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PICM?s forte is to give out-of-the-box solutions to its customers

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Jayanta Saha, Director, Penta Engineering.

We endeavour to build a reputation for being the consultant of choice for most cement plant personnel. We hope that our niche offerings in the realm of process expertise and systems engineering will remedy some of the major problems that beset many new projects as well as existing operations, says Jayanta Saha, Director, Penta Engineering. Excerpts from the interview.

What has made PICM one of the leading providers of design engineering and consultancy services to the cement industry?

PICM always strives to understand the customer’s requirement correctly and provide quality solutions / services which are case-specific and not off-the-shelf. This is possible because our core team has a rich engineering / project cache of experience from working with OEMs and end users. PICM also encourages continuous improvement and upgradation of skills in employees to enhance their professional knowledge and skills. Our global presence enables us to pick up best practices from all over the world. Our competitive edge lies in the collective expertise of employees as well as our data base.

Our USP is our ability to satisfy the customer and provide the best solutions, with respect to technology, cost savings for their current needs, as well as for future upgrades. Our customers have begun to perceive PICM as their growth partners.

What can you tell us about the major projects completed by PICM?

A few of the major projects done by PICM are the Lafarge Jojobera grinding unit, Heidelberg Damoh expansion project, Kuwait Cement Line 2 brownfield project and Dangote Group’s New Senegal, Ibese Line 3&4 and Tanzania projects.

When PICM was growing, one of the major challenges was to build a competent team to deliver quality services and to complete the projects within their tight schedules. PICM’s rigorous and strict screening process and dedicated efforts made it possible to build a good and effective team to not only deliver the projects to the satisfaction of PICM and especially clients, but also in getting repeat orders from most of the clients. For field engineering services, PICM’s extensive network within the engineering industry had to be tapped to find the right people for the right job at site as required by the client.

How do you tackle unforeseen problems that may come up while executing big projects?

PICM endeavours to carry out project planning in a manner that unforeseen situations are minimised. However, in case unexpected situations do arise, the personnel at PICM are quick to adapt and adopt.

Unforeseen problems are bound to come up while executing a project and one has to be alert and constantly on one’s toes to resolve them without affecting the schedule and staying within the budget.

Project management plays a vital role in this regard. The project manager has to keep the entire team tied up together to avoid lapses and gaps amongst various entities. With close co-ordination, regular meetings and follow- ups, suitable action can be planned before any unexpected development becomes a setback. Continous feedbacks and checks are a must.

Changing the layout, in many cases, seems to be a major issue. How do you tackle this?

Layout or engineering should ideally take place in the early stages of a project and not be changed at a later stage. Layouts have to be frozen in order to complete the project on time and within budget. Optimum layout design has to be carried out within the given constraints.

The role of project management is significant in controlling changes. Layout change at an advanced stage of project should not be welcomed unless the change is absolutely necessary and benefits outweighthe costs and delays.

In some cases, engineering is carried out before actual land acquisition to save execution time. Hence, changes in layout design may be warranted once the actual land becomes available. In such cases, the project management team should anticipate and keep options open accordingly.

What are the demands of the new age cement plants?

The cement industry has been in existence since 1914. In the earlier days, the requirement was to produce cement without too many other constraints. However, today’s cement plants are required to meet a lot of new challenges and demands, some of which is detailed below.

Land cost has increased considerably, and at times, the project becomes economically unviable only on account of land. Scarcity of land is another issue and the days are not far ahead when proper land may not be available for cement plants. So, every inch of land is going to be important in putting up a cement plant and smarter layout is going to be key here.

Strict pollution control norms. Whether it is dust emission or NOX or SOX , these norms are getting stricter and new cement plants have to comply with them.

Cost of production. Power and fuel are other major demands of new cement plants, to cut down on these natural resources. Efforts are to be put in not only in minimising the requirement of power and fuel but also in using renewable sources of energy. Costs. Improved means and ways have to be found to minimise capital as well as operating costs.

