Economy & Market

Clearing the Air in Cement

Published

10 months ago

October 10, 2025

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Effective dust control defines the health, efficiency, and sustainability of every modern cement plant. ICR explores how advanced filtration, smart design, and vigilant monitoring are shaping cleaner, compliant, and future-ready operations.

The generation of dust in cement production is far from a mere nuisance — it carries serious health, environmental, and operational consequences. In many industrial hubs across India, concentrations of PM2.5 and PM10 routinely exceed both national and World Health Organisation limits, intensifying respiratory and cardiovascular burdens on surrounding communities and workers. According to a review in Cement Industry Pollution and Its Impact on the Environment (MDPI), chronic exposure to cement dust is linked to impaired lung function, bronchitis, asthma, and even cardiovascular ailments.
Moreover, dust does not only threaten human health — it corrodes machinery, reduces equipment life, and degrades product quality through contamination. In cement plants, uncontrolled emissions from mills, crushers, coolers, and material handling can lead to 7–10 per cent loss of product as fugitive dust. This hidden inefficiency translates into higher energy costs, increased maintenance and consumables, and compromised environmental performance. It’s therefore not just an issue of compliance — dust control is integral to both operational excellence and sustainable stewardship.

Sources of dust across the cement process
Dust generation in cement manufacturing begins right at the source: raw material handling and preparation. Bulk material movement — loading, unloading, conveying, and crushing of limestone, clay, and other raw feed — liberates particulates, especially fine dust. According to dust-monitoring sources, clinker coolers, crushers, grinders, and material-handling equipment are among the principal dust emission points within a plant. In addition, the preheating and pyroprocessing zones see fugitive dust from kiln feed handling, preheater cyclones, and internal recirculation flows — all of which require robust interception and filtration upstream of the main stack.
Clinker production and cooling stages are especially dust-intensive, because hot clinker is quenched and cooled, releasing fine particulates and dust. According to Cement Industry Pollution and Its Impact on the Environment, particulate emissions remain one of the key pollution sources throughout cement production, including from kiln and cooler exhausts. In many plants, coolers’ air discharge carries significant dust load unless intercepted through bag filters or dedusting units. Moreover, in clinker transport and storage — including rotary or bucket transfer systems — mechanical abrasion and wind entrainment can cause further dust losses.
The cement grinding and packing section also contributes substantial dust emissions. The fine grinding of clinker, gypsum, and additives creates ultra-fine particles that can escape if mill circuits, separators, or filter stages are not optimally designed. Material spillage, pneumatic conveying, and packaging operations are common sources of fugitive dust in this zone. In operational literature, raw material handling followed by cement grinding are regularly cited as among the highest dust contributors in a cement plant.
Lalit Joshi, Co-Founder and Director, LeapThree Materials says, “Advanced non-woven materials are using different high-performance fibres and blending of the same to achieve effective and customised solutions for the projects and individual units to meet the targets sets by stringent emission norms. Though we are far from the western countries benchmark of allowed emission, but it has come down drastically in recent years and plants are also doing all the compliance using advanced materials made using high performance fibres like polyacrylonitrile, meta aramid and poly imide.”

Filtration technologies
Filtration is central to dust control in cement plants, because even with preventive design measures, residual particulates must still be captured before flue gases are emitted. Among the most widely used systems today are fabric filters (bag filters), electrostatic precipitators (ESPs), and hybrid combinations or newer gas-cleaning technologies. According to a review in Journal of International Society for Science and Engineering (2025), fabric filters boast superior performance in capturing fine particulate matter, largely independent of gas conditions, making them especially effective for meeting stringent emission norms. ESPs remain favoured in some high-temperature stages due to their ability to operate with lower pressure drop and lower parasitic energy when conditions are ideal, but they are sensitive to gas composition and require careful design.
In practice, many plants have shifted from ESPs to bag filters—or retrofitted existing ESPs into hybrid configurations—to meet stricter emission standards. In fact, utility in the cement industry has shown that replacing ESPs with bag filter systems can reduce outlet dust concentrations from around 35 mg/m³ down to 6 mg/m³. According to Improvement of Cement Plant Dust Emission by Bag Filter (2018), this also yielded a marginal CO2 reduction by virtue of lower electricity consumption. Such performance gains are a driving factor behind the trend: many industry voices now regard bag filters as the new benchmark for gas filtration in cement plants, especially in plants aiming for ultra-low emissions.
Yet filtration systems are not without challenges. Filter media degrade over time, leakage or bag damage can erode performance, and maintenance becomes critical. A recent study A Study on Failure Rate, Reliability, and Collection Efficiency Trend of Bag Filters in a Cement Plant (2023) observed that while bag filters can achieve initial efficiencies approaching 99.998 per cent, collection efficiency may decline to ~95.05 per cent by the 15th year of service. To sustain high performance, design must account for filter area, pulse cleaning strategy, gas flow distribution, fabric selection (e.g. temperature resistance, chemical resistance), and ease of maintenance access. Hybrid systems—combining ESPs, cyclones, or scrubbers with bag filters—are increasingly popular in complex gas streams to balance efficiency, energy consumption, and reliability.

