Dr Y Chandri Naidu, Chief Technology Officer, Nextcem Consulting highlights how digital technologies are enabling Indian cement plants to improve efficiency, reduce emissions, and transition toward sustainable, low-carbon manufacturing.

Cement manufacturing is inherently resource- and energy-intensive due to high-temperature clinkerisation and extensive material handling and grinding operations. In India, where cement demand continues to grow in line with infrastructure development, producers must balance capacity expansion with sustainability commitments. Energy costs constitute a major share of operating expenditure, while process-related carbon dioxide emissions from limestone calcination remain unavoidable.
Traditional optimisation approaches, which are largely dependent on operator experience, static control logic and offline laboratory analysis, have reached their practical limits. This is especially evident when higher levels of alternative fuel and raw materials (AFR) are introduced or when raw material variability increases.
Digital technologies provide a systematic pathway to manage this complexity by enabling
real-time monitoring, predictive optimisation and integrated decision-making across cement manufacturing operations.
Digital cement manufacturing is enabled through a layered architecture integrating operational technology (OT) and information technology (IT). At the base are plant instrumentation, analysers, and automation systems, which generate continuous process data. This data is contextualised and analysed using advanced analytics and AI platforms, enabling predictive and prescriptive insights for operators and management.

Digital optimisation of energy efficiency

• Thermal energy optimisation
  The kiln and calciner system accounts for approximately 60 per cent to 65 per cent of total energy consumption in an integrated cement plant. Digital optimisation focuses on reducing specific thermal energy consumption (STEC) while maintaining clinker quality and operational stability.
  Advanced Process Control (APC) stabilises critical parameters such as burning zone temperature, oxygen concentration, kiln feed rate and calciner residence time. By minimising process variability, APC reduces the need for conservative over-firing. Artificial intelligence further enhances optimisation by learning nonlinear relationships between raw mix chemistry, AFR characteristics, flame dynamics and heat consumption.
  Digital twins of kiln systems allow engineers to simulate operational scenarios such as increased AFR substitution, altered burner momentum or changes in raw mix burnability without operational risk. Indian cement plants adopting these solutions typically report STEC reductions in the range of 2 per cent to 5 per cent.
• Electrical energy optimisation
  Electrical energy consumption in cement plants is dominated by grinding systems, fans and material transport equipment. Machine learning–based optimisation continuously adjusts mill parameters such as separator speed, grinding pressure and feed rate to minimise specific power consumption while maintaining product fineness.
  Predictive maintenance analytics identify inefficiencies caused by wear, fouling or imbalance in fans and motors. Plants implementing plant-wide electrical energy optimisation typically achieve
  3 per cent to 7 per cent reduction in specific power consumption, contributing to both cost savings and indirect CO2 reduction.

Digital enablement of AFR
AFR challenges in the Indian context: Indian cement plants increasingly utilise biomass, refuse-derived fuel (RDF), plastic waste and industrial by-products. However, variability in calorific value, moisture, particle size, chlorine and sulphur content introduces combustion instability, build-up formation and emission risks.
Digital AFR management: Digital platforms integrate real-time AFR quality data from online analysers with historical kiln performance data. Machine learning models predict combustion behaviour, flame stability and emission trends for different AFR combinations. Based on these predictions, fuel feed distribution, primary and secondary air ratios, and burner momentum are dynamically adjusted to ensure stable kiln operation. Digitally enabled AFR management in cement plants will result in increased thermal substitution rates by 5-15 percentage points, reduced fossil fuel dependency, and improved kiln stability.

Digital resource and raw material optimisation
Raw mix control: Raw material variability directly affects kiln operation and clinker quality. AI-driven raw mix optimisation systems continuously adjust feed proportions to maintain target chemical parameters such as Lime Saturation Factor (LSF), Silica Modulus (SM), and Alumina Modulus (AM). This reduces corrective material usage and improves kiln thermal efficiency.
Clinker factor reduction: Reducing clinker factor through supplementary cementitious materials (SCMs) such as fly ash, slag and calcined clay is a key decarbonisation lever. Digital models simulate blended cement performance, enabling optimisation of SCM proportions while maintaining strength and durability requirements.

