Concrete
The Great Differentiator
Published
7 months agoon
By
admin
Branding is a strategic lever driving trust, preference and profitability in a highly competitive, commodity-driven market. By blending regional relevance, digital innovation and the art of storytelling, cement brands are transforming product parity into emotional and reputational differentiation.
In a price-sensitive market like India, cement has traditionally been viewed as a commodity—chosen more for availability and cost than for emotional appeal or consumer perception. However, this perception is rapidly shifting. India’s cement industry, which recorded over 3,755 million tonnes of production in FY23 and demonstrated a staggering 65 per cent CAGR between 2016 and 2022, is now embracing branding not just as an added value, but as a core business strategy. Especially in Tier-2 and Tier-3 towns, where numerous brands vie for attention, companies are investing heavily in building visibility and loyalty to stand out in an otherwise homogenous product landscape.
A well-established brand in cement signifies more than product availability—it conveys trust, performance consistency and service dependability. For contractors, masons and even individual home builders, a trusted brand name helps mitigate the perceived risk of using poor-quality material. With limited access to third-party testing and technical evaluation, stakeholders often rely on branding as a proxy for quality. Through our industry interaction on this subject, we at Indian Cement Review strongly believe that an effective branding strategy can be both the differentiating and deciding factor. In a sector where technical specs across brands may seem similar, perception can be a game changer.
Furthermore, as India’s infrastructure and housing needs accelerate, the stakes have grown higher. Government-led initiatives such as the PM Awas Yojana, Smart Cities Mission, and increased capex in highways and railways have raised demand for fast, reliable construction. Brands that promise durability, consistency and after-sales support gain an edge, particularly with institutional buyers and project developers. This reliability often allows manufacturers to command a pricing premium, turning branding into a profitability lever—not just a marketing expense.
Ultimately, branding elevates cement from a low-engagement commodity to a strategic, experience-driven product. In a scenario where physical differentiation is limited, emotional and reputational moats—such as legacy, trust, and service quality—become key drivers of growth. Companies that position themselves as partners in construction, not just suppliers, will be best poised to influence long-term customer loyalty and market leadership. Branding, therefore, is not just about logos or slogans—it is a strategic imperative that transforms business outcomes in India’s high-stakes cement sector.
Tactics that transform branding
Cement branding in India has undergone a radical evolution—from static billboards and rural hoardings to dynamic, omnichannel strategies rooted in data, emotion, and digital intelligence.
In an interview, Meghna Mittal, Co-Founder and CRO of Hoopr, shared that music holds a unique power to tell stories that people don’t just hear but truly feel. She explained that with UltraTech Cement, the goal was not just to create a song but to give a voice to millions of Indians who leave their hometowns to earn a living while holding onto the dream of building their own home—reclaiming their identity in the place they come from. According to her,‘Ek Ghar Banaunga’ represents their journey and emotion, with every lyric and melody crafted to evoke feelings of nostalgia, belonging, and the unbreakable connection to one’s roots.
Mittal added that the team leveraged deep audience insights to ensure the composition resonated with regional cultures and emotional nuances. She emphasized that the song is not just a brand asset but an anthem for every home builder—a tribute to those who, regardless of where life takes them, strive to build a home of their own.
And a sense of familiarity continue to drive impact—especially among contractors, dealers and masons who form the backbone of cement distribution and recommendation.
Sushrut Pant, Head – Marketing, Shree Cement, says, “Our approach blends emotional storytelling with functional delivery. Campaigns like ‘Solid Ghar Sirf Bangur’ tap into the pride and aspirations of Individual Home Builders (IHBs), helping them connect with the idea of building something enduring. Similarly, during the general elections, we launched ‘Vote Solid, Desh Solid,’ which drew a parallel between responsible voting and choosing a solid cement brand resulting in over 17 lakh pledges through an interactive digital experience. At the same time, strategic branding has helped build emotional equity with contractors, engineers, dealers and masons encouraging preference beyond price.
Regional outreach, omni-channel engagement, and purposeful brand activations have improved visibility, driving conversion and long-term loyalty. This shift from transactional buying to brand-led preference is also validated by the successful introduction of premium offerings like Bangur Magna, Bangur Marble and Bangur Roofon aligned with evolving customer needs and aspirations.”