Prevent, optimise, maintain and monitor
Preventive design and process optimisation form the first line of defence in effective dust control — the goal is to minimise dust generation before filtration even begins. Thoughtful layouts of conveyors, transfer points, drop heights, and enclosure strategies can substantially reduce entrainment. For example, optimising air velocities to keep dust entrained, ensuring proper duct slopes, and minimising sharp drops in material transfer all help suppress fugitive emissions. Using enclosed and covered conveyor systems, choke points, and inerting measures further curbs dust liberation. In the context of cement plants, integrating dust minimisation into process design — for instance by matching pneumatic transport pressures, reducing material tumbling, and limiting turbulence — creates a baseline reduction in the dust load that filtration systems must handle.
Maintenance and monitoring are equally crucial for sustaining filtration effectiveness over the long term. Even the best-designed system will lose performance if leaks, worn media, or dirty filters go undetected. According to A Study on Failure Rate, Reliability, and Collection Efficiency Trend of Bag Filters in a Cement Plant (2023), collection efficiency of bag filters can fall from 99.998 per cent in the early years down to ~95.05 per cent by the 15th year, underscoring the need for vigilant upkeep. Regular inspections, bag leak detection systems, and real-time monitoring of differential pressures and gas flows help identify underperforming compartments before they compromise overall performance. Use of distributed optical fibre or pressure sensing within baghouses is increasingly being explored to localise bag failures.
Jerad Heitzler, Training Manager, Martin Engineering says, “Dust emissions don’t just create a harmful environment for those working in the area. Abrasive particulates make their way into exposed machine parts and rolling components, causing them to wear quicker, seize and require replacement sooner. Particulates also clog air intakes of nearby equipment, further raising the need for maintenance and downtime. Then as it settles, dust builds up to cover walkways and stairs, engulfing control units, obscuring signage and, in some cases making access for maintenance impossible without a full shutdown and clean-up.”
To optimise maintenance planning, predictive and condition-based strategies are becoming indispensable. Rather than rigid maintenance schedules, data-driven health indices (e.g. pressure drop trends, pulse valve performance, vibration, temperature anomalies) can trigger maintenance only when needed, reducing unnecessary downtime. Application of preventive maintenance scheduling models, such as those developed via mathematical programming or metaheuristic algorithms, helps cement plants balance reliability and cost in their bag filter programmes. This approach ensures both high dust collection performance and economic operation over the life of the system, turning filtration integrity into a reliable contributor to sustainable plant operation.

Energy and cost
Energy consumption is a significant component of the cost equation when deploying dust filtration systems — the energy needed to drive fans, maintain pressure differentials, and operate cleaning pulses adds up. According to Energy Benchmarking Manual for the Indian Cement Industry (2023), many Indian cement plants are already among the world’s most efficient, yet still have considerable headroom for energy improvements given the wide performance spread across the industry. In fact, in cement manufacturing more broadly, energy expenditures (fuel + electricity) often account for 20-40 per cent of total production costs. Thus, any inefficiency in filtration — high resistance, leaks, or excessive cleaning cycles — directly burdens the bottom line.
On the upside, well-designed filtration systems and process integration can actually yield energy savings and cost reduction. For example, deploying advanced waste-heat recovery (WHR) solutions can lower clinker costs by 3.81 per cent and cut indirect CO2 emissions substantially, making the overall process more energy efficient. Moreover, optimising filter design — reducing pressure drop, improving gas flow distribution, using pulses more judiciously, and selecting low-resistance fabric — can diminish fan power demand. In the context of dust collection, using reverse-air regeneration or intelligent control to avoid over-cleaning can further trim energy use. In sum, the cost of filtration should be viewed not merely as a parasitic load but as an opportunity: every kilowatt saved reinforces the case for high-performance, low-emission plant design.

