Concrete
Bifacial panels add another layer of performance
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1 month agoon
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Raman Bhatia, Founder and Managing Director, Servotech Renewable Power System discusses how innovations are reshaping industrial energy with cutting-edge solar and storage solutions.
In an industry where energy costs form a significant share of operational expenses, cement manufacturers are increasingly turning to renewable solutions to stay competitive and sustainable. Servotech Renewable Power System, under the leadership of Founder and Managing Director Raman Bhatia, is pioneering advanced solar and storage technologies that not only reduce costs but also redefine how energy-intensive industries like cement operate. In this exclusive conversation, he sheds light on how Servotech’s innovations—from on-grid solar and bifacial panels to patented peak-shaving technology—are transforming industrial energy efficiency while driving progress toward decarbonisation.
How can your on-grid solar systems directly reduce energy costs in cement plants?
Our on-grid solar systems are designed to directly reduce energy costs in cement plants by offsetting a significant portion of their high electricity demand with clean, renewable power. Since cement manufacturing operates on a continuous and energy-intensive scale, drawing power directly from solar during the day helps reduce dependency on the grid, which in turn lowers electricity bills.
With Servotech’s on-grid solar solutions, plants can also take advantage of net metering, ensuring that any surplus power generated is fed back into the grid for credits, further optimising cost savings. Beyond financial benefits, these systems contribute to sustainability goals by reducing reliance on fossil fuels and lowering carbon emissions. By integrating solar into daily operations, cement plants can achieve both long-term cost efficiency and environmental responsibility without compromising their energy reliability.
What efficiency advantages do your Mono PERC or bifacial solar panels?
Our Mono PERC and bifacial solar panels are engineered to deliver high efficiency and reliability, making them especially well-suited for heavy-duty industrial rooftops. With higher energy conversion rates, Mono PERC panels maximise output even in limited rooftop space, allowing cement plants and other large industries to generate more power per square metre. This directly translates into better cost efficiency and faster return on investment.
Bifacial panels add another layer of performance by capturing sunlight from both the front and back. On reflective industrial rooftops, this can significantly boost energy generation and ensure consistent output throughout the day. Combined with Servotech’s on-grid solar solutions, these panels not only enhance overall system efficiency but also provide long-term durability in challenging industrial environments. For energy-intensive operations, this means lower energy costs, higher sustainability impact and greater resilience against fluctuating grid prices.
How does your patented peak-shaving technology enhance energy usage efficiency in energy-intensive operations?
Our patented peak-shaving technology is designed to optimise energy usage efficiency by reducing costly demand spikes that are common in energy-intensive operations. In industries like cement manufacturing, where power consumption can suddenly surge due to heavy machinery, these peaks often translate into higher demand charges on electricity bills. By intelligently managing when and how energy is drawn from the grid and dispatching battery energy storage (BESS) during peak grid usage, we ensure smoother load profiles, lower costs and mitigate tariff exposure.
When integrated with Servotech’s on-grid solar systems, the impact is even greater. Daytime solar covers base loads, while BESS charges from solar or off-peak power and discharges at peak times to avoid grid spikes and maintain stability. This coordinated control improves efficiency and power quality, reduces stress on electrical infrastructure, and delivers reliable operations with predictable energy costs, driving measurable progress toward sustainability goals.
What role do module-level monitoring and inverter tuning play in maintaining peak energy performance?
Module-level monitoring and inverter tuning play a vital role in keeping a solar system operating at peak efficiency. With module-level monitoring, we are able to see the performance of each panel in real time. This level of visibility makes it possible to quickly identify issues like shading, soiling or hardware faults before they impact the overall system. It also allows for proactive maintenance and faster troubleshooting, ensuring minimal downtime and higher long-term energy yields.
On the other hand, inverter tuning, especially through advanced Maximum Power Point Tracking, ensures that every panel produces at its highest possible efficiency. By managing differences caused by shading, ageing or panel mismatch, inverter tuning helps maximise energy output while extending system longevity. Together, these functions ensure that solar arrays continue delivering reliable performance, even as environmental and operational conditions change over time.
Can your hybrid inverters and energy storage systems support continuous power and efficiency for cement operations?
Yes, our hybrid inverters and energy storage systems are engineered to support the demanding requirements of cement operations, ensuring both continuous power and improved efficiency. Cement manufacturing is highly energy-intensive, with grinding mills and kilns requiring consistent, large-scale
power. By integrating storage with hybrid inverters, we are able to manage peak demand, reduce costly demand charges and ensure a reliable power supply for critical equipment.
Equally important, these systems enable seamless transitions between solar, battery and grid power, providing the stability and reliability that cement plants need for uninterrupted production. With advanced energy management software, we can optimise energy use in real time, balancing renewables and storage to lower costs while meeting sustainability goals. While implementation requires careful customisation and investment, the long-term benefits include lower energy costs, improved reliability and meaningful progress toward decarbonisation in one of the most energy-intensive industries.
How has the company’s transition—rebranding to Servotech Renewable Power System—furthered its mission for clean, efficient energy delivery?
Our transition to Servotech Renewable Power System Limited has been a defining step in furthering our mission of clean and efficient energy delivery. By rebranding, we have aligned our identity with our broader vision, covering solar, EV charging, energy storage and next-gen renewable technologies. This shift isn’t just a cosmetic one; it reflects who we are today and where we are headed as a company.
With a focused renewable-centric identity, we are able to communicate our value more effectively, strengthen stakeholder trust and create stronger opportunities for nationwide adoption of sustainable solutions. For us, this rebranding symbolises more than a name change, it’s about reaffirming our responsibility to build a greener tomorrow through innovation, reliability and a commitment to powering India responsibly.
Concrete
The primary high-power applications are fans and mills
Published
1 day agoon
October 10, 2025By
admin
Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.
As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.
How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.
What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.
Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.
Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.
How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.
What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.

Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.
In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.
How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.
What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.
What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.
What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.
How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.
What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.
Concrete
Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport
The airport is set to become Asia’s largest air connectivity hub.
Published
1 day agoon
October 10, 2025By
admin
Enlight Metals has supplied 3,200 metric tonne of steel for the newly inaugurated Navi Mumbai International Airport, marking a major contribution to one of India’s largest infrastructure projects and reinforcing the company’s commitment to supporting national development.
The Navi Mumbai International Airport, developed under a Public-Private Partnership led by the Adani Group, was inaugurated today by Prime Minister Narendra Modi. The airport is set to become Asia’s largest air connectivity hub, enhancing regional connectivity, boosting economic growth, and expanding trade opportunities. Prime Minister Modi described the project as a “glimpse of Viksit Bharat,” highlighting its transformative impact on infrastructure and development in the region.
“The supply of 3,200 metric tonne of steel for this key project aligns with our focus on supporting critical infrastructure development through reliable and timely metal sourcing. Enlight Metals is committed to enhancing transparency and efficiency in the steel supply chain, contributing to projects integral to India’s growth objectives,” said Vedant Goel, Director, Enlight Metals.
Enlight Metals has implemented technology-driven solutions to strengthen supply chain efficiency, ensuring consistent availability of construction materials for large-scale projects nationwide. Its contribution to the Navi Mumbai International Airport underscores the company’s growing role in supporting India’s infrastructure development initiatives.
This milestone reflects Enlight Metals’ ongoing engagement in delivering quality materials and timely services for major national projects, further cementing its position as a reliable partner in India’s infrastructure sector

The primary high-power applications are fans and mills

We conduct regular internal energy audits

Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport

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The primary high-power applications are fans and mills

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Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport

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