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Reshaping the Competitive Landscape

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Adani’s consolidation of its cement businesses marks a major shift in the Indian cement landscape, challenging industry leaders and reshaping competitive dynamics. ICR explores how this move could redefine market strategy, scale, and efficiency—read the full story to uncover the implications.

The Indian cement industry is currently witnessing a wave of consolidation and capacity expansion. UltraTech Cement, part of the Aditya Birla Group, remains the market leader with a capacity of around 135 MTPA. It continues to expand aggressively with a target to reach 200 MTPA in the coming years. UltraTech has recently acquired smaller regional players and is investing in green energy and digital transformation to cement its leadership.
Shree Cement, Dalmia Bharat, JSW Cement, and India Cements are also expanding capacities and investing in sustainability-led innovations. Shree Cement, with over 50 MTPA, is focused on cost-efficiency and clinker optimisation. Dalmia Bharat is rapidly expanding in the eastern and southern markets and has pledged to become carbon-negative by 2040. JSW Cement is banking on eco-friendly cement and targeting capacity additions in western and southern India.
Himanshu Ghawri, Partner, PwC India, says, “Mergers in the cement industry offer substantial opportunities to streamline compliance processes and cut operational overheads by unifying and optimising key functions. By bringing related entities—particularly those operating under contract manufacturing or tolling arrangements—under one roof, companies can consolidate environmental clearances, tax filings, statutory licenses, and other regulatory submissions, thereby reducing the number of filings and administrative complexity. A single corporate structure enables the standardisation of quality management systems across plants and simplifies the process of obtaining and renewing government approvals for product standards, environmental norms, and industrial operations.”
“Consolidation also eliminates redundant processes in procurement, finance, HR, legal, and administration, replacing them with shared services and centralised decision-making to boost agility and lower fixed costs. Economies of scale further improve cost efficiency, as fixed overheads such as compliance staff, legal advisors, and auditors are spread across a larger operational base, while procurement and logistics benefit from bulk efficiencies. Moreover, capital-intensive projects like Waste Heat Recovery Systems (WHRS), IT infrastructure, mining leases, or advanced digital technologies such as AI can be deployed more cost-effectively across a consolidated entity, reducing per-tonne investment costs and enhancing returns on capital” he adds.
The competitive intensity is further magnified by the entry of global players and private equity investments. Companies like HeidelbergCement and Holcim (prior to its exit) brought international best practices to India. Now, Adani’s aggressive consolidation places it in direct contention
with UltraTech—not just in terms of scale, but also influence across procurement, project bidding, and price negotiations.

Cementing a Giant
In a strategic move that is set to reshape the contours of the Indian cement industry, the Adani Group has initiated a sweeping consolidation of its cement operations under a single umbrella. By bringing together Ambuja Cements, ACC, Sanghi Industries, Penna Cement, and Orient Cement under what could be branded as “Adani Cement,” the group aims to unify operations, streamline compliance, and leverage economies of scale. With a combined capacity already crossing 100 million tonnes per annum (MTPA) and ambitious plans to reach 140 MTPA by FY2028, Adani is positioning itself not just as a dominant domestic player, but as a global cement powerhouse.
The National Company Law Tribunal (NCLT) recently approved the merger of Adani Cementation with Ambuja Cements, reinforcing the conglomerate’s “One Business, One Company” vision. The consolidation is more than just a financial maneuver—it reflects a broader industry trend of vertical integration, operational synergy, and market consolidation. As India continues its infrastructure expansion, the race for cement dominance has never been more intense.

