Economy & Market

The Refractory Advantage

Published

8 months ago

December 12, 2025

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From AFR-driven chemistry shifts to digitalised kiln monitoring, refractory strategy has become central to operational stability and cost control. Plants that treat refractories as strategic assets and not consumables are redefining efficiency in the modern cement industry. ICR delves into the innovations in refractories and their repercussions on pyroprocessing efficiency in India’s cement industry.

Refractories form the quiet backbone of cement pyroprocessing—absorbing thermal shocks, resisting corrosive chemical attacks, and maintaining process continuity in the most extreme conditions of the plant.
While kiln drives, heat exchangers and burners often dominate conversations, the refractory lining allows a kiln to operate at 1,400–1,500°C daily without structural damage. According to the World Refractories Association, the cement sector accounts for nearly 30 per cent of refractory demand in construction materials industries, driven by the need for monolithic castables, high-alumina bricks and magnesia-based linings. Meanwhile, a report by the Indian Minerals Yearbook states that India is among the top refractory-consuming markets in Asia, driven by capacity expansions, debottlenecking and higher AFR substitution in integrated plants.
What makes refractories strategically important is their direct influence on clinker cost, fuel consumption and kiln efficiency. According to the Bureau of Energy Efficiency (BEE), thermal energy consumption in Indian cement plants ranges from 650–800 kcal/kg of clinker, depending on fuel mix, pyroprocessing stability and technology. Even minor refractory wear triggers cascading inefficiencies. A report by FLSmidth states that coating instability in the burning zone can increase energy use by 3 per cent to 7 per cent, raise free-lime variability and reduce kiln output by up to 10 per cent. These disruptions travel downstream—overloading coolers, damaging clinker granulometry, and affecting grinding systems. Refractory performance is not maintenance—it is margin protection.
Pyroprocessing, however, is evolving faster than ever. High AFR rates, aggressive calciner chemistry and stricter NOx/SOx limits have made “temperature-only” refractory selection obsolete. Modern plants demand linings resilient to thermal cycling, alkali infiltration, and abrasion. They also demand digital eyes inside the kiln, and installation methodologies that compress shutdown windows without compromising life. As India moves toward Net Zero, refractories and pyroprocessing systems are no longer supporting actors—they are the backbone of sustainability and competitiveness.

Kiln lining fundamentals
The rotary kiln remains the thermal heart of every cement plant. It is an environment where temperatures exceed 1,400°C and stresses are constant. The refractory lining is the sole shield between this world and a shell that must remain below 350–400°C to avoid structural failure. According to the World Refractories Association, refractories inside kilns endure 1,200–1,700°C, as well as chemical infiltration from sulphur, alkalis and volatile metals. Each zone brings unique threats: calcining zones see dust impingement, burning zones face clinker abrasion, and coolers battle high mechanical shock. Refractory selection must therefore be a zone-specific exercise balancing heat, chemistry and wear.
Material science underpins this design. A report by RHI Magnesita states that magnesia-spinel and magnesia-hercynite bricks deliver 15 per cent to 25 per cent higher resistance to clinker infiltration than traditional magnesia-chrome options, making them suitable where coating is unstable. According to the Indian Minerals Yearbook, high-alumina bricks, when paired with low-cement castables in transition zones, reduce spalling risk and extend lining life by 20 per cent to 30 per cent. Preheaters and coolers, meanwhile, respond better to abrasion-resistant alumina castables and silicon carbide. Effective refractory design maps these environments to the correct materials, ensuring kiln uptime and stable clinker output.
Beyond chemistry, three disciplines drive lining longevity: thermal elasticity, coating compatibility and installation. A lining that tolerates expansion without cracking, supports protective coating formation and is installed with proper anchoring will outperform a superior material installed badly. Treating refractory installation as a routine shutdown task invites wear, hotspots and premature relining. Modern refractories must work with the process, not merely endure it.

Preheater, calciner and cooler zones: unique refractory demands
Preheaters and calciners are the most aggressive wear environments in pyroprocessing. Fast gas velocities, thermal cycling and volatile chemistry punish linings relentlessly. According to the Portland Cement Association, gas velocities in preheater risers reach 18–22 m/s, with particle loading of 30–40 g/m3, creating intense erosion. Unlike kilns, preheaters rarely develop stable coating layers, making abrasion and thermal shock resistance more critical than temperature tolerance. Calciners intensify chemical stress: AFR combustion, sulphur oxidation and alkali vapours penetrate refractories, demanding low-porosity, chemically stable materials.
Material strategy in these areas differs. Silicon carbide, abrasion-resistant alumina and low-cement castables dominate because they survive dust, vibration and thermal cycling. A report by FLSmidth states that incorrect refractory choice in preheaters can increase pressure drop by 8 per cent to 12 per cent, raise exit temperatures and compromise calcination efficiency—pushing fuel load downstream. According to RHI Magnesita, refractory wear spikes sharply when SO3 in fuels exceeds 1.5 per cent, accelerating alkali-sulphate attack. Refractory strength alone is insufficient—it must align with the gas phase and fuel blend.
The clinker cooler poses a different battle: mechanical shock and direct impact. Abrasive clinker chunks repeatedly strike the lining, often destroying material faster than heat ever could. Abrasion-resistant castables, modular precast blocks or armour tiles are essential to maintain heat recovery and minimise downtime. Plants that treat these zones as extensions of the kiln overlook their unique physics—and pay for it in energy and throughput.

