Economy & Market

We track our energy consumption and water usage

Published

1 year ago

September 20, 2024

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Nitin Jain, Unit Head – Integrated Plant, Nimbahera, Wonder Cement talks about how they are setting new standards for environmental stewardship in the industry.

Can you provide an overview of your company’s current circular economy initiatives and how they are integrated into the cement manufacturing process?
In recent years, the manufacturing sector has made significant progress in various areas. However, there’s an ever-increasing demand for solutions that are both environmentally responsible and economically viable. This is where Wonder Cement has carved out a distinctive niche. Wonder Cement has positioned itself as an industry pioneer, offering products that redefine quality standards in cement manufacturing. Their cement is engineered to deliver exceptional strength and durability, while also incorporating sustainable practices in its production. This combination of high performance and environmental consciousness sets Wonder Cement apart in a competitive market.
By focusing on innovation, we are not just meeting current industry needs, but actively shaping the future of sustainable construction. Their approach demonstrates how forward-thinking companies can drive positive change in the building materials sector, paving the way for more resilient and eco-friendly infrastructure. Wonder Cement is actively adopting circular economy strategies to reduce its ecological footprint and lead the way in sustainable cement production. By implementing innovative recycling and resource efficiency measures, the company is working to transform its manufacturing processes and promote environmental stewardship in the industry.

Utilisation of Alternative Fuels (AF) plays a pivotal role in advancing the circular economy within the cement industry. Wonder Cement is utilising waste materials such as plastics, RDF, MSW, Pharma waste, FMCG products, Hazardous industrial by-products, and biomass into the production process, thereby significantly reducing its reliance on traditional fossil fuels.
Utilisation of alternative raw materials in the cement industry is a key strategy for enhancing sustainability and resource efficiency. Wonder Cement has substituted traditional raw materials like limestone with industrial by-products such as fly ash, marble slurry, chemical gypsum, red mud, mine telling reject, alumina slat, iron sludge, etc. Wonder Cement not only reduces its reliance on natural resources but also mitigates environmental impacts.
Wonder Cement has embarked on a pioneering endeavour by integrating a Waste Heat Recovery System (WHRS), epitomising the circular economy paradigm. By harnessing the excess thermal energy generated during the clinkerisation process, the WHRS ingeniously repurposes this residual heat to produce electricity. This innovative closed-loop system significantly amplifies energy efficiency, substantially diminishes reliance on external power sources, and exemplifies a beacon of sustainability in the cement industry.
Low-carbon cement production is an innovative approach by Wonder Cement aimed to reduce the carbon footprint associated with traditional cement manufacturing. This process involves several strategies to minimise CO2 emissions, which are typically high due to the energy intensive nature of clinker production. The production of blended cement, Portland Pozzolana Cement (PPC) involves mixing clinker with supplementary materials like fly ash. This not only reduces CO2 emissions but also enhances the durability and performance of the cement.
Recycling and reuse: Wonder Cement is managing wastewater, ensuring environmental protection, and promoting sustainable practices by Effluent Treatment Plant (ETP) and Sewage Treatment Plant (STP). Also, bed ash and fly ash generated from Captive Power Plant are used as a raw material for cement production.
Sustainable mining practices: Wonder Cement has adopted fully mechanised opencast limestone mining, utilising advanced technology which provides a highly efficient and environmentally responsible method for resource extraction. State-of-the-art machinery enables controlled blasting, effective vibration management, and noise reduction, significantly minimising the environmental impact of mining operations.
Research and development: Wonder Cement is making significant investments in research and development to find alternatives to traditional fossil fuels such as coal and pet coke etc. as well as to explore substitutes for raw materials like limestone, mineral gypsum etc. used in clinker and cement production. These initiatives aim to enhance sustainability by reducing dependency on non-renewable resources and minimising the environmental impact of cement manufacturing. By developing innovative solutions and alternative materials, Wonder Cement is paving the way for a more eco-friendly and efficient approach to cement production.
Digital technologies: Advance technologies are transforming the cement industry by enhancing efficiency, reducing costs, and improving sustainability. In Wonder Cement, we have developed advanced predictive maintenance for equipment monitoring. With the help of predictive maintenance system AI/ ML algorithms analyse data from sensors on machinery to predict potential failures before they occur.