Strategic Rationale Behind the Move
Adani’s cement consolidation is designed to streamline multiple brands and capacities into a single, efficient entity. Merging entities like Penna Cement and Sanghi Industries into Ambuja Cements is expected to simplify the organisational structure and reduce administrative overhead. The move
also aligns with Adani’s infrastructure-first vision, enabling a more cohesive supply chain and centralised decision-making.
Moreover, the consolidation is expected to unlock significant cost synergies, especially in logistics and procurement. A single command structure allows for centralised negotiation with vendors, optimised freight movement, and integrated distribution networks. In a sector where logistics can constitute up to 30 per cent of total production costs, such optimisation can significantly improve margins.
Another advantage lies in brand unification. While Ambuja and ACC are legacy names, integrating regional players like Penna and Sanghi under one corporate roof allows Adani to target specific geographies more effectively while still presenting a consolidated brand identity to institutional clients and government buyers.
According to Milind Khangan, Marketing Head, Vertex Market Research, “The Adani Group is carrying out a comprehensive reorganisation of its cement business under its ‘One Business, One Company’ strategy, aimed at integrating its diverse holdings into a single corporate entity named Adani Cement. The consolidation process began in September 2022 with the $6.4?billion acquisition of Holcim’s majority stakes in Ambuja Cements and ACC, positioning Ambuja as the focal point for integration. This was followed by the purchase of Sanghi Industries in December 2023 to strengthen its presence in western India, the acquisition of Penna Cement in August 2024 to expand in the southern market, and in April 2025, an increase in its stake in Orient Cement to 46.66 per cent, making Adani the promoter with control. On 18?July?2025, the National Company Law Tribunal sanctioned the amalgamation of Ambuja Cements with Adani Cement, effective 1?April?2024, bringing limestone reserves and new assets into Ambuja. The group has board approvals to merge Sanghi and Penna into Ambuja by the end of 2025 and is considering integrating ACC as the final step, with Orient Cement set to serve as a principal manufacturing facility post-merger.”
In FY?2025, Adani Cement, including Ambuja, crossed 100?MTPA capacity, ranking among the world’s top ten cement producers and becoming India’s second-largest after UltraTech. The group reported sales of 65?million metric tonnes in FY?2025, claiming to supply nearly 30 per cent of cement used in Indian homes and infrastructure. With a current market share of around 14 to 15 per cent, Adani aims to reach 20 per cent by FY?2028, supported by aggressive brownfield expansions targeting 118?MTPA by FY?2026 and 140?MTPA by FY?2028.

Implications for the Indian
Cement Landscape
The implications of Adani’s consolidation ripple across the value chain. For competitors, this move sets a new benchmark for operational integration and capital efficiency. Smaller and mid-sized players may now face greater pressure to either scale up or align with larger entities to survive.
From a market standpoint, this consolidation may lead to regional duopolies or oligopolies, particularly in high-growth zones like Gujarat, Maharashtra, and Andhra Pradesh. This could improve price stability and supply chain coordination but may also attract regulatory scrutiny concerning market dominance. For suppliers and contractors, the emergence of mega-entities like Adani Cement means larger, more standardised procurement processes and tighter contract terms. Meanwhile, customers—especially institutional buyers and infrastructure developers—could benefit from integrated logistics, consistent product quality, and assured supply.
“Consolidation in the Indian cement sector is expected to reshape the competitive landscape and pricing dynamics in both the short and long term. In the immediate aftermath of a merger, consolidated companies typically focus on improving capacity utilisation across their newly acquired or integrated assets. This drive to maximise production can lead to excess material entering the market, disrupting the supply-demand balance and triggering aggressive price-based promotions, discounts, and dealer incentives as competitors strive to protect market share. However, in the medium to long term, pricing generally stabilises as the market adjusts to the new structure, with a smaller number of dominant players adopting more rational pricing strategies and defending their core markets, resulting in healthier price realisation. Additionally, larger consolidated entities benefit from enhanced bargaining power with suppliers and channel partners, strengthening their ability to sustain prices and margins even in competitive environments” says Pallab Dutta, Partner, PwC India.
This level of integration could set the stage for more digitisation in plant operations, predictive maintenance, and ESG compliance—all areas where Adani has already shown interest through other verticals like energy and logistics.

Conclusion
Adani’s move to bring all its cement businesses under one roof is not just a business consolidation—it’s a strategic statement. It signals a new era where scale, speed, and synergy are central to market leadership. As India’s infrastructure and housing sectors grow, the cement industry will continue to be a bellwether for broader economic trends.
This consolidation also raises the stakes for existing players, pushing them to invest more aggressively in innovation, sustainability, and digital infrastructure. With UltraTech, Shree, Dalmia, and JSW all racing to expand, the Indian cement landscape is set for a phase of intense, high-stakes competition. Whether this leads to long-term price rationalisation or increased market control remains to be seen—but one thing is clear: the cement war is heating up, and Adani has just raised the bar.

Concrete

Our strategy is to establish reliable local partnerships

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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.

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Concrete

Compliance and growth go hand in h and

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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.

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Concrete

Turning Downtime into Actionable Intelligence

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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

  1. 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.

  2. 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.

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