Concrete

We are developing advanced AI models

Published

6 months ago

August 5, 2025

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Uma Suryam, SVP & Head Manufacturing – Northern Region, Nuvoco Vistas, shares details about how automation is helping the company make a shift towards an efficient and sustainable ecosystem.

As India’s cement sector embraces digital transformation, automation is emerging as the cornerstone of future-ready manufacturing. Uma Suryam, SVP & Head – Manufacturing, Northern Region, Nuvoco Vistas, sheds light on how the company is driving intelligent operations, improving energy efficiency and preparing for a data-led future.

What are the key drivers behind the adoption of automation in cement manufacturing today?
Automation in cement manufacturing is being increasingly adopted to meet rising demand due to rapid urbanisation, which drives large scale infrastructure development. To keep pace, manufacturers are embracing automation and digital technologies to streamline operations, reduce manual intervention and ensure consistent product quality.
At Nuvoco, we are strengthening our automation capabilities by adopting advanced technologies and digital solutions that optimise processes, boost operational efficiency and elevate customer experience. Our approach integrates structured innovation, robust quality management, and a comprehensive digital transformation framework—enabling us to stay agile, competitive, and sustainable in a dynamic marketplace

How is automation improving process efficiency and reducing operational costs?
We are continuously investing in automation and process excellence to enhance efficiency and reduce costs across our operations. The roll-out of plant automation at select sites is setting the stage for an Internet of Things (IoT)-enabled smart factory environment, where real-time data and connected systems help optimise production and decision-making.
We have also introduced Robotic Process Automation (RPA) in our Shared Services Centre to fast-track routine processes such as freight bill settlements, significantly reducing manual effort and processing time. To further strengthen supply chain efficiency, the Master Data Repository Management (MDRM) tool ensures improved inventory accuracy, eliminates duplicate stock, and provides better visibility to reallocate excess materials across locations.
Complementing these initiatives, our Integrated Business Planning (IBP) solution by SAP has transformed demand and supply forecasting, enabling inventory planning aligned with demand cycles and ensuring adherence to our Goto market strategies (GTM).
Together, these digital interventions are streamlining end to end operations—optimising resources, minimising wastage, improving cost competitiveness and ultimately creating greater value for customers.

How does automation support energy optimisation and emissions control?
Automation is a key enabler of building safer, smarter and sustainable energy management systems at Nuvoco. A major milestone in this journey was the commissioning of our Grid Integration Project, which connected three of our geographically isolated cement plants through a common transmission line, creating a unified power network and setting a new benchmark for energy optimisation in the industry.
The project, anchored by a Line-In Line-Out (LILO) substation at our cement plant and supported by an optical fibre network, enables real-time communication and automated energy distribution across the cluster. This has significantly reduced contract demand, eliminated power disruptions, enhanced operational flexibility and delivered substantial savings on fixed energy charges.
By minimising energy wastage and optimising power usage, automation directly contributes to lower greenhouse gas emissions, making our operations more environmentally responsible while ensuring safer and more reliable plant performance.

What kind of data infrastructure is needed to enable effective automation?
Effective automation in relies on a strong and secure data infrastructure that enables seamless, real-time connectivity across the plant. Smart sensors and PLCs integrated into key machinery—such as kilns, crushers, and packing units—collect live performance and process data, which is then analysed through a centralised control room or cloud-based platform to enable timely, data-driven decision-making. Equally important are strong cybersecurity protocols that safeguard operational systems and sensitive production data from disruptions or breaches, ensuring plant safety and uninterrupted performance.
We are advancing towards a more data-intelligent manufacturing ecosystem with initiatives such as an AI-enabled dashboard to optimise waste heat recovery systems and kiln operations, enhancing energy efficiency. Additionally, we are developing advanced AI models that identify the most cost-effective fuel combinations by factoring in variables like moisture content, pricing and other operational parameters. These initiatives are laying the foundation for next-generation, data-driven decision-making, driving operational excellence and sustainable performance at scale.
In parallel, recognising the growing cyber threat landscape, we have strengthened our digital security framework by deploying next-generation firewalls, endpoint protection, enhanced network segmentation and implementing multi-factor authentication across all applications—ensuring that our digital infrastructure remains as resilient as our physical operations.

What is your roadmap for scaling automation across the organisation in the next five years?
Over the next five years, the company will focus on automating critical processes especially in production and quality control to drive operational excellence. AI will be integrated to support real-time, data-driven decision-making across functions. Additionally, the organisation is evaluating next-generation digital platforms to simplify and integrate its IT landscape.
As part of this evolving roadmap, there is also a continued emphasis on building a digitally capable workforce to stay aligned with emerging technologies.
These efforts reflect a broader shift towards a connected, future-ready manufacturing ecosystem where people, processes and systems are increasingly integrated to respond with agility to changing business dynamics.