This helps in scheduling maintenance activities proactively, reducing downtime and extending equipment life.
Wonder Cement has introduced AI technology to optimise operations in cement kiln, raw mill and cement mill. By integrating AI technologies into cement kilns, raw mills, and cement mills, Wonder Cement has achieved greater operational efficiency, improved product quality and enhanced sustainability. AI-driven insights and automation help in optimising processes, reducing energy consumption, and maintaining equipment reliability, leading to a more efficient and environmentally friendly production process.
Wonder Cement recognises the critical role of Operational Technology (OT) in enhancing efficiency and productivity within the manufacturing sector. Understanding that the importance of robust OT cybersecurity measures cannot be overstated, we are actively working to safeguard our complex industrial processes from potential threats. By implementing a comprehensive security strategy and adhering to best practices, Wonder Cement positions itself as a future leader in protecting its operations, employees, and data, thereby ensuring uninterrupted production and resilience against the growing threat of cyberattacks.
The company leverages cutting-edge automation in its state-of-the-art robotic laboratory, enabling the complete automation of processes from sample collection through to the analysis of the final product, effectively eliminating the need for manual intervention. Additionally, Wonder Cement’s integration of an advanced cross-belt analyser system represents a strategic initiative aimed at achieving circular economy objectives by enhancing the efficiency and sustainability of natural resource utilisation.
Apart from the core technical prowess, our organisation has set a new benchmark in the cement industry by leading the way in digital transformation. By pioneering the use of advanced technology, the company has successfully implemented paperless systems across logistics, inventory management and financial accounting, establishing a new standard for operational excellence and efficiency.

What are the main challenges you face in implementing circular economy practices in the cement industry, and how are you addressing them?
Implementing circular economy practices in Wonder Cement involves navigating several challenges.

Consistent quality of waste materials: Securing high-quality waste materials that meet rigorous standards is challenging due to variability. We address this by implementing stringent quality control measures and developing strong partnerships with suppliers to ensure reliability.
Financial constraints: Adopting circular economy practices often requires significant investment in new technologies and processes. We focus on projects that provide substantial economic and environmental benefits to manage financial constraints.
Regulatory challenges: Strict regulations around the use of certain waste materials can pose obstacles. We proactively collaborate with regulatory authorities to ensure compliance and advocate for supportive policies that facilitate the transition to circular economy practices.

How does your company incorporate waste materials and by-products into the cement production process to promote resource efficiency?
Wonder Cement integrates a diverse array of waste materials and by-products into its cement production process to boost resource efficiency. We incorporate various waste materials, including plastics, Refuse-Derived Fuel (RDF), Municipal Solid Waste (MSW), pharmaceutical waste, FMCG by-products, hazardous industrial residues, and biomass. This approach significantly reduces our dependence on conventional fossil fuels. Additionally, Wonder Cement has partially substituted traditional raw materials like limestone, mineral gypsum etc. with industrial by-products such as marble slurry, chemical gypsum, red mud, mining reject, alumina slat, iron sludge etc. This strategy not only lessens our reliance on natural resources but also mitigates environmental impacts. The use of fly ash in Portland Pozzolana Cement (PPC) is a key example, supplementing clinker to lower CO2 emissions while enhancing the durability and performance of the cement.

Can you discuss specific projects or partnerships your company has undertaken to advance circular economy principles in cement manufacturing?
Wonder Cement is leading the way in advancing circular economy principles through several innovative projects and partnerships. We have collaborated with local municipalities to use municipal solid waste (MSW) as an alternative fuel in our kilns. Additionally, we have teamed up with pharmaceutical and FMCG companies to process waste material as alternative fuels into our kilns. These partnerships help divert waste material, convert it into energy, and reduce our dependence on traditional fossil fuels. These collaborations are crucial in developing new materials and technologies that further enhance the sustainability of our operations.

What role do recycling and reuse of materials play in your circular economy strategy, and can you provide examples of successful implementations?
Recycling and reuse are key components of Wonder Cement’s circular economy strategy. We prioritise the integration of recycled industrial by-products and waste materials, including fly ash, marble slurry, chemical gypsum, red mud, mining rejects, alumina salt, and iron sludge. Additionally, we manage wastewater through our Effluent Treatment Plant (ETP) and Sewage Treatment Plant (STP), ensuring environmental protection and promoting sustainable practices. Bed ash and fly ash from our Captive Power Plant are also utilised as raw materials in our cement production process.

How do you measure the impact and success of your circular economy initiatives, and what key metrics are used?
Wonder Cement measures the impact and success of our circular economy initiatives using a variety of environmental, operational, and financial metrics. Key performance indicators include the percentage of alternative raw materials and fuels used in production, reductions in CO2 emissions per tonne of cement and the amount of waste diverted from landfills through recycling and reuse. We track our energy consumption and water usage to evaluate the efficiency of our resource management practices. Our integrated management systems provide real-time data and insights on these metrics. Regular audits and assessments help us gauge the effectiveness of our initiatives, identify areas for improvement, and refine our strategies. The insights gained from these evaluations guide the setting of new sustainability targets and the continuous enhancement of our practices.