Digital storytelling, meanwhile, is unlocking new audience segments—particularly urban millennials, architects, and independent homebuilders. JK Cement has embraced this trend with its campaigns #YehPuccaHai and #AndarSeSundar, promoting the idea that building materials are not just structural but emotional investments. Using platforms like LinkedIn, Instagram, and Facebook, the brand weaves a narrative that links quality with personal values—such as commitment, inner beauty, and lasting legacy. These content strategies aim to shift cement from a transactional good to a value-laden choice, increasing emotional attachment and long-term preference.
Sanchit Dua, Founder and Principal Strategist, WeGress Media says, “Even in a specification-driven category like cement, decision-makers now start their journey online. High-impact digital campaigns can therefore position the brand long before the purchase order is raised. I focus on three levers: (a) Account-based targeting on LinkedIn, programmatic B2B networks and trade-specific WhatsApp lists to reach architects, structural consultants and project engineers with technical proof points; (b) Storytelling around reliability and sustainability, delivered via short-form video, interactive 3-D site walk-throughs and AR demos that let engineers “see” performance in simulated conditions; and (c) Community-building—hosting webinars, CPD credits and job-site masterclasses that turn the brand into a knowledge partner, not just a supplier. When these touch-points are orchestrated through a unified data layer (CRM + pixel data), every digital interaction steadily increases familiarity, favourability and, most importantly, inclusion in tender specs and BOQs.”
“Content is now the credibility engine. In India, 70 per cent+ of construction professionals research materials online before short-listing vendors, so authoritative content closes the trust gap faster than any sales pitch. Effective cement brands publish: (1) Technical deep dives—mix-design guides, IS code explainers, durability case studies; (2) Localised, vernacular storytelling—site-visit reels in Hindi, Tamil, Kannada, etc., showing real outcomes for local climate conditions; and (3) Thought-leadership on green construction—LC3 blends, clinker-factor reduction, ESG scorecards. Pairing this with micro-influencers such as civil-engineering professors or respected contractors turns the brand into a peer-endorsed authority. The result: higher perceived competence, reduced perceived risk and a smoother path from curiosity to consideration to advocacy”, he adds.
Finally, sustainability has become a powerful branding lever. In a sector known for high CO2 emissions, brands that openly commit to green practices are gaining credibility and consumer goodwill. Campaigns that highlight investments in alternative fuels (AFR), waste heat recovery, and low-carbon cement production do more than signal compliance—they build reputation. As decarbonisation becomes central to global construction conversations,
cement companies that lead the narrative will not only earn customer trust but also align with ESG-conscious investors, builders, and government stakeholders. In today’s cement branding, being environmentally responsible is not just ethical—it’s strategically essential.
Regional vs national branding
India is not one cement market—it is many. Each region, from the limestone-rich corridors of Rajasthan and Andhra Pradesh to the Northeast’s hilly terrain, presents unique cultural, linguistic, and infrastructural contexts. This diversity demands that branding strategies evolve from a one-size-fits-all model to a regionally nuanced approach that resonates locally while reinforcing national brand identity.
“Trust is a cornerstone of our brand strategy. Recognising its importance, we have revisited and redefined our mission statement which reads: ‘Trusted Building Materials Company Creating Value for our Stakeholders.’ This wasn’t just a cosmetic change, it was a conscious, strategic decision that reflects our intent to be recognised not merely for the scale of our operations, but as a trusted brand that delivers lasting value to our most important stakeholder—our customer. By placing customer centricity at the centre of our approach, we aim to understand evolving needs, respond with agility and ultimately create experiences that drive customer delight, reinforcing trust at every touchpoint” says Chirag Shah, Head – Marketing, Nuvoco Vistas.
National brands like UltraTech, Shree Cement and ACC have invested in creating umbrella brand identities that project strength, scale, and trust. But they are also acutely aware that local adaptation is critical for resonance. Language is a key lever—campaigns in South India often feature regional celebrities and vernacular scripts, while in Gujarat and Rajasthan, brands draw on visual symbolism and local idioms. Even product packaging may vary subtly to reflect market-specific certifications, batch codes, or slogans that carry regional emotional weight.