What is the scenario in the repair / retrofit of existing plants?

These kinds of projects are initiated due to various reasons. Some of them are:

  • New environmental norms which mandate the adoption of new pollution control technology.
  • Obsolete equipment makes the older plants non-competitive. Hence, improvements in certain sections to be carried out to improve energy efficiency or enhance production. Sustainability initiatives such as the use of alternate fuels/ waste derived fuels.
  • PICM’s forte lies in offering out- of ûthe-box solutions to the problems faced by the customer. These could lie in the choice of new technology or smarter design. We act as thinking partners wherein we guide our clients in carrying out those incremental changes which can reap visible benefits before larger investments are made.

What kinds of energy efficiency measures do you recommend to your clients?

Some of the measures for existing operations are:

  • Carrying out technical audit and optimisation of raw mix design, as well as operation optimisation and minor feasible changes in the design of existing equipment, mainly to reduce a pressure drop.
  • Addition of pre-grinders to existing ball mill circuits.
  • Addition of waste heat recovery systems.
  • Use of alternate fuel.

Some of the measures for greenfield projects are:

  • Working out optimum plant layout to achieve minimum material handling.
  • Selecting state- of- the- art technology that gives minimum specific energy consumption.
  • To this end, PICM always targets energy savings better than the best achieved so far in the industry.

How do you assess the interface between a consulting agency like PICM, cement manufacturers, various plant and machinery OEMs and auxiliary equipment suppliers?

All interactions between clients, OEMs, vendors and sub-contractors are aimed at creating a win-win situation for all parties. PICM works as the owner’s engineer to its clients. PICM guides them in preparing optimum packages and selecting the best in field suppliers in unbiased manner, and ultimately ensuring proper interface to get rid of any mismatch.

Another focus is on completion of the project in time and on a well- planned budget. PICM has been able to set right some mired projects by reopening communication lines between the client and OEMs, independently studying the systems, proposing changes both in the vendors` and client`s systems, and eventually achieving better than guaranteed results.

What is your take on the lack of highly skilled technicians and experienced engineers? PICM believes that in the long run, the right attitude in an employee is his/ her most valuable asset and the company’s, too. PICM adds youngsters to the experienced force and moulds them to company philosophy to achieve professional excellence.

Which are the geographical regions that are driving demand in your sector?

At the moment, India is facing a glut in cement capacity and expansion plans are limited. However, we see opportunity in the Middle East as well as in some regions of Africa.

What is the level of technology being adopted by cement producers in India?

The high competition in the cement market in India has resulted in owners adopting state- of- the- art technology in their plants. However, certain areas still requires technology advancement.

What are the opportunities and challenges that you foresee for PICM in India?

Although at present, the industry in India is going through a bad patch, we are confident of the future being very bright and are gearing ourselves to avail of the opportunity in the right manner. Challenges come in the form of competition but we can face them due to our efforts to upgrade our knowledge and skills along with providing our clients the best service and solutions. In fact, we view competition in a positive way as it helps us keep ourselves always updated. Many cement plants have now started recognising our services in the form of process audits and optimisation, setting right basic and system engineering defects, and maximising output from existing plant and machinery. In the present Indian scenario, the demand for these high- end engineering services is increasing day by day. We also perceive that with the entry of Chinese OEMS, many owners will be losing out on the thoroughness and design expertise inherent in European OEMs. In that situation, our talents will be in even greater demand in the days to come when owners begin to operate such systems.

Tell us about the growth story of PICM. What are your long -term and short -term goals?

PICM started its operation as a support office for its parent US- based consulting firm, Penta Engineering Corporation. Over the last seven years, we have been able to build a competent team with experts from the Indian cement industry. This has enabled us to become a leading solutions provider in our own right and a force to reckon with in the cement consulting industry.

