Concrete

Digital tools have improved quality control and consistency

Published

1 year ago

January 15, 2025

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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.

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Concrete

Ramco Cements’ Hard Worker Campaign Wins Seven Awards

Campaign earns honours for direction, editing and cinematography

Published

2 hours ago

June 15, 2026

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The Hard Worker campaign by The Ramco Cements has secured seven honours at the Good Ads Matter Awards 2026, adding to its growing list of accolades and reinforcing its standing among the year’s most recognised advertising campaigns.

The awards were presented during the Good Ads Matter Awards Night 2026 held at Mehboob Studios in Mumbai. The campaign received recognition across multiple categories, highlighting excellence in direction, editing, cinematography and storytelling.

Among the honours, the campaign won Silver in the Campaign of the Year – Direction category, while filmmaker Prakash Varma was named Director of the Year for the films Tortoise & Hare and Eco Plaster. Tortoise & Hare also received Silver awards for Best Editing and Best Colour Grading, along with a Bronze award for Best Cinematography. Eco Plaster earned Bronze awards in the Best Direction – Narrative and Best Direction – Humour categories.

Both films extended their award-winning run, with Eco Plaster being recognised for its narrative centred on water conservation through innovative construction solutions, while Tortoise & Hare was honoured for its storytelling and craft execution.

The Hard Worker campaign was built around the idea that hard work deserves recognition and respect. Through culturally rooted and emotionally engaging stories, the campaign has connected with consumers, engineers, masons and the wider construction community across the country.

Commenting on the achievement, A V Dharmakrishnan, CEO of The Ramco Cements Limited, said that the continued recognition across leading creative platforms reflects the company’s commitment to meaningful and authentic communication rooted in the values of the people it serves.

Balaji K Moorthy, Executive Director – Marketing, The Ramco Cements Limited, said the awards recognise the craftsmanship behind the storytelling, from direction and cinematography to editing and narrative execution.

Following recognition at both the Kyoorius Creative Awards and the Good Ads Matter Awards, the Hard Worker campaign continues to demonstrate the impact of purpose-driven storytelling combined with strong creative execution and consumer relevance.

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

1 week ago

June 5, 2026

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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 weeks ago

June 4, 2026

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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.