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The Collaborative Revolution

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Dijam Panigrahi, Co-founder and COO, GridRaster, discusses how AI, digital twins and cobots are reshaping cement manufacturing.

The modern industrial landscape in cement production is changing, driven by the convergence of artificial intelligence (AI), digital twins and collaborative robots (cobots). This trifecta is not only enhancing existing operations but fundamentally reimagining how cement manufacturing functions, creating a synergistic environment where human and machine capabilities are maximised.
The International Federation of Robotics (IFR) notes that the global operational stock of industrial robots reached 4.2 million units in 2023, with cobots accounting for a considerable share. Furthermore, the global collaborative robot (Cobot) sales market, valued at $1,020 million in 2024, is projected to reach $2,199 million by 2031, growing at a compound annual growth rate of 11.8 per cent during the forecast period of 2025-2031.
At the heart of this evolution is AI, serving as the intelligent core that orchestrates a multitude of processes in cement production. Its capabilities span from optimising cobot control and predictive maintenance for kilns and grinding mills to ensuring stringent quality control of cement mixtures and streamlining complex supply chain management of raw materials like limestone, clay and gypsum.
AI empowers machines and robots with the ability to learn, adapt, and make real-time decisions, leading to significant improvements in operational efficiency and responsiveness across the board in cement plants. This intelligent automation is enabling the cement industry to achieve levels of precision and speed previously unattainable.

Digital twins: Virtual replicas for real-world optimisation
Complementing AI’s computational prowess are digital twins, which offer virtual replicas of physical assets and processes within a cement plant. These digital models provide an invaluable sandbox for businesses, allowing them to simulate and rigorously test new systems and workflows in a virtual environment before committing to costly physical implementation, such as optimising a new production line or a material handling system.
This capability is particularly crucial for optimising human-robot collaboration, as it allows for the fine-tuning of interactions and processes to ensure seamless integration and maximum output in potentially hazardous areas of a cement facility. The real-time monitoring capabilities of digital twins further enhance their utility, enabling continuous optimisation and proactive problem-solving, for example, by predicting equipment failure in a kiln. The synergy between AI and digital twins significantly reduces risks associated with new deployments and accelerates their time to market.

Empowering the human workforce: Upskilling and collaboration
While the focus on advanced automation might suggest a diminishing role for human workers, the reality is quite the opposite in cement manufacturing. Workforce enablement technologies are designed to empower and elevate the human element within this increasingly automated ecosystem.
These innovative tools facilitate comprehensive upskilling through immersive augmented reality (AR) and virtual reality (VR) training programmes, preparing the workforce for the demands of new technologies and roles, such as operating and maintaining cobots or analysing digital twin data. User-friendly interfaces are simplifying human-robot interaction, making it more intuitive and accessible for workers to collaborate directly with cobots in areas like quality control or material handling.
Furthermore, remote assistance capabilities provide on-demand expert support, ensuring that human workers have the resources they need to troubleshoot and optimise operations effectively in a cement plant.

A synergistic future: Boosting productivity, flexibility and safety
One of the most significant advantages of integrating cobots in cement manufacturing is their ability to offload repetitive, dangerous or physically demanding tasks from human workers, such as bagging cement, loading trucks, or operating in dusty environments. This frees up the human workforce to concentrate on higher-value activities that
demand critical thinking, problem-solving, and creativity – uniquely human attributes that machines cannot replicate.
This integrated approach not only drives remarkable gains in productivity, flexibility and safety but also cultivates a truly synergistic relationship between cutting-edge technology and a skilled, adaptable human workforce.
The implications of this integrated approach extend across various facets of cement manufacturing. The precision and speed offered by AI-powered cobots, validated through digital twin simulations, lead to reduced errors in mixing, faster production cycles, and greater customisation capabilities for different cement types. This translates into higher quality products and the ability to respond more rapidly to market demands.
The optimisation of supply chains through AI and the efficient handling of raw materials and finished goods by cobots result in faster delivery times, reduced operational costs and enhanced inventory management in cement plants. The ability to simulate and optimise complex logistical networks with digital twins means that potential bottlenecks in material flow can be identified and resolved before they impact real-world operations, leading to a more resilient and responsive supply chain for cement.
Moreover, the emphasis on workforce enablement ensures that as technology advances, human workers are not left behind but rather become integral components of the new industrial paradigm in cement production. Upskilling initiatives, facilitated by AR/VR, allow for continuous learning and adaptation, creating a dynamic workforce capable of navigating technological shifts.
The simplified human-robot interfaces remove barriers to entry, making collaborative robotics accessible to a broader range of workers in
cement facilities. This human-centric approach to automation fosters a more engaged and empowered workforce, leading to increased job satisfaction and reduced turnover.
The combination of AI, digital twins and cobots today represents a fundamental modernisation of the cement manufacturing landscape. AI provides the intelligence, digital twins offer the foresight and cobots provide the physical execution, all while workforce enablement technologies ensure that humans remain at the center of innovation and decision-making in cement plants. This integrated approach promises a future where operations are more efficient, resilient and adaptive, ultimately leading to unprecedented levels of productivity and a more fulfilling work environment for all in the cement industry.

About the author:
Dijam Panigrahi is Co-Founder and COO of Gridraster with over 21 years of international experience in market development, business growth, and product management.

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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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.

 

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Concrete

Building a Greener Future Together

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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.

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Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

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