In the short- term, beating the downturn, retaining our expert team and gradually increasing our client base and market share are our foremost concerns.

In the long run, we will endeavour to build such a reputation so that we become the consultant of choice for most cement plant personnel. We hope that our niche offerings in the realm of process expertise and systems engineering will remedy some of the major problems that are plaguing the success of many new projects as well as existing operations.

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Economy & Market

RAHSTA Roundtable Sets Agenda for Smarter, Safer Highways

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Roundtable discussions focus on innovation for safer highways.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the RAHSTA Roundtable brought together stakeholders from across the highways and infrastructure ecosystem to shape the agenda for the 16th RAHSTA 2026, scheduled for 8–9 July 2026 at the Jio Convention Centre, Mumbai. The session focused on key industry themes including road construction, technology, safety and long-term sustainability.

Opening the discussion, Pratap Padode, Founder, FIRST Construction Council, said the roundtable marked the beginning of a broader consultative process leading up to the July event. The aim, he noted, is to bring together industry stakeholders to refine the agenda for discussions on the future of roads, bridges, tunnels and allied infrastructure.

Padode noted that while central road project awards have slowed in recent years, states are increasingly driving the next phase of infrastructure growth. Maharashtra, with its long-term road development plans and agencies such as MSRDC and MSIDC, is expected to play a significant role in this expansion.

RAHSTA Expo 2026 as a specialised platform dedicated to road infrastructure, covering highways, tunnels, bridges and flyovers along with construction technologies, safety systems and maintenance solutions. He also highlighted the growing importance of rural connectivity and said the organisers are engaging with government bodies to highlight rural road development initiatives.

Tanveer Padode, CIO, ASAPP Info Group, presented insights from IMPACCT, the group’s infrastructure intelligence platform. He pointed to a strong project pipeline despite slower highway awards earlier in the year, noting that states such as Maharashtra, Odisha and Arunachal Pradesh are emerging as key drivers of new projects. The data also revealed that only a small group of contractors participates in large-value infrastructure bids.

Lt Gen Rajeev Chaudhary, former Director General, Border Roads Organisation and Chairman of the RAHSTA Expo Committee, emphasised the need for stronger collaboration across the ecosystem, including policymakers, contractors, technology providers and financiers. He also called for addressing systemic issues within the sector and encouraged greater participation of women in infrastructure leadership.

The discussion also explored the evolving economics of road development. Phani Prasad Mandalaparthy, Associate Director, CRISIL Intelligence, noted that the slowdown in project awards reflects a shift towards higher-value logistics corridors rather than simple road widening projects. However, private participation through BOT and TOT models remains limited.

From the contractors’ perspective, Sudhir Hoshing, Whole-Time Director, Ceigall, said companies are becoming more selective in bidding, favouring projects with clearer payment mechanisms and efficient processes. While NHAI continues to offer greater operational clarity, states such as Uttar Pradesh and Bihar were cited as relatively supportive environments for project execution.

Durability and sustainability also emerged as key themes. Himanshu Agarwal, COO – Road & Infrastructure, Zydex Group India, highlighted the need to prioritise lifecycle performance and resilient pavements, while participants discussed the potential of alternative materials such as plastic waste, steel slag and industrial by-products in road construction.

Dr LR Manjunatha, Vice President, JSW Cement, emphasised that India has abundant fly ash, slag and other industrial materials that can improve durability and sustainability if integrated into specifications and policy frameworks.

Technology and equipment challenges were also discussed. Dr Lakshmana Rao Mantri, Dy General Manager, Afcons Infrastructure, highlighted the shortage of tunnel boring machines (TBMs), which is delaying several underground infrastructure projects. Participants agreed that developing domestic TBM manufacturing capabilities will be critical for future infrastructure expansion.

The future of concrete pavements was another area of discussion. Dr V Ramachandra, President, Indian Concrete Institute, stressed that the debate should focus on lifecycle performance rather than material choice alone, noting that evolving design standards are improving the feasibility of concrete roads.