Regulatory framework and emission standards
India has a structured regulatory framework governing emissions and dust control, primarily enforced through the Central Pollution Control Board (CPCB) under the Environment (Protection) Act, Air Act, and allied rules. The CPCB has issued Guidelines for Continuous Emission Monitoring Systems (CEMS) to ensure real-time measurement of stack pollutants including particulates, SO2 and NOx, and mandates minimum stack heights (usually 30 m) to assist dispersion. In addition, ambient air quality norms (National Ambient Air Quality Standards, NAAQS) set upper limits for PM2.5 and PM10 concentrations in industrial zones, which industries must help adhere to through emission control.
More recently, regulatory impetus is tightening further: many state pollution control boards are demanding stricter limits on particulate emissions (e.g. 50 mg/Nm³ target values), zero or minimal fugitive emissions plans, and rigorous leak-detection and control systems. According to a report by emerging industrial norms, plants failing to comply with emission or fugitive dust standards may face penalties, closure orders or forced remedial action. Moreover, environmental clearances for new expansions and modernisation increasingly require demonstration of best available technologies (BAT) for dust control and air pollution—pushing filtration systems and process optimisation into the sphere of not just compliance but strategic investment.

Conclusion
The road to sustainable air management in the cement industry lies in recognising that dust control is no longer an operational add-on but a defining feature of modern plant design and environmental stewardship. From quarry to kiln and grinding to packing, every stage of production now demands an integrated approach that prioritises preventive design, energy-efficient filtration, and continuous monitoring. With CPCB’s tightening emission
norms and global ESG expectations, compliance has evolved into a matter of reputation and resilience. A truly sustainable plant must minimise its particulate footprint not only within regulatory limits but also in alignment with community expectations and climate objectives. The cement sector, as one of India’s most energy- and emission-intensive industries, stands to gain enormously by embedding smart dust control and air-management strategies into its sustainability roadmap.
Looking ahead, the convergence of digitalisation, advanced materials, and predictive maintenance will redefine how cement plants manage air quality. Data-driven diagnostics, AI-assisted leak detection, and adaptive fan-control systems will ensure filtration operates at peak efficiency while conserving energy. But technology alone cannot deliver sustainability; it must be matched with a culture of accountability, skilled workforce training, and continuous process improvement. The journey towards sustainable air management is, therefore, not just about cleaner stacks — it is about creating plants that breathe efficiency, responsibility, and innovation into every cubic metre of air they release.

– Kanika Mathur

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Economy & Market

The Road Ahead Begins Here

Published

1 day ago

August 11, 2026

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The future of India’s roads took centrestage at RAHSTA Expo 2026, where policymakers, contractors and industry leaders came together under one roof. The event blended thought leadership, technology showcase and industry recognition into a single powerful platform.

India’s roads and highways community gathered in full strength at the Jio World Convention Centre, Mumbai, for the 16th edition of the RAHSTA Expo (Roads and Highways Sustainable Technologies & Advancement). Over two action-packed days, the event brought together policymakers, contractors, consultants, developers, equipment manufacturers, material suppliers, technology providers and investors to deliberate on the future of India’s ,infrastructure while showcasing the latest innovations driving the sector.

The event culminated in the prestigious RAHSTA Awards, where Shri. Ajay Tamta, Union Minister of State for Road Transport & Highways, felicitated organisations and professionals for their outstanding contributions to road construction, engineering, safety, sustainability and technology. With leading contractors, senior government officials, industry veterans and technology providers under one roof, the event reaffirmed RAHSTA’s position as one of India’s most influential platforms for the roads, highways, bridges and tunnels ecosystem.

Organised by FIRST Construction Council in association with ASAPP Info Global Group, RAHSTA has steadily evolved beyond an exhibition into a platform where policy, technology, engineering and business converge to address the opportunities and challenges shaping India’s next generation of transport infrastructure.