AFR revolution: How changing fuels reshape refractory strategy
Alternative fuels—biomass, RDF, rubber, industrial waste—have transformed kiln chemistry. According to the Global Cement and Concrete Association (GCCA), AFR usage has increased over 60 per cent in the last decade, with European plants reaching 60 per cent to 80 per cent thermal substitution versus 15 per cent to 20 per cent in emerging economies. AFR adoption improves emissions and cost profiles, but destabilises coating, introduces salt vapours and shifts heat profiles—each of which impacts refractory life.
Naveen Kumar Sharma, AVP – Sales and Marketing, Toshniwal Industries, says, “Our solutions are built around four core parameters: energy efficiency, yield loss reduction, product quality and environmental responsibility. These pillars drive our engineering decisions and define how our technologies support cement plants, especially as they adopt alternative fuels and raw materials (AFR). We strongly believe in energy conservation. Every product we offer—whether for thermal monitoring, kiln control or flame optimisation—is engineered to improve energy performance. Reducing yield loss is another principle deeply embedded in our solutions, because production interruptions and material losses directly affect plant profitability and clinker quality. We are also highly conscious of the end-product quality delivered by our customers to their markets. Consistency in burning, heat transfer, and thermal profiling directly influences clinker characteristics, and our instruments help maintain this stability. By optimising flame patterns, energy use, and pollution, our solutions deliver direct and indirect savings. Plants benefit from lower operational losses, reduced maintenance, and improved reliability, especially in pyroprocessing zones.”
Alkalis, chlorine and metals volatilise in hot zones and condense in cooler areas, infiltrating refractory pores. A report by the European Cement Research Academy (ECRA) states that chlorides from plastic-rich fuels reduce lining life by 30 per cent to 50 per cent in burning and preheater zones. According to the International Energy Agency (IEA), high AFR increases NOx/SOx and alkali-sulphate circulation, forcing plants to use higher-grade refractories. VDZ Germany research shows AFR kilns experience more coating instability, accelerating fatigue.
AFR requires moving from “high-temperature resistance” to “high-chemistry tolerance.” Magnesia-spinel and hercynite bricks help resist vapours; abrasion-resistant monolithics handle calciner dust. Plants that swap fuels without revising refractory strategy see premature failure. AFR is not a fuel choice—it is a process redesign requiring burner tuning, sulphur balancing and digital monitoring.

Failure modes and root causes
Refractory failure is rarely material—it is process. Alkali cycles deposit potassium and sodium deep into refractory pores, forming expansion phases. According to the European Cement Research Academy (ECRA), alkali-silica reactions reduce brick strength by up to 40 per cent. Combined with SO3 fuels, alkalis destabilise coating, induce spalling and trigger hotspots. Carbon monoxide damage is subtler. A report by the World Refractories Association states that 500–1,000 ppm CO exposure weakens refractory bonding, causing micro-cracks.
Sunil Kumar Gupta, Chief Project Officer, Star Cement, says, “Thermal profiling and digital monitoring have become essential predictive-maintenance tools for managing kiln and preheater performance. Online shell scanners now provide continuous thermography from inlet to outlet, helping teams assess coating behaviour and refractory health. Drone-based thermography is gaining popularity because it captures hotspots in areas manual checks cannot reach, especially inside cyclones and the calciner during shutdowns. Alongside kiln and cooler cameras, emerging instruments such as cooler-bed thickness sensors further optimise operation. Together, these technologies deliver better KPIs, more stable coating and improved refractory life. Digital data ensures that refractory life is maximised by maintaining stable thermal conditions.”
Thermal shock is mechanical: sudden temperature drops, often 100–150°C during start/stop, fracture high-modulus materials. According to VDZ Germany, uncontrolled thermal cycling shortens burning-zone lining life by 25 per cent to 35 per cent, even if the material is chemically sound. Plants rarely blame combustion or AFR shifts—they blame the brick. Refractories must be read as diagnostic tools, not just consumables.

Shaped vs monolithic refractories
Shaped bricks dominate burning and transition zones. Their dense microstructure resists abrasion and supports coating. According to the World Refractories Association, shaped refractories provide 10 per cent to 20 per cent higher abrasion resistance than castables above 1,400°C. Their modularity preserves shell geometry under load. A report by VDZ Germany states that brick linings withstand 50–60 coating collapse events annually, while monolithics lose strength under repeated instability. Monolithics excel in dynamic wear zones—cyclones, risers, coolers—where jointless continuity resists dust erosion. According to the European Cement Research Academy (ECRA), low-cement castables reduce cold-face heat loss by 8 per cent to 12 per cent and extend cyclone inlet life by 20 per cent to 30 per cent. Anchoring flexibility and rapid installation make monolithics ideal for modern operations.