What innovations or technologies are being developed or utilised by your company to support circular economy practices in cement production?
Advanced technologies are revolutionising the cement industry by improving efficiency, lowering costs, and boosting sustainability. At Wonder Cement, we have implemented advanced predictive maintenance software for equipment monitoring. Our predictive maintenance system uses AI/ ML algorithms to analyse data from machinery sensors, enabling us to predict potential failures before they occur. This proactive approach helps schedule maintenance activities, reduce downtime and extend equipment life. Additionally, we have integrated AI technology to optimise operations across kiln, raw mill and cement mill. This integration has led to improved operational efficiency, enhanced product quality, and greater sustainability. AI-driven insights and automation optimise processes, reduce energy consumption, and ensure equipment reliability, contributing to a more efficient and environment friendly production process.

Looking ahead, what are your company’s strategic priorities for enhancing circular economy practices, and what future projects or goals do you have in this area?
Wonder Cement is committed to enhancing circular economy practices through several strategic priorities. We plan to increase the use of alternative raw materials and fuels in our production processes and expand our collaborations with industries that produce compatible by-products. Our goal is to develop new products with higher recycled content, such as eco-friendly cement blends, to deliver additional environmental benefits. We are conducting research and development to explore the possibility of synthetic gypsum as a substitute of mineral gypsum and many more such alternative raw materials. By focusing on these priorities, we aim to lead the cement industry in circular economy practices and contribute to a more sustainable future.

– Kanika Mathur

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Jean-Jacques Bois, President, Nanolike, discusses how real-time data is reshaping cement delivery planning and fleet performance.

As cement producers look to extract efficiency gains beyond the plant gate, real-time visibility and data-driven logistics are becoming critical levers of competitiveness. In this interview with Jean-Jacques Bois, President, Nanolike, we discover how the company is helping cement brands optimise delivery planning by digitally connecting RMC silos, improving fleet utilisation and reducing overall logistics costs.

How does SiloConnect enable cement plants to optimise delivery planning and logistics in real time?
In simple terms, SiloConnect is a solution developed to help cement suppliers optimise their logistics by connecting RMC silos in real time, ensuring that the right cement is delivered at the right time and to the right location. The core objective is to provide real-time visibility of silo levels at RMC plants, allowing cement producers to better plan deliveries.
SiloConnect connects all the silos of RMC plants in real time and transmits this data remotely to the logistics teams of cement suppliers. With this information, they can decide when to dispatch trucks, how to prioritise customers, and how to optimise fleet utilisation. The biggest savings we see today are in logistics efficiency. Our customers are able to sell and ship more cement using the same fleet. This is achieved by increasing truck rotation, optimising delivery routes, and ultimately delivering the same volumes at a lower overall logistics cost.
Additionally, SiloConnect is designed as an open platform. It offers multiple connectors that allow data to be transmitted directly to third-party ERP systems. For example, it can integrate seamlessly with SAP or other major ERP platforms, enabling automatic order creation whenever replenishment is required.

How does your non-exclusive sensor design perform in the dusty, high-temperature, and harsh operating conditions typical of cement plants?
Harsh operating conditions such as high temperatures, heavy dust, extreme cold in some regions, and even heavy rainfall are all factored into the product design. These environmental challenges are considered from the very beginning of the development process.
Today, we have thousands of sensors operating reliably across a wide range of geographies, from northern Canada to Latin America, as well as in regions with heavy rainfall and extremely high temperatures, such as southern Europe. This extensive field experience demonstrates that, by design, the SiloConnect solution is highly robust and well-suited for demanding cement plant environments.

Have you initiated any pilot projects in India, and what outcomes do you expect from them?
We are at the very early stages of introducing SiloConnect in India. Recently, we installed our
first sensor at an RMC plant in collaboration with FDC Concrete, marking our initial entry into the Indian market.
In parallel, we are in discussions with a leading cement producer in India to potentially launch a pilot project within the next three months. The goal of these pilots is to demonstrate real-time visibility, logistics optimisation and measurable efficiency gains, paving the way for broader adoption across the industry.

What are your long-term plans and strategic approach for working with Indian cement manufacturers?
For India, our strategy is to establish strong and reliable local partnerships, which will allow us to scale the technology effectively. We believe that on-site service, local presence, and customer support are critical to delivering long-term value to cement producers.
Ideally, our plan is to establish an Indian entity within the next 24 months. This will enable us to serve customers more closely, provide faster support and contribute meaningfully to the digital transformation of logistics and supply chain management in the Indian cement industry.

Economy & Market

Power Build’s Core Gear Series

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A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build 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 the freedom in design and reliability in execution.
Together, these four series reflect Power Build’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.

http://www.powerbuild.in
Call: +919727719344

Concrete

Compliance and growth go hand in h and

Published

3 hours ago

February 19, 2026

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Pankaj Kejriwal, Whole Time Director and COO, Star Cement, on driving efficiency today and designing sustainability for tomorrow.