Beyond expansion, towards value

The conference opened with a thought-provoking address by Pratap Padode, Founder and Editor-in-Chief, Construction World, who observed that India’s highways sector has reached an important inflection point. Introducing this year’s theme – ‘From Expansion to Value: The Next Phase of India’s Highways’ – he noted that while the country has successfully expanded its road network over the past two decades, the industry’s priorities are now shifting towards building infrastructure that delivers greater lifecycle value, durability, safety and operational efficiency. With funding pressures, asset monetisation and evolving project models changing the sector’s dynamics, he said the focus must now move beyond kilometres constructed to the quality and long-term performance of every asset.

Dr Brijesh Dixit, Managing Director, Maharashtra State Infrastructure Development Corporation (MSIDC), reminded delegates that successful infrastructure delivery is ultimately a collective effort. Emphasising on collaboration between government, industry and engineering professionals, he remarked, “There is no loser in a winning team, and there is no winner in a losing team,” urging stakeholders to work together to deliver projects with quality, financial sustainability and technological excellence.

Delivering the keynote address, Bidur Kant Jha, Director, New Technologies for Highway Development, Ministry of Road Transport & Highways (MoRTH), outlined the Government’s long-term vision for India’s highway network. Highlighting the country’s 6.26 million km roads network, he spoke about the growing adoption of digital planning tools such as BIM and GIS, bridge health monitoring systems and Integrated Smart Transport Corridors under the Vision 2047 roadmap. He emphasised that while India remains open to global innovations, every new technology must be adapted to Indian conditions before large-scale deployment.

Addressing the gathering during the awards ceremony, Tamta underlined the increasing role of specialised equipment and modern construction technologies in executing complex infrastructure projects across diverse terrains. Referring to challenging tunnel projects in Uttarakhand, he noted how advanced machinery has transformed execution capabilities, while also acknowledging the rapid evolution of Indian contractors into globally competitive infrastructure companies. Recognising excellence through industry awards, he said, motivates organisations to continually raise performance standards and embrace innovation.

Meanwhile, Dr Sanjay Mukherjee, IAS, Metropolitan Commissioner, MMRDA, highlighted that infrastructure development must increasingly focus on integrated urban mobility. Reflecting on Mumbai’s engineering journey – from its historic underground utility network to the Coastal Road and other transformative projects – he underlined that future infrastructure planning must seamlessly integrate roads, metro systems and public transport to create efficient, multimodal cities.

Uttar Pradesh takes centrestage

One of the highlights of the second day was Uttar Pradesh’s comprehensive presentation on its infrastructure-led industrial transformation.

Srihari Pratap Shahi, IAS, Additional CEO, Uttar Pradesh Expressways Industrial Development Authority (UPEIDA), demonstrated how the state’s expanding expressway network is evolving into a catalyst for industrial development through integrated manufacturing and logistics clusters. Expressways, he noted, are no longer merely transport corridors but engines of economic competitiveness.

Building on this narrative, Deeksha Jain, IAS, Additional Chief Executive Officer, Uttar Pradesh State Industrial Development Authority (UPSIDA), showcased the state’s rapidly expanding industrial ecosystem supported by extensive expressway connectivity, dedicated freight corridors, airports, industrial townships and investor-friendly policies. She highlighted Uttar Pradesh’s strong manufacturing growth, expanding industrial land bank, plug-and-play infrastructure and increasing use of digital governance to facilitate investments.

Further underlining the significance of the platform, Deepak Kumar, IAS, Infrastructure & Industrial Development Commissioner, Government of Uttar Pradesh, remarked, “RAHSTA provides an excellent platform for states to showcase our infrastructure progress and investment ecosystem. Uttar Pradesh has transformed significantly over the past decade, backed by more than 34 investor-friendly industrial policies, and platforms like RAHSTA help communicate these developments to industry stakeholders from across the country.”

Ideas that shaped the industry conversation

The two-day conference featured seven panel discussions, each examining a critical dimension of India’s evolving roads and highways sector.

The opening discussion on ‘Financing Roads & Highways in a Capital-Constrained Era’ brought together experts from Cube Highways, NIIF, SBI Capital Markets, Centrum Capital and Bandhan Infra Fund, who examined how the financing landscape is changing. Discussions revolved around asset monetisation, InvITs, institutional investments and new funding structures, with panellists agreeing that better project preparation, transparent governance and predictable returns will be crucial for attracting long-term capital into infrastructure.