Prof Dharamveer Singh of IIT Bombay added that while India has made significant progress in infrastructure development, stronger capacity building and better execution practices are essential to ensure consistent road quality.

The discussion also touched upon technology adoption in the sector. Rushabh Mamania, Partner & CBO, Roadvision, highlighted the growing role of AI in road infrastructure, noting that AI-driven monitoring systems are already being deployed across large stretches of national highways.

Overall, the roundtable underscored that the future of highway infrastructure will depend not only on the pace of construction but also on durability, safety, technology integration and sustainable materials. The discussions offered valuable insights that will help shape the agenda for RAHSTA 2026 and guide future collaboration within the industry.

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Economy & Market

CTS Roundtable Charts Tech-Led Roadmap for Construction

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CTS Roundtable Maps Technology Roadmap for Construction

Ahead of the Construction Technology Show (Con Tech Show) 2026, industry leaders, technology innovators and academia came together in Mumbai to deliberate on how digitalisation, automation and industrialised construction can reshape the sector. The discussion made one thing clear: construction can no longer afford to treat technology as optional.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the CTS Roundtable served as a precursor to the Construction Technology Show 2026, scheduled for 19–20 August 2026 at NESCO, Mumbai.

A platform to move from discussion to deployment

Opening the session, Pratap Padode, Founder and Editor-in-Chief, ASAPP Info Global Group, said construction technology has long remained close to his heart, especially given the sector’s traditionally slow pace of technology adoption. He noted that over the years, the Construction Technology Summit had steadily built interest, and the next step was now to expand it into a larger, more meaningful platform that could bring together technology providers, users, startups and innovators under one roof.

Padode said the vision for CTS is not limited to software alone. The platform aims to embrace all forms of technology that can improve construction efficiency, quality and execution—from digital tools and project management systems to lean construction, off-site fabrication and startup-led innovation. He also highlighted plans to deepen startup participation and create space for young companies to showcase emerging construction solutions.

Industry at a turning point

Moderating the roundtable, Naushad Panjwani, Chairman, Mandarus Partners, set the context by pointing out that the global construction industry, despite being a multi-trillion-dollar sector, continues to lag in productivity. He noted that while manufacturing has consistently improved efficiency, construction has remained slow to modernise.

Referring to both global and Indian trends, Panjwani underlined that the industry is now at a decisive moment. India, he said, is entering a major build cycle, and delivering the next phase of infrastructure and real estate growth through traditional methods alone is no longer viable. The goal of the roundtable, therefore, was not to debate technology in isolation, but to identify the most critical conversations that would bridge the gap between innovation and implementation.

His central message was clear: CTS 2026 must be shaped around themes that make CEOs, CIOs and CTOs feel they cannot afford to miss the event.

From BIM to AI, data to governance

A major theme that emerged through the discussion was the need for better data, better visibility and better decision-making. Dr Venkata Santosh Kumar of IIT Bombay echoed this, saying that the underlying data infrastructure itself needs attention. Construction projects, particularly remote ones, often face issues around connectivity, data collection and data use. Without this foundation, more advanced technologies cannot deliver their full value.

Chandra Vasireddy, CEO & Co-founder, Inncircles, expanded the discussion to governance, arguing that technology must help connect the many moving parts of a construction business. For him, the real value of digital transformation lies in creating better governance, clearer visibility and stronger business outcomes.

Tejas Vara of Inncircles stressed the importance of timely site data for leadership teams, especially in large and remote projects where decisions on materials, machinery and manpower often get delayed because information does not reach headquarters in time.

The role of AI also featured prominently. Rushabh Mamania, Partner and CBO, Roadvision said that while AI and machine learning are now common terms, vision intelligence and language intelligence have still not deeply penetrated the construction sector. He emphasised that startups in India are building relevant AI-led solutions and are already attracting international interest, showing that innovation need not be imported—it can be built locally and scaled globally.