Challenges and strategies for digital adoption
Key challenges in Indian cement plants include data quality limitations due to legacy instrumentation, resistance to algorithm-based decision-making, integration complexity across multiple OEM systems, and site-specific variability in raw materials and fuels.
Successful digital transformation requires strengthening the data foundation, prioritising high-impact use cases such as kiln APC and energy optimisation, adopting a human-in-the-loop approach, and deploying modular, scalable digital platforms with cybersecurity by design.

Future Outlook
Future digital cement plants will evolve toward autonomous optimisation, real-time carbon intensity tracking, and integration with emerging decarbonisation technologies such as carbon capture, utilisation and storage (CCUS). Digital platforms will also support ESG reporting and regulatory compliance.
Digital pathways offer a practical and scalable solution for sustainable cement manufacturing in India. By optimising energy consumption, enabling higher AFR substitution and improving resource efficiency, digital technologies deliver measurable environmental and economic benefits. With appropriate data infrastructure, organisational alignment and phased implementation, digital transformation will remain central to the Indian cement industry’s low-carbon transition.

About the author:
Dr Y Chandri Naidu is a cement industry professional with 30+ years of experience in process optimisation, quality control and quality assistance, energy conservation and sustainable manufacturing, across leading organisations including NCB, Ramco, Prism, Ultratech, HIL, NCL and Vedanta. He is known for guiding teams, developing innovative plant solutions and promoting environmentally responsible cement production. He is also passionate about mentoring professionals and advancing durable, resource efficient technologies for future of construction materials.

Stoppage Insights instantly identifies root causes and maps their full operational impact.

In cement, mining and minerals processing operations, every unplanned stoppage equals lost production and reduced profitability. Yet identifying what caused a stoppage remains frustratingly complex. A single motor failure can trigger cascading interlocks and alarm floods, burying the root cause under layers of secondary events. Operators and maintenance teams waste valuable time tracing event chains when they should be solving problems. Until now.
Our latest innovation to our ECS Process Control Solution(1) eliminates this complexity. Stoppage Insights, available with the combined updates to our ECS/ControlCenter™ (ECS) software and ACESYS programming library, transforms stoppage events into clear, actionable intelligence. The system automatically identifies the root cause of every stoppage – whether triggered by alarms, interlocks, or operator actions – and maps all affected equipment. Operators can click any stopped motor’s faceplate to view what caused the shutdown instantly. The Stoppage UI provides a complete record of all stoppages with drill-down capabilities, replacing manual investigation with immediate answers.

Understanding root cause in Stoppage Insights
In Stoppage Insights, ‘root cause’ refers to the first alarm, interlock, or operator action detected by the control system. While this may not reveal the underlying mechanical, electrical or process failure that a maintenance team may later discover, it provides an actionable starting point for rapid troubleshooting and response. And this is where Stoppage Insights steps ahead of traditional first-out alarm systems (ISA 18.2). In this older type of system, the first alarm is identified in a group. This is useful, but limited, as it doesn’t show the complete cascade of events, distinguish between operator-initiated and alarm-triggered stoppages, or map downstream impacts. In contrast, Stoppage Insights provides complete transparency:

• Comprehensive capture: Records both regular operator stops and alarm-triggered shutdowns.
• Complete impact visibility: Maps all affected equipment automatically.
• Contextual clarity: Eliminates manual tracing through alarm floods, saving critical response time.

David Campain, Global Product Manager for Process Control Systems, says, “Stoppage Insights takes fault analysis to the next level. Operators and maintenance engineers no longer need to trace complex event chains. They see the root cause clearly and can respond quickly.”

Driving results
1.Driving results for operations teams
Stoppage Insights maximises clarity to minimise downtime, enabling operators to:
• Rapidly identify root causes to shorten recovery time.
• View initiating events and all affected units in one intuitive interface.
• Access complete records of both planned and unplanned stoppages

2. Driving results for maintenance and reliability teams
   Stoppage Insights helps prioritise work based on evidence, not guesswork:
   • Access structured stoppage data for reliability programmes.
   • Replace manual logging with automated, exportable records for CMMS, ERP or MES.(2)
   • Identify recurring issues and target preventive maintenance effectively.
3. 
   A future-proof and cybersecure foundation
   Our Stoppage Insights feature is built on the latest (version 9) update to our ACESYS advanced programming library. This industry-leading solution lies at the heart of the ECS process control system. Its structured approach enables fast engineering and consistent control logic across hardware platforms from Siemens, Schneider, Rockwell, and others.
   In addition to powering Stoppage Insights, ACESYS v9 positions the ECS system for open, interoperable architectures and future-proof automation. The same structured data used by Stoppage Insights supports AI-driven process control, providing the foundation for machine learning models and advanced analytics.
   The latest releases also respond to the growing risk of cyberattacks on industrial operational technology (OT) infrastructure, delivering robust cybersecurity. The latest ECS software update (version 9.2) is certified to IEC 62443-4-1 international cybersecurity standards, protecting your process operations and reducing system vulnerability.