Attention then shifted to execution realities during the panel on ‘Contractors’ Perspective: Execution Realities, Risks & the Quality Imperative.’ Representatives from GHV Infra Projects, PNC Infratech, NCC and Maccaferri candidly discussed the challenges of delivering projects amid contractual complexities, land acquisition delays, rising costs and tight timelines. While execution pressures remain significant, the discussion reinforced that better collaboration across the project value chain is essential for achieving both speed and quality.

Day 2 opened with a technically rich discussion on ‘Designing Roads for Sustainability, Durability & Climate Resilience’. Experts from CSIR-CRRI, IIT Bombay, IIT Madras, Zydex Group and SRMB Steel explored advanced pavement technologies, recycled materials, climate-resilient designs and scientific construction practices that can significantly improve durability while lowering lifecycle costs. Sustainability, they agreed, must become an integral part of road design rather than an afterthought.

The subsequent session on ‘Bridges & Tunnels: Complex Engineering, Safety & Future Readiness’ highlighted the growing complexity of India’s infrastructure projects. Panellists discussed advances in structural engineering, digital monitoring, risk management and safety practices that are enabling the successful delivery of increasingly ambitious bridge and tunnel projects across the country.

Technology remained a recurring theme during the discussion on ‘Technology as a Risk-Mitigation Tool for Developers & Investors’. Experts explained how AI, BIM, drones, predictive analytics, digital twins and intelligent monitoring systems are helping improve project planning, minimise execution risks, strengthen quality assurance and enhance asset management throughout the infrastructure lifecycle.

The construction equipment panel brought together leading industry experts to examine how technology, sustainability and digitalisation are redefining construction equipment in an era of rising cost pressures. Discussions centred on enhancing productivity, reducing lifecycle costs and preparing the industry for India’s infrastructure ambitions leading up to 2047.

The conference concluded with an engaging CXO Forum on ‘Rebuilding Confidence in India’s Roads & Highways Sector’, where senior industry leaders emphasised that stronger governance, better project preparation, digitalisation, transparent contracting and closer public-private collaboration will be essential to sustain India’s infrastructure growth over the coming decades.

Technology and recognition under one roof

Beyond the conference halls, RAHSTA Expo reflected the technological transformation underway across India’s road infrastructure ecosystem. Leading equipment manufacturers, technology companies and material suppliers showcased advanced construction equipment, intelligent digital platforms, pavement technologies, structural materials and productivity-enhancing solutions designed to improve project efficiency and asset performance. The exhibition created valuable opportunities for contractors, consultants, government agencies and project developers to evaluate new technologies while interacting directly with solution providers.

The event also served as a celebration of excellence through the RAHSTA Awards 2026, which recognised outstanding achievements across road construction, contracting, materials, equipment, technology, safety, sustainability and infrastructure development. Presented by Minister Tamta, the awards honoured organisations that are setting new benchmarks for quality, innovation and execution across India’s roads sector.

RAHSTA Expo 2026 also received extensive support from across the infrastructure ecosystem. Alongside leading corporate sponsors, the event was backed by industry bodies including the Builders Association of India (BAI), Construction Equipment Rental Association (CERA), Consulting Engineers Association of India (CEAI), International Road Federation (IRF), CSIR-CRRI, CILT India, All India Transporters Welfare Association, Hydraulic Trailer Owners Association (HTOA), Gujarat Contractors Association, Bitumen Forum, Fluid Power Society of India, Indian Institute of Material Management, Ministry of Ports, Shipping and Waterways, Gati Shakti Vishwavidyalaya and Mumbai First, reflecting the industry’s collective commitment to advancing India’s road infrastructure.

As the curtains came down on the two-day event, one message resonated throughout the conference: India’s highways story is entering a new chapter. While expansion will continue, the future will increasingly be defined by smarter planning, stronger partnerships, digital transformation, sustainable engineering and long-term value creation. By bringing together the entire infrastructure value chain on a single platform, RAHSTA Expo 2026 once again demonstrated why it has become one of the country’s most influential forums for shaping the future of roads, highways, bridges and tunnels.

Economy & Market

Fornnax Names Lukas Baur as Authorised Service Partner to Bolster EU Operations

Published

3 weeks ago

July 23, 2026

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Strapline: Fornnax Technology has appointed NOBA Maschinenservice’s Lukas Baur as its authorised service partner for the European Union, strengthening its commitment to delivering fast, reliable, and localised after-sales support across the region.