Industrialised construction gains ground

The roundtable also placed strong emphasis on industrialised construction methods. Kalyan Vaidyanathan, CTO – Construction & R&D, Tvasta, called for greater focus on off-site fabrication and the broader industrialisation of construction. Bhargav Jog, General Manager, Dextra, highlighted precast technology and alternative sustainable materials as areas with immediate relevance.

Several participants agreed that modular, precast and pre-engineered approaches are no longer niche ideas. They are increasingly becoming practical responses to the sector’s challenges around labour shortage, timelines, quality control and predictability.

Anup Mathew, Sr VP & Business Head, Godrej, argued that the industry needs a fully integrated approach—from design and procurement to execution and asset management. Unless these are connected, technology adoption will remain fragmented and sub-optimal. He pointed to pre-engineered and modular systems as examples of how industrial thinking can compress timelines, improve quality and reduce dependence on difficult on-site conditions.

Adoption remains the biggest hurdle

While there was broad agreement on the promise of technology, the discussion repeatedly returned to one fundamental challenge: adoption.

Abhishek Kumar, COO, LivSYT, observed that the market is crowded with solutions, but many buyers still struggle to evaluate which technology suits which use case. According to him, the industry needs clearer frameworks to help users select, compare and adopt solutions, rather than expecting a single platform to solve every problem.

Dr Tenepalli JaiSai, Associate Professor, School of Construction(SoC), NICMAR University, noted that isolated technologies will not solve the productivity problem by themselves. What is required is an integrated Construction 4.0 approach, where digital, physical and cyber-physical systems work together rather than in silos.

That concern around silos was reinforced by Subodh Dixit, former Director, Shapoorji Pallonji, who said the issue is not just that technologies are disconnected, but that stakeholders are as well. Clients, consultants, contractors and partners often operate with different priorities. Unless these silos are broken, technology will struggle to percolate across the full project value chain.

Harleen Oberoi, Project Management, Tata Realty shared a practical perspective from the client side, saying that successful BIM implementation requires investment across the ecosystem, not just within one organisation. Trade partners, vendors and other stakeholders must also be trained and aligned if the technology is to deliver its intended results.

Beyond buzzwords

A notable takeaway from the session was that the industry is moving past the phase of treating technology as a buzzword. Participants repeatedly stressed that the real question is not whether technology should be used, but where it creates measurable value and how that value can be scaled.

The conversation also expanded beyond mainstream themes to include repairs and rehabilitation, construction and demolition waste, sustainability, circular economy, green sourcing, carbon measurement, design interoperability, generative design, robotics, and the role of horticulture and greener built environments.

Setting the agenda for CTS 2026

By the close of the session, the roundtable had surfaced a strong set of themes for the upcoming show: BIM and digital twins, AI and data platforms, industrialised construction, startup innovation, governance-led technology adoption, robotics, sustainable materials, and integrated project delivery.

More importantly, the session established CTS 2026 as more than an exhibition. It is shaping up to be a serious industry platform where users, technology providers, researchers and policymakers can collectively define the future of construction.

As Padode noted in his closing remarks, the conversation will continue through further consultations and possibly webinars in the run-up to the show. If the roundtable is any indication, CTS 2026 will aim not merely to showcase technology, but to push the industry towards meaningful adoption at scale.

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Concrete

Human Factor in Grinding Optimisation

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Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, discusses the role of skilled operators as the decisive link between advanced additives, digital control and world-class mill performance.