Regional brands such as Dalmia Cement, Penna Cement, and Star Cement have used their geographical roots to their advantage. Their branding emphasises regional pride, accessibility, and cultural alignment—projecting themselves as ‘closer to the people’ and ‘partners in local progress.’ These companies are often more agile in sponsoring local festivals,
sports teams, and community infrastructure—embedding their presence not just on the shelves, but in the social fabric. For example, Star Cement’s deep involvement in the Northeast has made it the go-to brand in a logistically challenging yet high-potential market.
The future of cement branding lies in balancing brand consistency with local sensitivity. This could mean deploying hyper-targeted mobile ads in rural Bihar, influencer-driven digital campaigns in Tamil Nadu, and grassroots activations during harvest seasons in Madhya Pradesh. In a country with over 20 official languages and hundreds of dialects, regional nuance is not a creative luxury—it is a branding imperative. Winning the hearts of India’s diverse construction ecosystem requires brands to speak not just in their voice, but in the voices of the markets they serve.
Tangible and intangible ROI
In the Indian cement sector, effective branding delivers a powerful combination of tangible business benefits and intangible competitive advantages. Brands like UltraTech Cement have demonstrated how a well-executed strategy can significantly influence buyer perception and behaviour. The company’s ‘Mauka Ek’ campaign, for instance, resulted in a 62 per cent increase in endorsement share, 72 per cent surge in recall, and a noteworthy 44 per cent of homebuilders naming it their most trusted brand. These metrics highlight the direct correlation between strategic branding and measurable commercial success—where perception drives preference,and preference translates into market share and repeat business.
Arun Shukla, President and Director, JK Lakshmi Cement in an interview said, “Our new TVC aims to inspire the Indian youth to understand that a successful future starts with big dreams. Our overall campaign, ‘Soch Karo Buland,’ embodies our philosophy of building. aspirations and trust. Through this brand refresh, we aim to align with the evolving needs of our customers, combining innovation, sustainability, and delivering customer-centric solutions. As we move forward, we aim to build structures and contribute to creating enduring legacies.”
For both B2C consumers and institutional clients, branding serves as a proxy for quality and reliability—especially when the product category offers limited scope for visible differentiation. In such scenarios, emotional trust and professional credibility become deciding factors. Research shows that cement buyers, even in procurement-heavy institutional roles, often opt for brands they perceive as superior—even when technical specifications are comparable. This ‘perceived value’ allows strong brands to command premium pricing, thereby improving margins without necessarily increasing costs—a compelling case for sustained brand investment in a low-margin industry.
Love Raghav, AVP & Head of Branding, JK Cement, said that with their new brand identity and bold campaign #GameBadalDe, the company was breaking barriers and reshaping the narrative in the cement industry. He explained that Jasprit Bumrah’s story of perseverance aligned with JK Cement’s brand values and offered a fresh perspective on construction and growth. By featuring Bumrah as a symbol of transformation, the brand aimed to inspire game-changing stories across all walks of life.
Anusree V Yannam, Marketing Consultant, says, “When we think about influencer marketing, we often picture glamorous content creators or social media personalities driving purchase decisions. But in industries like cement- where the business is predominantly B2B – influencing looks and functions very differently. As an average consumer building a home or undertaking construction, I wouldn’t instinctively know which cement brand is best. Instead, I’d rely on someone more experienced- my contractor, builder, or even the local distributor- to guide me. That’s where the real influence lies. In the cement business, these allied professionals act as everyday influencers. They’re the ones who understand product performance, availability, pricing, and consistency. Their recommendations carry weight and directly shape consumer choices, even though they’re not on Instagram or YouTube talking about it.”
“This makes influencer marketing in the cement sector unique. The brand’s communication strategy must target this network of contractors, resellers, and distributors, not just as end-users but as crucial brand advocates. Unlike conventional influencer campaigns, this relies heavily on offline trust-building, relationship management, loyalty programs, on-ground activations, and training sessions. It’s about empowering these on-field influencers with the right knowledge and motivation to recommend your brand consistently. In short, in the world of cement, influence is built brick by brick- offline, through people who build trust every day,” she adds.