Fornnax Technology, a leading manufacturer of industrial shredding solutions, has announced the appointment of Mr. Lukas Baur of NOBA Maschinenservice as its authorised service partner for the European Union. The partnership, formalised under the authorisation of Fornnax CEO Mr. Jignesh Kundaria, reinforces the company’s commitment to providing dependable, localised service support to its expanding customer base across Europe.

Strengthening Service Through Proven Expertise

With over two decades of experience in servicing, maintaining, and overhauling industrial shredders, Mr. Baur brings extensive technical expertise to the partnership. His capabilities span welding, hardfacing, shaft and knife rebuilding, complex assembly, hydraulics, and complete electrical engineering services, delivered in collaboration with a trusted partner company based in Halle/Saale.

Operating from Worbis, Germany, Mr. Baur is strategically positioned to provide emergency support across the European Union within 24 hours, covering an operational radius of approximately 1,000 kilometres.

Supporting this capability is a well-equipped service infrastructure comprising 12 Mercedes Sprinter service vans, a team of 24 skilled technicians, specialised bearing-change tools, a fully equipped hydraulic workshop, and a 1,000-square-metre facility with a five-ton crane track. Together, these resources position his team to manage the complete spectrum of Fornnax’s European service requirements efficiently and reliably.

Partnership Driven by Industry Insight

Having spent years servicing Eldan, Lindner, and Vecoplan shredders across the European recycling industry, Mr. Baur’s decision to collaborate with Fornnax is rooted in his understanding of market needs and customer expectations. His experience has provided valuable insight into what recycling plant operators require—not only from their machinery but also from the service teams supporting them.

According to Mr. Baur, Fornnax’s reputation for robust machine construction, superior wear protection, and maintenance-friendly design made the partnership a natural fit.

The collaboration comes at a time when Europe’s tyre recycling industry is facing mounting challenges, including rising cost pressures, shrinking margins, delayed investments, and a shortage of skilled labour. Mr. Baur believes these conditions reinforce the need for technically strong service partners capable of delivering rapid, dependable support.

Commenting on the partnership, he said, “Fornnax, with its exceptional price-performance ratio and superior quality, has the potential to become a market leader in Europe. We would like to be their service partner in this journey.”

Comprehensive Support Across the Equipment Lifecycle

As Fornnax’s authorised service partner, Mr. Baur will oversee the complete lifecycle support of the company’s equipment throughout the European Union. His responsibilities will include installation, commissioning, preventive maintenance, emergency repairs, and spare parts support across mechanical, hydraulic, and electrical systems.

Looking ahead, he also plans to develop a centralised spare parts distribution hub for European customers, particularly if Fornnax establishes a warehouse facility in Worbis to facilitate faster deliveries. To further strengthen service coverage, Mr. Baur intends to expand operations by adding two to three additional service teams and vehicles each year, progressively increasing capacity across the continent.

A Shared Commitment to Customer Excellence

Highlighting the strategic importance of the partnership, Mr. Jignesh Kundaria, Director and CEO of Fornnax, said:

“We strongly believe that by continuously improving our service quality and customer satisfaction index, we can build long-term relationships with our customers. Higher customer satisfaction leads to greater trust, which significantly increases repeat orders and ultimately drives sustained growth in our sales revenue.”

This customer-first philosophy underpins Fornnax’s strategy of building a dedicated European service partner network instead of relying solely on remote support. With Mr. Baur joining this network, customers across the European Union will benefit from faster response times, expert technical assistance, and dedicated on-ground support from a partner with extensive experience in high-throughput shredding operations.

Mr. Baur’s appointment also reflects Fornnax’s broader ambition to establish itself as the preferred shredding solutions provider for the European recycling industry, marking another important milestone in the company’s international growth strategy.

Concrete

Nuvoco Vistas launches Limla cement plant, expands Gujarat footprint

Published

1 month ago

July 13, 2026

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Nuvoco Vistas opens a 2 MMTPA grinding unit at Limla, entering Gujarat and advancing its target of 35 MMTPA capacity by FY 2028.

Surat (Gujarat)

Nuvoco Vistas Corporation Ltd, a part of Nirma Group and one of India’s leading building materials company, has inaugurated the Limla Cement Plant in Surat (Gujarat), one of Vadraj Cement Limited’s (VCL) principal manufacturing facilities. The commissioning represents a key milestone in Nuvoco’s acquisition and restoration of VCL, while supporting the company’s expansion across the Western Indian cement market.