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Concrete

Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

Published

19 hours ago

January 31, 2026

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Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

To read the full article Click Here

Concrete

JK Cement Commissions 3 MTPA Buxar Plant, Crosses 31 MTPA

Company becomes India’s fifth-largest grey cement producer

Published

2 days ago

January 30, 2026

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JK Cement has commissioned its new 3 MTPA grey cement plant in Buxar, Bihar, taking the company’s total installed capacity to 31.26 million tonnes per annum (MTPA) and moving it past the 30 MTPA milestone. With this addition, JK Cement now ranks among the top five grey cement manufacturers in India, strengthening its national presence.

Commenting on the development, Dr Raghavpat Singhania, Managing Director, JK Cement, said, “Crossing 31 MTPA is a significant turning point in JK Cement’s expansion and demonstrates the scale, resilience, and aspirations of our company. In addition to making a significant contribution to Bihar’s development vision, the commissioning of our Buxar plant represents a strategic step towards expanding our national footprint. We are committed to developing top-notch manufacturing capabilities that boost India’s infrastructure development and generate long-term benefits for local communities.”

Spread across 100 acres, the Buxar plant is located on the Patna–Buxar highway, enabling efficient distribution across Bihar and neighbouring regions. While JK Cement entered the Bihar market last year through supplies from its Prayagraj plant, the new facility will allow local manufacturing and deliveries within 24 hours across the state.

Mr Madhavkrishna Singhania, Joint Managing Director & CEO, JK Cement, said, “JK Cement is now among India’s top five producers of grey cement after the Buxar plant commissioning. Our capacity to serve Bihar locally, more effectively, and on a larger scale is strengthened by this facility. Although we had already entered the Bihar market last year using Prayagraj supplies, local manufacturing now enables us to be nearer to our clients and significantly raise service standards throughout the state. Buxar places us at the center of this chance to promote sustainable growth for both the company and the region in Bihar, a high-growth market with strong infrastructure momentum.”

The project has involved an investment of Rs 5 billion. Commercial production began on 29 January 2026, following construction commencement in March 2025. The company said the plant is expected to generate significant direct and indirect employment and support ancillary industrial development in the region.

Concrete

JK Cement Crosses 31 MTPA Capacity with Commissioning of Buxar Plant in Bihar

Published

2 days ago

January 30, 2026

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JK Cement has commissioned a 3 MTPA Grey Cement plant in Buxar, Bihar, taking its total capacity to 31.26 MTPA and placing it among India’s top five grey cement producers. The ₹500 crore investment strengthens the company’s national footprint while supporting Bihar’s infrastructure growth and local economic development.

JK Cement Ltd., one of India’s leading cement manufacturers, has announced the commissioning of its new state-of-the-art Grey Cement plant in Buxar, Bihar, marking a significant milestone in the company’s growth trajectory. With the commissioning of this facility, JK Cement’s total production capacity has increased to 31.26 million tonnes per annum (MTPA), enabling the company to cross the 30 MTPA threshold.

This expansion positions JK Cement among the top five Grey Cement manufacturers in India, strengthening its national footprint and reinforcing its long-term growth strategy.

Commenting on the strategic achievement, Dr Raghavpat Singhania, Managing Director, JK Cement, said, “Crossing 31 MTPA is a significant turning point in JK Cement’s expansion and demonstrates the scale, resilience, and aspirations of our company. In addition to making a significant contribution to Bihar’s development vision, the commissioning of our Buxar plant represents a strategic step towards expanding our national footprint. We are committed to developing top-notch manufacturing capabilities that boost India’s infrastructure development and generate long-term benefits for local communities.”

The Buxar plant has a capacity of 3 MTPA and is spread across 100 acres. Strategically located on the Patna–Buxar highway, the facility enables faster and more efficient distribution across Bihar and adjoining regions. While JK Cement entered the Bihar market last year through supplies from its Prayagraj plant, the Buxar facility will now allow the company to serve the state locally, with deliveries possible within 24 hours across Bihar.

Sharing his views on the expansion, Madhavkrishna Singhania, Joint Managing Director & CEO, JK Cement, said, “JK Cement is now among India’s top five producers of grey cement after the Buxar plant commissioning. Our capacity to serve Bihar locally, more effectively, and on a larger scale is strengthened by this facility. Although we had already entered the Bihar market last year using Prayagraj supplies, local manufacturing now enables us to be nearer to our clients and significantly raise service standards throughout the state. Buxar places us at the center of this chance to promote sustainable growth for both the company and the region in Bihar, a high-growth market with strong infrastructure momentum.”

The new facility represents a strategic step in supporting Bihar’s development vision by ensuring faster access to superior quality cement for infrastructure, housing, and commercial projects. JK Cement has invested approximately ₹500 crore in the project. Construction began in March 2025, and commercial production commenced on January 29, 2026.

In addition to strengthening JK Cement’s regional presence, the Buxar plant is expected to generate significant direct and indirect employment opportunities and attract ancillary industries, thereby contributing to the local economy and the broader industrial ecosystem.