Installation discipline and shutdown planning
Refractory success is determined at installation—not purchase. Joint thickness, curvature, anchor layout and heating curves matter more than material brochures. A report by the WBCSD–CSI states that poor installation causes over 50 per cent of global refractory failures. In India, compressed shutdowns amplify these risks. Outages carry direct and indirect cost. According to the International Energy Agency (IEA), unscheduled kiln shutdowns increase plant-wide energy consumption by 3 per cent to 6 per cent for 30 days. Plants that treat shutdowns as cross-functional engineering events—not maintenance—see longer lining life and fewer emergencies. Precision is a performance technology.

Digital monitoring, thermal profiling and predictive maintenance
Thermal cameras, shell scanners and kiln-eye systems have replaced intuition. According to the International Energy Agency (IEA), digital monitoring reduces refractory downtime by 20 per cent to 25 per cent. A report by ECRA shows that continuous temperature profiling predicts coating instability up to 48 hours earlier, enabling proactive intervention.
Professor Procyon Mukherjee explains, “Advanced refractory technologies are moving beyond material selection toward engineered performance systems. Next-generation monolithics and castables—enhanced with improved bonding chemistries, nano-modifiers and reduced alkali reactivity—extend campaign life and significantly reduce patch repair frequency. These materials also shorten shutdown windows because they cure faster and offer more predictable installation characteristics, directly lowering kiln downtime. 3D-printed refractory modules and prefabricated assemblies are now being used for burner blocks, riser ducts and throat geometries, allowing bespoke shapes that are difficult or risky to build onsite. Additive manufacturing enables tighter dimensional tolerances and faster installation in constrained spaces, where precise fitting is critical to avoid stress concentrations or mechanical wear.”
“A step further is the emergence of sensorised and embedded-monitoring refractories. Distributed fibre-optic lines, acoustic-emission sensors and integrated thermocouples provide real-time heat maps and detect micro-fracture initiation long before visual damage appears. These systems support condition-based maintenance instead of calendar-based shutdowns, enabling more informed decisions on when and how to intervene. Hybrid lining systems are also gaining traction—pairing high-performance bricks at the hot face with insulating monolithics behind them to optimise both cost and thermal reliability. Industry trials and publications from 2023–25 show early adoption of these technologies, with predictive analytics and sensor-embedded linings proving especially impactful in reducing unplanned outages and extending refractory life” he adds.
Predictive maintenance is the next frontier. According to ABB Industrial Analytics, AI systems cut unscheduled stoppages by 30 per cent to 50 per cent and extend refractory life. Plants that digitise pyroprocessing gain higher uptime, smoother ramp-ups and safer AFR adoption.

Retrofit pathways for older kiln lines
Older kilns are not obsolete—they are underutilised. According to the International Energy Agency
(IEA), targeted system upgrades improve clinker efficiency by 10 per cent to 15 per cent without new CAPEX. A report by GCCA states that retrofit optimisation reduces fuel by 3 per cent to 6 per cent. Retrofits begin with refractories: replacing chrome bricks, deploying abrasion monolithics, adding shell monitoring.
Their power is modularity. As per VDZ Germany, switching riser bricks to monolithics extends lining life by 20 per cent to 30 per cent and speeds installation by up to 35 per cent. Plants that treat old kilns as living systems—not legacy assets—win.

Towards Net Zero
Net Zero is a kiln stability challenge. GCCA claims that decarbonisation demands lower clinker intensity, higher AFR and efficiency—all refractory-dependent. A report by the IEA states that thermal improvements deliver 16 per cent to 20 per cent of total CO2 reduction, unattainable without coating stability and engineered refractories.
For India, incremental efficiency is everything. Proper refractory selection extends lining cycles by 25 per cent to 35 per cent, lowering shutdown emissions and volatility. Plants that view refractories as strategic assets—not consumables—achieve uptime, kWh/tonne improvement and real Net Zero momentum, according to VDZ Germany.

Conclusion
A new refractory philosophy is emerging in the cement industry—one where materials, process control, digital monitoring and shutdown discipline work together as a single ecosystem. Plants that still treat refractories as a replaceable commodity inevitably fall into cycles of premature wear, coating instability and soaring maintenance cost. But those that integrate material science with pyroprocessing logic—choosing the right brick for the right zone, using abrasion-resistant monolithics where needed, planning installations with precision, and upgrading older lines with smarter systems—are consistently outperforming their peers. In a market defined by tighter margins, unpredictable fuels, and rising sustainability expectations, refractories have become a lever of efficiency, not an afterthought.
The path forward is clear: engineered materials, digitalised diagnostics, predictive maintenance and intelligent retrofit strategies will shape the future of cement pyroprocessing. As AFR substitution grows, kiln loads intensify and environmental standards tighten, refractory solutions will evolve from passive armour to active enablers of reliability and emissions control. The plants that recognise refractories as strategic assets—rather than shutdown consumables—will unlock longer campaigns, lower kWh per tonne, greater clinker consistency and fewer disruptive outages. In that future, the kiln lining is not only a protective layer—it is the foundation on which India’s cement producers will build resilience, competitiveness and meaningful progress toward Net Zero.

– 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.