Concrete

Our technology pinpoints excess energy use

Published

2 years ago

September 20, 2024

admin

Dries Van Loon, Vice President – Products, Nanoprecise Sci Corp, talks about the transformative impact of their advanced solutions on the cement industry.

Provide an overview of your company’s current initiatives and strategies to enhance energy efficiency in cement production. How does Nanoprecise’s predictive maintenance technology specifically benefit the cement industry, and what makes it unique compared to other industries?
Nanoprecise’s predictive maintenance technology offers key benefits for the cement industry by providing real-time monitoring of equipment, predicting faults before they occur, and optimising maintenance schedules. This helps reduce unplanned downtime, lower energy consumption, and cut greenhouse gas emissions. What sets Nanoprecise apart is its focus on the unique needs of cement manufacturing, where equipment operates under harsh conditions and efficiency is crucial.
By integrating AI and IoT, Nanoprecise delivers precise insights into machinery performance, enhancing operational efficiency and environmental sustainability. Our technology pinpoints excess energy use and high emissions in processes and equipment. By tackling these inefficiencies, Nanoprecise’s predictive maintenance solutions directly cut energy consumption and GHG emissions while enhancing operation efficiency. For example, if a motor’s energy use rises due to faults, the system alerts the team to
resolve the issue, reducing both wasted energy and associated emissions.

Can you elaborate on the importance of your IP68-certified IoT hardware in ensuring reliable data collection in the dusty environments of cement plants?
Conditions in the cement industry are some of the harshest among industries; most critical equipment and its instrumentation are exposed to natural elements as well as high heat, humidity and dust. Accurately certified hardware ensures reliability and repeatability of the data collected and transmitted to ensure timely insights. Instead of constantly addressing instrumentation issues, the hardware will reliably inform you about the status of critical equipment, allowing for timely and effective maintenance decisions and enhancing your productivity.

How does your customised AI-based health analytics platform cater to the specific needs and challenges of cement manufacturing plants?
Rotating equipment is the most critical in the cement-making process. Issues with slow-speed kilns, dryers, high-speed gearboxes of conveyors and critical fans can shut down the process for extended periods, causing big financial losses.
Partnering with Nanoprecise can eliminate this unplanned downtime. Our platform additionally tracks changes in energy consumption, directly linking inefficiencies and emerging mechanical or electrical issues to lost kilowatt-hours (kWh) and associated costs. This enables you to prioritise maintenance actions that will significantly impact energy savings and cost reduction.

How does your 6-in-1 wireless IoT sensor enhance the ability of cement manufacturers to monitor equipment health remotely, particularly in confined or challenging spaces?
Our wireless IoT sensors, with their easy installation, magnet mount and compact size, significantly reduce the cost of an implementation project (the gateway hardware installation and IT project typically take more than 1/2 of the initial installation project cost) but also reduce the time to scale as any IT project and gateway installation across an industrial environment takes time to prepare and execute. Due to the direct cellular connectivity from each sensor, there is no need for vendor-proprietary gateways and networks to be deployed for the sensors to communicate. If cellular connectivity in a plant is limited, the customer’s WiFi network can also be used for our sensors to connect to directly. Often, this is already available and can be a shared resource for multiple IoT and modernisation projects.

Can you explain how your AI algorithms predict the Remaining Useful Life (RUL) of critical components and the impact of these predictions on maintenance planning and operational efficiency?
The true value of any predictive maintenance programme is a combination of three types of outputs.

Accurate change detection: This helps to understand any change is present on the equipment and how it impacts normal operating conditions.
Root cause identification: A maintenance action can only be defined based on an accurate root cause. So, any detected changes should
be linked to an actionable root cause, allowing proper preparation and execution of the maintenance task.
Remaining useful life: This allows maintenance planners to understand the severity of a developing issue and ensure the maintenance task can be planned in a timeline with minimal impact on operations without increased risk of lost production.

Many PdM systems provide the first output by flagging general changes. However, this needs to be actionable data for the maintenance and operations team as it would require more in-depth investigation. The value for any PdM Solution is created only if the correct maintenance action is planned based on the insights created from the data. Here is where Nanoprecise has been relentlessly focused in the past years to be a true value adder for our current and future customers. Additionally, we are the only predictive maintenance solution on the market that combines predictive maintenance and energy consumption due to any process inefficiencies or developing faults. This feature allows for linking maintenance and process issues to measurable impact on energy consumption, ensuring a plant can run as efficiently as possible.

What specific solutions does Nanoprecise offer to combat the adverse effects of dust on machinery in cement plants, ensuring optimal performance and longevity?
Our solution of IP68 hardware has been specifically designed for the harsh requirements of a cement plant. Our sensors are fully enclosed while in operation and can work autonomously for 3-5 years. This design ensures that the focus is on the reliability of the equipment, not on the IoT hardware, giving you confidence in the performance of our product.

How does your technology handle the challenges of monitoring diverse and intricate machinery, such as kilns, mills, crushers and conveyors, in cement plants?
To monitor the wide variety of applications specific to the cement industry, from slow speed to high speed, our sensors can be configured to ensure proper data is collected for each type of application. For slow-speed applications, our total collection time can be extended to ensure a sufficient number of shaft revolutions are captured, which is the only way to identify the root causes of issues.
Additionally, our unique combination of Triax Vibration, Ultrasound, Temperature and Flux
into the same sensor hardware allows for a full picture of the machine health and identify developing
faults in an early stage regardless of application or operating speed.

In what ways does predictive maintenance help in mitigating the environmental impact of cement manufacturing, particularly in terms of reducing carbon emissions?
When predictive maintenance is an integral part of a company’s maintenance practices it will increase equipment efficiency and directly impact the total energy consumed for the same output for any equipment.
With the Nanoprecise solution fully integrated, our end users not only receive actionable insights with defined ‘remaining useful life’, but also continuous data on the impact to energy consumption and its effect on carbon emissions. This is crucial in prioritising maintenance tasks not purely based on potential saved downtime and repair cost, but also on the highest energy impact, ensuring that maintenance tasks have a significant, measurable contribution to reducing carbon emissions.

What future trends do you foresee in the realm of IT initiatives for the cement industry, and how is Nanoprecise preparing to address these trends?
With cybersecurity being at the top of every IT department’s concern, implementing any outside solution will require compliance with ever more strict IT requirements. At Nanoprecise, we have ensured our system is designed from the ground up with stringent security requirements, from data encryption and secure data transfer to cyber security for our cloud environment. By adopting direct cellular and WiFi communication protocols, we do not need to be integrated inside the customer’s IT environment, making implementation easier as end-to-end data security is entirely handled by our solution.
Additionally, we are proud to be the first and one of the few IIoT solutions that have been SOC 2 Type 2 compliant for multiple years. This assures our entire company and infrastructure is compliant with the most stringent security requirements and continuously adapted to new cyber security threats, as it’s a rapidly developing risk that needs continuous adoption.

Up Next

Regulatory and compliance challenges play a significant role

Don't Miss

Powering progress

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

1 day ago

June 5, 2026

admin

World Environment Day spotlight on innovation and circularity

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

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

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

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

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

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

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

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

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

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

Concrete

Building a Greener Future Together

Published

2 days ago

June 4, 2026

admin

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

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

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

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

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

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

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

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

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

Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

Published

5 days ago

June 1, 2026

admin

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

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

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

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