What’s available now and what’s coming next?
The ECS/ControlCenter 9.2 and ACESYS 9 updates, featuring Stoppage Insights, are available now for:

• Greenfield projects.
• ECS system upgrades.
• Brownfield replacement of competitor systems.
  Stoppage Insights will also soon integrate with our ECS/UptimeGo downtime analysis software. Stoppage records, including root cause identification and affected equipment, will flow seamlessly into UptimeGo for advanced analytics, trending and long-term reliability reporting. This integration creates a complete ecosystem for managing and improving plant uptime.

(1) The ECS Process Control Solution for cement, mining and minerals processing combines proven control strategies with modern automation architecture to optimise plant performance, reduce downtime and support operational excellence.
(2) CMMS refers to computerised maintenance management systems; ERP, to enterprise resource planning; and MES to manufacturing execution systems.

Jignesh Kundaria, Director & CEO, Fornnax Recycling Technology

As 2026 begins, Fornnax is accelerating its global growth through strategic expansion, large-scale export-led installations, and technology-driven innovation across multiple recycling streams. Backed by manufacturing scale-up and a strong people-first culture, the company aims to lead sustainable, high-capacity recycling solutions worldwide.

As 2026 begins, Fornnax stands at a pivotal stage in its growth journey. Over the past few years, the company has built a strong foundation rooted in engineering excellence, innovation, and a firm commitment to sustainable recycling. The focus ahead is clear: to grow faster, stronger, and on a truly global scale.

“Our 2026 strategy is driven by four key priorities,” explains Mr. Jignesh Kundaria, Director & CEO of Fornnax.

First, Global Expansion

We will strengthen our presence in major markets such as Europe, Australia, and the GCC, while continuing to grow across our existing regions. By aligning with local regulations and customer requirements, we aim to establish ourselves as a trusted global partner for advanced recycling solutions.

A major milestone in this journey will be export-led global installations. In 2026, we will commission Europe’s highest-capacity shredding line, reinforcing our leadership in high-capacity recycling solutions.

Second, Product Innovation and Technology Leadership

Innovation remains at the heart of our vision to become a global leader in recycling technology by 2030. Our focus is on developing solutions that are state-of-the-art, economical, efficient, reliable, and environmentally responsible.

Building on a decade-long legacy in tyre recycling, we have expanded our portfolio into new recycling applications, including municipal solid waste (MSW), e-waste, cable, and aluminium recycling. This diversification has already created strong momentum across the industry, marked by key milestones scheduled to become operational this year, such as:

• Installation of India’s largest e-waste and cable recycling line.
• Commissioning of a high-capacity MSW RDF recycling line.

“Sustainable growth must be scalable and profitable,” emphasizes Mr. Kundaria. In 2026, Fornnax will complete Phase One of our capacity expansion by establishing the world’s largest shredding equipment manufacturing facility. This 23-acre manufacturing unit, scheduled for completion in July 2026, will significantly enhance our production capability and global delivery capacity.

Alongside this, we will continue to improve efficiency across manufacturing, supply chain, and service operations, while strengthening our service network across India, Australia, and Europe to ensure faster and more reliable customer support.

Finally: People and Culture

“People remain the foundation of Fornnax’s success. We will continue to invest in talent, leadership development, and a culture built on ownership, collaboration, and continuous improvement,” states Mr. Kundaria.

With a strong commitment to sustainability in everything we do, our ambition is not only to grow our business, but also to actively support the circular economy and contribute to a cleaner, more sustainable future.

Guided by a shared vision and disciplined execution, 2026 is set to be a defining year for us, driven by innovation across diverse recycling applications, large-scale global installations, and manufacturing excellence.