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Digital tools have improved quality control and consistency

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MSR Kaliprasad, Chief Digital and Information Officer, Shree Cement, shares his ideas about digitalisation with Kanika Mathur.

Digitalisation is revolutionising the cement manufacturing process, driving efficiency, sustainability, and innovation across operations. Understanding the impact of digitalisation on plant performance and efficiency involves getting an insider’s perspective. Through this interview, we endeavour to bring various aspects of technology that are affecting the march towards Net Zero.

How has digitalisation transformed operational efficiency and productivity in the cement manufacturing process?
Digitalisation has revolutionised our operational efficiency and productivity by centralising control and enhancing real-time decision making . Each of our plants has a central control room equipped with SCADA and PLC systems that manage the entire manufacturing process. Key parameters captured from numerous sensors are stored in our IIoT historian, providing a comprehensive view of operations from limestone mining to cement dispatch. This integration has minimised manual interventions and enabled near real-time operational insights through BI dashboards accessible at all management levels. As a result, we have seen significant improvements in process optimisation, resource utilisation and overall productivity, ensuring we consistently meet production targets and deliver high-quality cement to our customers.

Can you share examples of advanced technologies currently being adopted in cement manufacturing, such as AI, IoT, or machine learning?
We are actively integrating advanced technologies to enhance our manufacturing processes. Our platform leverages IoT to collect and store data from various sensors across the plant. Additionally, robotic systems are employed for sample collection, preparation and testing using XRF and XRD machines, ensuring precise quality control. Machine learning and AI are being utilised for predictive maintenance, where models predict equipment failures before they occur, reducing downtime and maintenance costs. Automated process control and blending optimisation technologies deployed in our cement and raw mills enhance efficiency and consistency.

What role does automation play in improving the accuracy and speed of processes across cement production?
Automation plays a critical role in improving both accuracy and speed across our production processes. By automating operations through SCADA systems and PLCs, we ensure precise control over key manufacturing parameters, reducing human error and increasing consistency. Robotic systems used for sample handling and automated testing accelerate quality assurance while providing reliable data. Automated process control further streamlines production, enabling faster adjustments and minimising downtime while maintaining high-quality standards.

How has digitization helped in predictive maintenance for critical equipment in cement plants, and what benefits have you observed?
Digitalisation has been pivotal in shifting our maintenance strategy to a predictive approach. By capturing granular data on key parameters and equipment vibrations, we are building AI/ML models that predict potential failures before they occur. This proactive approach reduces maintenance costs and improves equipment uptime and availability. Predictive models address issues in critical machinery
before they lead to costly breakdowns, enhancing operational reliability.

Could you discuss the impact of digital tools on quality control and consistency in cement production?
Digital tools have significantly improved quality control and consistency in cement production. All quality data, including results from bomb calorimeters, compression strength testing machinery and other equipment, are centrally stored in our historian. This centralised repository enables seamless analysis and reporting, ensuring consistent quality standards across all production stages. Automated testing and
robotic sample handling minimise human error, further enhancing the accuracy and reliability of our quality assessments.

How does your company use digital technology to monitor and reduce environmental impact and emissions?
Our commitment to sustainability is deeply embedded in our digital strategy. We integrate power and production data captured through sensors with SAP S4 HANA, enabling real-time tracking of power efficiency and consumption, optimising energy use across operations. Renewable energy projects, such as the solar plant in Beawar (Rajasthan) and wind plants in Kushtagi and Jath, are monitored digitally to ensure optimal performance. Digital tools effectively help monitor, manage and reduce our environmental footprint, aligning with our sustainability goals.

What challenges have you faced in implementing digital solutions in cement manufacturing, and how have these been overcome?
Implementing digital solutions in cement manufacturing necessitates change management. Transitioning to a digitalised environment required a significant shift in organisational culture and employee mindset. To address this, we launched a capability-building programme to train our workforce at all levels on new technologies and ways of working. Additionally, integrating diverse digital systems like IIoT historian and SAP S4 HANA require meticulous planning and a robust IT infrastructure. We are fostering a culture of continuous learning and investing in our technology backbone with future-ready cloud computing tools that support advanced analytics and AI/ML.

How has digitalisation improved the supply chain and logistics in cement distribution?
Digitalisation has significantly enhanced supply chain and logistics operations. GPS tracking across our truck fleet provides real-time visibility to both our supply chain team and customers via our apps. This track-and-trace capability ensures timely deliveries and improves customer satisfaction. Our ongoing supply chain transformation project leverages digital tools to implement a robust Sales and Operations Planning (S&OP) process. This initiative helps us optimise logistics costs and increase reach while meeting our EBITDA goals. Advanced
network optimisation tools alongside an intelligent GIS platform and a prescriptive order management solution for trade customers ensure effective service at optimised costs.

What impact has technology had on enhancing workplace safety in high-risk areas of cement production?
Technology has played a crucial role in enhancing workplace safety across high-risk areas in cement production. Our Hazard Identification and Risk Assessment (HIRA) system proactively identifies and mitigates potential risks before an incident occurs. Regular safety inspections, mock drills and ongoing training ensure consistency and effectiveness. Our mobile-first ‘boots on ground’ tool empowers frontline personnel to report safety issues directly from the field. The SAP PM module further enhances safety by tracking walk-by inspections, breakdowns and remedial actions in real time. These technologies foster a ‘zero-injury’ culture by ensuring safety protocols are rigorously followed.

Looking forward, which digital or technological advancements do you see as having the greatest potential to shape the future of the cement industry?
Several digital and technological advancements hold immense potential to shape the cement industry’s future. GenAI will scale AI/ML across the value chain, enabling foundation models to be leveraged at all locations without specific ML models. Use cases like cement strength prediction, fineness optimisation and cyclone jamming prediction will further enhance efficiency and quality. Advanced pricing analytics will enable targeted customer strategies to ensure profitability. These advancements, coupled with a customer-centric approach and a future-ready workforce, will keep us at the forefront of innovation in the cement industry.

Concrete

Adani’s Strategic Emergence in India’s Cement Landscape

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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.

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Concrete

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

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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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Concrete

Driving Measurable Gains

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Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.

Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.

Beyond energy efficiency, the retrofit significantly improved operational parameters:

  • Lower thermal stress on equipment
  • Extended lubricant drain intervals
  • Reduction in CO2 emissions and operational costs

These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.

Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:

  • Enhanced component protection
  • Extended oil life under high loads
  • Stable performance across fluctuating temperatures

By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.

Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.

A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

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