The dealer and distributor network forms the lifeline of cement sales in India, and branding plays a pivotal role in building this channel loyalty. UltraTech’s expansive network of 5,500 dealers and 30,000+ retailers, and Ambuja’s 50,000+ outlets, are not simply a result of distribution logistics—they are the outcome of strong brand pull. Dealers prefer associating with brands that move faster off the shelves, minimise returns, and carry the assurance of consistent quality. For them, a strong brand means better credit terms, faster turnover, and repeat demand—factors that reinforce long-term partnerships and increase market penetration.
Khushboo Mulani Founder and ShEO, Slay Media, says, “Branding is the antidote to commoditisation. Cement might physically be a uniform grey powder, but a strong brand identity can elevate it beyond a mere commodity. We’ve long sought to shun the pejorative tag of being a mere commodity by transforming cement into a differentiated brand. A trusted brand carries a promise of quality and consistency that sets it apart from generic alternatives. In a price-competitive market, branding helps build preference and loyalty.”
Intangibly, a strong brand acts as a shield during times of uncertainty or transformation. A prime example is ACC, which retained a positive brand image among stakeholders even during its merger with Holcim/Lafarge. Despite the organisational upheaval and changes in leadership, dealers and customers continued their association with the brand because it stood for reliability. This kind of brand equity—earned over years of consistent performance, trust-building, and emotional connection—proves invaluable when navigating market volatility or corporate restructuring. Ultimately, branding in cement is not just about advertising—it’s about building reputational capital that sustains through cycles.
The influencer chain
In India’s cement industry, purchase decisions are rarely made by the end-user alone. Instead, a complex web of influencers—dealers, site engineers, contractors, and masons—shapes brand preference at the grassroots level. These stakeholders are not just distributors or service providers; they are trusted advisors for homebuilders and project developers, especially in semi-urban and rural markets. As a result, branding strategies that overlook this intermediary chain risk missing the real decision-makers on the ground.
Dealers play a dual role: they are both business partners and brand evangelists. Cement manufacturers invest heavily in dealer development programs—offering volume-based incentives, credit support, and exclusive promotional schemes—to secure shelf space and loyalty. But financial incentives alone are not enough. What matters more is the brand’s pull in the market, which ensures faster turnover, fewer complaints, and repeat business. That’s why national players like UltraTech and Ambuja have structured loyalty platforms and dealer engagement apps that keep them constantly connected and aligned with the brand’s goals.
Masons and site contractors, meanwhile, serve as powerful micro-influencers. Their endorsement can tip decisions, especially in individual home building (IHB) segments, where technical knowledge is limited. Cement companies have begun offering training programmes, loyalty clubs, and on-site demos to educate and engage this vital audience. For example, Ambuja Cement’s ‘Ambuja Abhimaan’ and UltraTech’s ‘Samruddhi’ initiative reward masons with points, gear, and recognition, turning them into brand ambassadors who spread trust through word-of-mouth. Some brands have even gone a step further, linking these efforts to vocational upskilling and insurance support.
The cement industry is beginning to recognise that branding doesn’t stop at mass media. In fact, it starts where the bags are stocked and the walls are built—on-site, in real time. Influencer engagement programmes, built on consistent training, trust, and long-term relationship-building, are now an essential part of the branding playbook. The strength of a cement brand is only as solid as the trust it commands from those who work with it daily.
Discussing the impact of digital branding, Mulani states, “The digital revolution has reached every corner of India. With affordable smartphones and cheap data, even small-town contractors and individual home builders are on WhatsApp, Facebook and YouTube. During the pandemic, we noticed a spike in digital engagement from non-metro regions. Case in point is the JK Cement online campaign (#YehPuccaHai), which got great engagement, including 600+ user-generated videos from those audiences. That was an eye-opener – it proved that if content is relatable (local language, addressing local building challenges, etc.), people will actively participate online. We now use vernacular content marketing, Facebook groups for contractor communities, and YouTube tutorials on best construction practices to connect with our
B2B audience.”