In an era where the cement industry is under growing pressure to decarbonise while scaling capacity, Star Cement is charting a pragmatic yet forward-looking path. In this conversation, Pankaj Kejriwal, Whole Time Director and COO, Star Cement, shares how the company is leveraging waste heat recovery, alternative fuels, low-carbon products and clean energy innovations to balance operational efficiency with long-term sustainability.

How has your Lumshnong plant implemented the 24.8 MW Waste Heat Recovery System (WHRS), and what impact has it had on thermal substitution and energy costs?
Earlier, the cost of coal in the Northeast was quite reasonable, but over the past few years, global price increases have also impacted the region. We implemented the WHRS project about five years ago, and it has resulted in significant savings by reducing our overall power costs.
That is why we first installed WHRS in our older kilns, and now it has also been incorporated into our new projects. Going forward, WHRS will be essential for any cement plant. We are also working on utilising the waste gases exiting the WHRS, which are still at around 100 degrees Celsius. To harness this residual heat, we are exploring systems based on the Organic Rankine Cycle, which will allow us to extract additional power from the same process.

With the launch of Star Smart Building Solutions and AAC blocks, how are you positioning yourself in the low-carbon construction materials segment?
We are actively working on low-carbon cement products and are currently evaluating LC3 cement. The introduction of autoclaved aerated concrete (AAC) blocks provided us with an effective entry into the consumer-facing segment of the industry. Since we already share a strong dealer network across products, this segment fits well into our overall strategy.
This move is clearly supporting our transition towards products with lower carbon intensity and aligns with our broader sustainability roadmap.

With a diverse product portfolio, what are the key USPs that enable you to support India’s ongoing infrastructure projects across sectors?
Cement requirements vary depending on application. There is OPC, PPC and PSC cement, and each serves different infrastructure needs. We manufacture blended cements as well, which allows us to supply products according to specific project requirements.
For instance, hydroelectric projects, including those with NHPC, have their own technical norms, which we are able to meet. From individual home builders to road infrastructure, dam projects, and regions with heavy monsoon exposure, where weather-shield cement is required, we are equipped to serve all segments. Our ability to tailor cement solutions across diverse climatic and infrastructure conditions is a key strength.

How are you managing biomass usage, circularity, and waste reduction across
your operations?
The Northeast has been fortunate in terms of biomass availability, particularly bamboo. Earlier, much of this bamboo was supplied to paper plants, but many of those facilities have since shut down. As a result, large quantities of bamboo biomass are now available, which we utilise in our thermal power plants, achieving a Thermal Substitution Rate (TSR) of nearly 60 per cent.
We have also started using bamboo as a fuel in our cement kilns, where the TSR is currently around 10 per cent to 12 per cent and is expected to increase further. From a circularity perspective, we extensively use fly ash, which allows us to reuse a major industrial waste product. Additionally, waste generated from HDPE bags is now being processed through our alternative fuel and raw material (AFR) systems. These initiatives collectively support our circular economy objectives.

As Star Cement expands, what are the key logistical and raw material challenges you face in scaling operations?
Fly ash availability in the Northeast is a constraint, as there are no major thermal power plants in the region. We currently source fly ash from Bihar and West Bengal, which adds significant logistics costs. However, supportive railway policies have helped us manage this challenge effectively.
Beyond the Northeast, we are also expanding into other regions, including the western region, to cater to northern markets. We have secured limestone mines through auctions and are now in the process of identifying and securing other critical raw material resources to support this expansion.

With increasing carbon regulations alongside capacity expansion, how do you balance compliance while sustaining growth?
Compliance and growth go hand in hand for us. On the product side, we are working on LC3 cement and other low-carbon formulations. Within our existing product portfolio, we are optimising operations by increasing the use of green fuels and improving energy efficiency to reduce our carbon footprint.
We are also optimising thermal energy consumption and reducing electrical power usage. Notably, we are the first cement company in the Northeast to deploy EV tippers at scale for limestone transportation from mines to plants. Additionally, we have installed belt conveyors for limestone transfer, which further reduces emissions. All these initiatives together help us achieve regulatory compliance while supporting expansion.

Looking ahead to 2030 and 2050, what are the key innovation and sustainability priorities for Star Cement?
Across the cement industry, carbon capture is emerging as a major focus area, and we are also planning to work actively in this space. In parallel, we see strong potential in green hydrogen and are investing in solar power plants to support this transition.
With the rapid adoption of solar energy, power costs have reduced dramatically – from 10–12 per unit to around2.5 per unit. This reduction will enable the production of green hydrogen at scale. Once available, green hydrogen can be used for electricity generation, to power EV fleets, and even as a fuel in cement kilns.
Burning green hydrogen produces only water and oxygen, eliminating carbon emissions from that part of the process. While process-related CO2 emissions from limestone calcination remain a challenge, carbon capture technologies will help address this. Ultimately, while becoming a carbon-negative industry is challenging, it is a goal we must continue to work towards.