technologies are redefining the backbone of India’s Construction 4.0 revolution.

India is on the verge of an infrastructure revolution. With government initiatives such as National Infrastructure Pipeline (NIP) and Gati Shakti Master Plan, India is earmarking investments in infrastructure that will stretch into the multi-trillions to build modern cities, highways, ports and industrial corridors. This rapid acceleration, often termed as ‘Construction 4.0,’ calls for more than just better equipment and digital applications; it calls for dependable support systems, of which compressed air is one of the most important.
Compressed air powers everything from drilling, blasting, tunneling, and concrete spraying to pneumatic tools and energy efficient operation. However, despite its widespread use, conventional air compressors alone won’t be sufficient to meet the demands of the paradigm shift occurring in India’s infrastructure sector. The time for intelligent, environmentally friendly, and digitally enabled compressor solutions that take efficiency, uptime, and environmental effects into account has finally arrived.
Here’s how compressor technology transforms and empowers Construction 4.0 in India.

Crucial changes in construction needs
Since the construction industry has always dependent on heavy machinery, many of which rely on compressed air solutions. All these factors are still crucial in today’s time; however, the contractors and other infrastructure developers nowadays need much more:
• Reliability in hazards of extreme dust, humidity, and ambient temperature: Many projects take place in remote or extreme locations thus, compressors must deliver reliable performance without restriction regardless of dust and/or humidity or ambient extremes
• Smart technology integration: Under Construction 4.0, contractors are seeking data-based insights! Contractors require a compressor with smart controllers and telematics to execute monitoring of air quality, fuel consumption, maintenance capability, and predictive diagnostics.
• Mobility and size: The world is becoming densely populated, urbanised and this is leading to an increase in restrictions where equipment is operated. A compressor occupies very little space and provides a level of portable mobility and minimum noise with higher efficiency.

Energy efficiency as an epicentre
Energy efficiency is the epicenter of the nation’s infrastructure ambition. Construction is energy-intensive and compressed air represents a significant portion of the operational costs. Usually, contractors are focused on the purchase price rather than total lifecycle costs and efficiencies, but with escalating fuel prices and slow-moving projects contractors are finally beginning to examine energy efficiency during project timelines.
• Efficient bulker unloading with low pressure solution: For efficient bulker unloading of materials such as cement and fly ash, compressed air at a controlled pressure is essential. The typical pressure requirement lies in the range of 1.3 to 1.9 bar(g), with a strict upper safety limit of 2.5 bar(g). Delivering air beyond this threshold can risk damage to the bulker or pipeline system. The most efficient solution is to use a low-pressure compressor that generates pressure in this range rather than using a pressure-reducing valve which leads to loss of energy.
• Use of PRV to achieve low pressure is wrong wractice: Pressure Reducing Valves (PRV) are safety devices, not regulators. PRV are not designed for continuous blowing off pressurised air. Using them continuously highlights the poor and oversized design of the air system. This action also results in waste on money and energy as PRV keeps venting, compressed air is wasted leading to higher compressor load, increased energy consumption, and higher CO2 footprint. A sustainable approach will entail using the right product that runs
on the required limits, resulting in energy
efficient action.
• Fuel efficient portable compressors: In specialist applications, a diesel-driven compressor with fuel management features will offer reduced diesel consumption and emissions and increased runtime. The airflow demand varies with tanker size and unloading time, generally ranging between 500 and 1,300 m³/h depending on material bulk density. To achieve consistent unloading performance, oil-free and dry compressed air should be ensured through proper cooling and moisture separation, supported by adequately sized pipelines, valves, and monitoring instruments. For this application, low-pressure screw compressors designed for up to 2.5 bar(g) are preferred over lobe blowers, as they provide the reliability, efficiency, and air quality required for safe bulker unloading operations.
• Optimised air flow: Delivery of the correct air pressure at the right time. Energy efficient compressors will deliver less air and minimised leakages and wasted capacity. The use of VSD in general industry is considered to save energy, however not in this application. As the blower ramps up, any clogging or material buildup in the conveying line causes a false pressure to rise. The VSD interprets this as a signal to reduce motor RPM, which reduces airflow. But in reality, the system needs more flow, not less, to clear the blockage. The blower, instead of helping, slows down further worsening the clog. This feedback loop continues until the blower trips shut down. This phenomenon is known as hunting. A correctly sized fixed flow positive displacement compressor is an ideal solution
• Digital monitoring for energy signals: Connected compressors can provide contractors with real-time data providing them with the ability to benchmark energy use, identify inefficiencies and to take corrective action in real time. Energy efficiency is not just a cost advantage; it is increasingly a differentiator in compliance
and branding.