Challenges in cement branding
Branding in the cement industry comes with a distinct set of challenges rooted in its inherently B2B nature and legacy of price-focused operations. Unlike consumer goods where emotional connection drives preference, cement transactions—especially in institutional and bulk markets—are dominated by considerations of price, delivery timelines and volume discounts. Internal stakeholders such as procurement officers, production engineers, and even dealers often focus on operational efficiency rather than brand storytelling. This creates friction when marketing teams attempt to introduce emotional or aspirational narratives, as the value of brand equity is not always immediately recognised in performance-led environments.
A further complication lies in the homogeneity of cement products. With standard types like OPC (Ordinary Portland Cement), PPC (Portland Pozzolana Cement), and PSC (Portland Slag Cement) dominating the market, technical differentiation is minimal and often invisible to the end-user. This makes it difficult for consumers to justify a premium purely on product attributes. As a result, the brand must go beyond specs and focus on perception—crafting compelling stories around quality assurance, sustainability commitments, customer service and reliability. In essence, branding becomes less about what the product is and more about what the brand represents.
However, this branding gap presents an immense opportunity—especially with the rise of digital platforms and the changing information consumption habits of even rural and semi-urban stakeholders. Mobile penetration in rural India enables campaigns through WhatsApp, YouTube shorts, and voice-activated bots, while AI-based targeting helps personalise brand messages. Technologies such as blockchain-based traceability, smart packaging, and digital warranty tracking are being explored to boost transparency and engagement. More significantly, sustainability branding—anchored in carbon reduction, waste heat recovery, use of alternative fuels, and green certifications—is gaining importance. It speaks to not just institutional stakeholders and regulators, but increasingly to environmentally-conscious consumers and developers.
Looking ahead, cement brands that successfully blend digital innovation, localised engagement and ESG narratives will redefine how cement is evaluated and chosen. The winners will be those who understand that in a product category where differentiation is thin, reputation is everything. A strong brand will not only move more bags—it will also command trust, influence purchase cycles, shape industry conversations, and contribute meaningfully to the sector’s Net Zero aspirations. Branding in cement, once a tactical tool, is fast becoming a strategic weapon for future-ready growth.
Conclusion
In what has long been viewed as a commodity-driven industry, branding in cement is emerging as a powerful catalyst for transformation. No longer confined to price wars or distribution strength alone, cement manufacturers are realising that emotional resonance, strategic storytelling, and stakeholder trust are the new currencies of market leadership. From rural murals to mobile dashboards, from dealer clubs to AI-powered campaigns, branding has evolved into a multi-layered discipline—rooted in insight, scaled by technology and shaped by regional nuance.
As demonstrated through leading campaigns by UltraTech, Ambuja and JK Cement, effective branding delivers measurable returns—enhancing recall, enabling pricing premiums, and creating pull through a loyal dealer and contractor ecosystem. It offers both short-term gains and long-term resilience, helping companies navigate market shifts, regulatory changes, and mergers without eroding brand equity. The intangible assets—trust, familiarity, and emotional connection—often become the most valuable differentiators in a market where product specifications are largely uniform.
As India’s construction and infrastructure growth story accelerates, cement brands must go beyond the bag and into the hearts of their stakeholders—contractors, architects, engineers and homebuilders alike. Because in a market built on str
– Kanika Mathurength, it is brand strength that will define the next decade of cement leadership.
Concrete
Our strategy is to establish reliable local partnerships
Published
4 hours agoon
February 19, 2026By
admin
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.
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.
Concrete
Turning Downtime into Actionable Intelligence
Published
5 hours agoon
February 19, 2026By
admin
Stoppage Insights instantly identifies root causes and maps their full operational impact.
In cement, mining and minerals processing operations, every unplanned stoppage equals lost production and reduced profitability. Yet identifying what caused a stoppage remains frustratingly complex. A single motor failure can trigger cascading interlocks and alarm floods, burying the root cause under layers of secondary events. Operators and maintenance teams waste valuable time tracing event chains when they should be solving problems. Until now.