The industry always tries to reduce the number of operators in the Centre Control Room. (CCR) Though the concept was succeeded to certain extent, still we need a skilled person in the CCR.
In an era where artificial intelligence (AI) grinding aids, performance enhancers, and digital optimisation tools are becoming increasingly sophisticated, it’s tempting to believe that chemistry alone can solve the challenges of mill efficiency. Yet plants that consistently outperform their peers share one common trait: highly skilled operators who understand the mill as a living system, not just a machine.
Additives can improve flowability, reduce agglomeration, and enhance separator efficiency, but they cannot replace the nuanced judgement that comes from experience. Grinding is a dynamic process influenced by raw material variability, moisture, liner wear, ball charge distribution, ventilation, and separator loading. No additive can fully compensate for poor control of these fundamentals.

Operators see what additives cannot
When I joined the cement industry in 1981, not much modernisation was available then. Mostly the equipment was run from the local panel. Once I was visiting the cement mills section. The cement mills were water sprayed over the shell to reduce the temperature to avoid the gypsum disintegration.
The operator stopped the feeding for one of the mills. When I asked the reason, he replied that mill was getting jammed, and he added that he could understand the mill condition by its sound. I also learned that and it was useful throughout my career. In another plant I saw the ‘Electronic Ear,’ which checked the sound of the mill and the signal was looped with feed control!
Whatever modernisation we achieve, it is from the human factor that the development starts.
Additives respond to conditions; operators interpret them.
A skilled operator can detect subtle shifts, like a change in mill sound, a slight variation in circulating load, or a drift in separator cut point. It’s long before instrumentation flags a problem. These micro-observations often prevent major efficiency losses.
Additives work best when the process is stable
I would like to share one real time incident. The mill was running on auto mode looped with the mill outlet bucket elevator kilowatt. (KW)There was a decrease in the KW, and the mill feed was increased by the auto control (PID). After a while, the operator stopped both the feed and the mill. He asked the local operator to check the airslide between mill outlet and the elevator. They found the airslide was jammed and no material flow to the elevator!
The operator deduced the abnormality by his experience by seeing the conditions and the rate of increase of the feed by the auto control.
It’s always the human factor that adds value to the optimisation.

Grinding aids are multipliers,
not magicians.
They deliver maximum benefit only when:
• Mill ventilation is correct
• Ball charge is balanced
• Feed moisture is controlled
• Separator speed and loading are improved
• Blaine targets are realistic
Without these fundamentals, even advanced additives may become costly investments. The operator is responsible for ensuring process stability, whether using a ball mill or a vertical mill. After ensuring the system is stable, the operator observes it briefly before transitioning to automatic control. If there is any anomaly in the system the operator at once takes control of the system, stabilises and bring back to auto control.

Skilled operators adapt in real time
It will be interesting to note that the operators who operate from local panel start to operate from DCS also. They have the experience and the ability to adapt the changes. Operator checks each parameter deeply. Any meagre change in the parameters is also visible to him.
Raw materials change. Weather changes. Wear patterns change.
A skilled operator adjusts:
• Feed rate
• Water injection
• Separator speed
• Grinding pressure (in VRMs)
• Mill load distribution.
These adjustments require intuition built from years of experience, something no additive can replicate.

Human insight prevents over reliance on additives
Plants sometimes increase additive dosage to mask deeper issues like:
• Poor clinker quality
• Inadequate drying capacity
• Incorrect ball gradation
• High residue due to worn separator internals.


A knowledgeable operator finds root causes instead of chasing temporary chemical fixes.
The real optimisation sweet spot is reached when:
• Operators understand how additives interact with their specific mill.
• Additive suppliers collaborate with plant teams.
• Process data is interpreted by humans who know the mill’s behaviour.
This constructive collaboration consistently delivers:
• Lower kWh/t
• Higher throughput
• Better product consistency
• Optimum standard deviation.

Advanced additives are powerful tools, but they are not substitutes for human ability. Grinding optimisation is ultimately a human driven discipline, where skilled operators make the difference between average performance and world class efficiency. Additives enhance the process but operators
control it.

About the author:
Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, is a seasoned cement process consultant with 43+ years of global experience in plant operations, process optimisation, refractory management, safety systems and training multicultural teams across international cement plants.

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