Maintaining efficiency in the face of urbanisation
Rapid urbanisation creates opportunities and unprecedented challenges. These challenges include aggressive timelines and zero downtime.
This is when our equipped compressor solutions become critical:
• Uptime assurance through smart diagnostics: Connected compressors can provide advance warnings of faults before they occur. For example, Atlas Copco’s smart monitoring platforms use IOT to notify operators of any alarming fault indicators, allowing them to perform maintenance to avoid unplanned stoppage.
• Sustainability without compromise: High-performance compressors with emissions-compliant engines, filtration with fine filters, and sound suppression technology are leading to contractors meeting defined sustainability requirements while still achieving peak performance.
• Flexibility across applications: Whether it’s deep foundation drilling, road building, or sandblasting, compressors need to seamlessly adapt. Contractors achieve flexibility by using multi-mode machines that can manage pressure level switching or flow optimisation and thereby eliminate multiple units.
• Service network and support: Technology alone is not enough to achieve up time. There are contracts that have a requirement for a service network to manage availability of parts, engineers for technical support, and local response. This part of the solution can and usually is a real differentiator. Atlas Copco has been extending its service footprint in India for this precise reason. Achieving sustainability and performance is no longer a compromise; it is a requirement.

Future prospects for the industry
Looking forward, India’s construction and infrastructure will be growing at levels never seen previously. The government projects US$ 1.4 trillion on infrastructure spending by 2030. Smart compressed air solutions will be the backbone to that transition, happening better, faster, greener and more reliable.
We see a few key hospitality opportunities coming:
• Digitally connected sites: The rapid evolution of IoT and cloud solutions will allow compressors to act as intelligent nodes in a connected construction world that provides real time analytics to project managers managing multiple projects.
• Hydrogen and electric compressors: With India’s plans to ramp up green energies, moving towards alternative fuel compressors that will support the transition away from diesel fuel and provide solutions that align with national targets for
net-zero.
• Circularity and lifecycle services: In addition to the machine side of the business, the industry will increasingly examine service models that support circularity throughout the lifecycle. The industry focuses on refurbishment services, remote diagnostics, and pay-per-use models for customers to confidently embrace sustainability.
• Skill development for Construction 4.0: Developing a smarter workforce is an important factor in the implementation of smarter machines. A training approach to encourage familiarisation with digital tools, sustainability and building data literacy through predictive maintenance.
Construction 4.0 is not simply about adopting different digital tools; it is about developing and growing a smarter, greener, and more resilient infrastructure ecosystem that can provide the
base point for economic growth. Compressors,
while less front and center than other machines, are vital enablers of this process. By evolving compressors from the traditional machines of the past to intelligent, energy-efficient, and sustainable elements, we are helping construction companies address their challenges of growth while assuming greater responsibility.
As India builds its future, railways, metros, and cities of the future, smart compressor solutions
will ensure every breath of compressed air helps the project along.

About the author:
Vikram Gulliani, Business Line Manager – Air and Gas Applications, Atlas Copco India, brings 18 years of diverse industrial experience, leveraging his global product and business development expertise to drive the AGA division’s growth in India.