Our latest innovation to our ECS Process Control Solution(1) eliminates this complexity. Stoppage Insights, available with the combined updates to our ECS/ControlCenter™ (ECS) software and ACESYS programming library, transforms stoppage events into clear, actionable intelligence. The system automatically identifies the root cause of every stoppage – whether triggered by alarms, interlocks, or operator actions – and maps all affected equipment. Operators can click any stopped motor’s faceplate to view what caused the shutdown instantly. The Stoppage UI provides a complete record of all stoppages with drill-down capabilities, replacing manual investigation with immediate answers.
Understanding root cause in Stoppage Insights
In Stoppage Insights, ‘root cause’ refers to the first alarm, interlock, or operator action detected by the control system. While this may not reveal the underlying mechanical, electrical or process failure that a maintenance team may later discover, it provides an actionable starting point for rapid troubleshooting and response. And this is where Stoppage Insights steps ahead of traditional first-out alarm systems (ISA 18.2). In this older type of system, the first alarm is identified in a group. This is useful, but limited, as it doesn’t show the complete cascade of events, distinguish between operator-initiated and alarm-triggered stoppages, or map downstream impacts. In contrast, Stoppage Insights provides complete transparency:
- Comprehensive capture: Records both regular operator stops and alarm-triggered shutdowns.
- Complete impact visibility: Maps all affected equipment automatically.
- Contextual clarity: Eliminates manual tracing through alarm floods, saving critical response time.
David Campain, Global Product Manager for Process Control Systems, says, “Stoppage Insights takes fault analysis to the next level. Operators and maintenance engineers no longer need to trace complex event chains. They see the root cause clearly and can respond quickly.”
Driving results
1.Driving results for operations teams
Stoppage Insights maximises clarity to minimise downtime, enabling operators to:
• Rapidly identify root causes to shorten recovery time.
• View initiating events and all affected units in one intuitive interface.
• Access complete records of both planned and unplanned stoppages
- Driving results for maintenance and reliability teams
Stoppage Insights helps prioritise work based on evidence, not guesswork:
• Access structured stoppage data for reliability programmes.
• Replace manual logging with automated, exportable records for CMMS, ERP or MES.(2)
• Identify recurring issues and target preventive maintenance effectively.
A future-proof and cybersecure foundation
Our Stoppage Insights feature is built on the latest (version 9) update to our ACESYS advanced programming library. This industry-leading solution lies at the heart of the ECS process control system. Its structured approach enables fast engineering and consistent control logic across hardware platforms from Siemens, Schneider, Rockwell, and others.
In addition to powering Stoppage Insights, ACESYS v9 positions the ECS system for open, interoperable architectures and future-proof automation. The same structured data used by Stoppage Insights supports AI-driven process control, providing the foundation for machine learning models and advanced analytics.
The latest releases also respond to the growing risk of cyberattacks on industrial operational technology (OT) infrastructure, delivering robust cybersecurity. The latest ECS software update (version 9.2) is certified to IEC 62443-4-1 international cybersecurity standards, protecting your process operations and reducing system vulnerability.
What’s available now and what’s coming next?
The ECS/ControlCenter 9.2 and ACESYS 9 updates, featuring Stoppage Insights, are available now for:
- Greenfield projects.
- ECS system upgrades.
- Brownfield replacement of competitor systems.
Stoppage Insights will also soon integrate with our ECS/UptimeGo downtime analysis software. Stoppage records, including root cause identification and affected equipment, will flow seamlessly into UptimeGo for advanced analytics, trending and long-term reliability reporting. This integration creates a complete ecosystem for managing and improving plant uptime.
(1) The ECS Process Control Solution for cement, mining and minerals processing combines proven control strategies with modern automation architecture to optimise plant performance, reduce downtime and support operational excellence.
(2) CMMS refers to computerised maintenance management systems; ERP, to enterprise resource planning; and MES to manufacturing execution systems.
Our strategy is to establish reliable local partnerships
Power Build’s Core Gear Series
Compliance and growth go hand in h and
Turning Downtime into Actionable Intelligence
FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe
Our strategy is to establish reliable local partnerships
Power Build’s Core Gear Series
Compliance and growth go hand in h and
Turning Downtime into Actionable Intelligence