Vadraj Cement Limited is a subsidiary of Nuvoco Vistas Corporation Limited and has installed cement capacity of 6 MMTPA across its assets. The Limla inauguration therefore represents the first operational step in the acquired platform’s wider revival, while the Kutch facilities provide clinker supply, mineral security and coastal logistics support for the western business.

Nuvoco completed its acquisition of Vadraj Cement Limited, then under the Corporate Insolvency Resolution Process, after paying a consideration of Rs 1,800 crore in June 2025. VCL’s asset portfolio comprises a clinker unit at Kutch and a grinding unit at Limla in Surat. It also includes high-quality captive limestone reserves and a captive jetty at Kutch, supporting more efficient logistics. Following the takeover, Nuvoco began an extensive programme of restoration, refurbishment and expansion at both locations, leading to the commissioning of the Limla plant.

The Limla Cement Plant is expected to support a phased increase in sales volumes across Gujarat. It will also help Nuvoco supply neighbouring markets in Western Maharashtra and release cement capacity from its northern plants, which can consequently be redirected towards markets in North India. The plant will manufacture a full portfolio comprising Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. It will additionally produce the complete Nuvoco Duraguard range, including the premium Nuvoco Duraguard Microfibre product. The acquisition is also expected to generate operational synergies with Nuvoco’s existing plants at Nimbol and Chittorgarh in Rajasthan, improving logistics optimisation and market reach across important regional markets.

The grinding unit at the Limla Cement Plant was completed ahead of schedule, with 2 MMTPA of capacity now inaugurated to expand Nuvoco’s operating scale and customer reach. After Vadraj Cement’s assets become fully operational, plants in North and West India are expected to account for nearly 40 per cent of Nuvoco’s total cement capacity. This will broaden the company’s manufacturing network, strengthen access to high-growth markets and support its plan to increase consolidated cement capacity to 35 MMTPA by FY 2028, reinforcing its longer-term growth strategy.

Commenting on the development, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said: “The inauguration of the Limla Grinding Unit in Surat is an important milestone in Nuvoco’s growth journey and demonstrates our commitment to disciplined, value-accretive expansion. Gujarat is strategically significant for Nuvoco, with substantial opportunities arising from infrastructure investment, industrial growth, rapid urbanisation and continuing demand from the housing and construction sectors. The facility strengthens our regional footprint, improves operational flexibility and increases our ability to serve customers across northern and western markets with greater reliability and efficiency.”

He added: “Through the Vadraj acquisition, we have refurbished and restarted a strategically important asset, returning it to operations in record time through strong execution and collaboration between teams. The achievement demonstrates our ability to create value from acquired assets, fulfil our commitments and retain the confidence of stakeholders. It also highlights the strength of our project delivery capabilities and our continued focus on building sustainable, profitable growth over the long term.”

Nuvoco Vistas Corporation Limited is a building materials company whose vision is to build a safer, smarter and more sustainable world. It is among the leading players in East India and has a significant presence across North and West India. Nuvoco began operations in 2014 with a greenfield cement plant at Nimbol, Rajasthan. It later acquired Lafarge India Limited, which had entered India in 1999, followed by Emami Cement Limited in 2020 and Vadraj Cement Limited in April 2025. The company has also announced an expansion in eastern India through a new grinding mill at the Arasmeta Cement Plant, supported by several debottlenecking programmes involving equipment upgrades, process improvements and internal capacity initiatives. These developments place Nuvoco on track to achieve total cement capacity of approximately 35 MMTPA. The company reported total income of Rs 11,362 crore in FY 2025-26, reflecting its continuing growth trajectory.

Nuvoco operates a diversified portfolio across three segments: Cement, Ready-Mix Concrete and Modern Building Materials. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem, covering Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. Its pan-India RMX business provides value-added products under Concreto for performance concrete, Artiste for decorative concrete, InstaMix for ready-to-use bagged concrete, X-Con covering M20 to M60 grades, and Ecodure for specialised green concrete. Nuvoco has supplied materials to projects including the Mumbai-Ahmedabad Bullet Train, Birsa Munda Hockey Stadium in Rourkela, Aquatic Gallery at Science City in Ahmedabad, and metro railway projects in Delhi, Jaipur, Noida and Mumbai.