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Today, setting up a mini plant it is no longer economically viable

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TD Katwa
Chairman, Katwa Cements
The year 2013 was a year of mergers and acquisitions, when mammoth organisations joined forces to take advantage of scale and supplementary distribution networks that spanned over several continents. Industry experts in India reiterate that a cement plant with production capacity less than 2 mtpa cannot survive in today?s competitive market. So is this the end of mini plants in India? ICR interacts with TD Katwa to know how their mini plant is holding up against the odds. Excerpts from the interview.

Please brief us about your company and markets served?
We started Katwa Cements (KCPL) way back in 1985. The 0.2 mtpa plant has been running non-stop ever since. KCPL has its cement manufacturing plant at Belgaum in Karnataka. The plant is strategically located close to the limestone deposits of Yadwad village in Karnataka. The company serves the cement markets of northern Karnataka, southern Maharashtra and Goa. The dealers network, established three decades ago, is still in place and has only grown stronger with time.

What is the range of products offered by your company?
We manufacture both Ordinary Portland Cement (grades 43 and 53) and Portland Pozzolana Cement. We manufacture and sell cement under the brand names: Katwa Super, Katwa Cement and Katwa Suraksha.

Please brief us about the revenue gathered from your different product lines?
Of all our products, OPC 53 grade cement sales contribute to around 75 per cent of our revenue. OPC 43 grade contributes around 20 per cent and PPC grade contributes around 5 per cent.

What does the management structure at KCPL look like?
We are three directors in the business namely: TD Katwa, Chairman; Nitin T Katwa, Technical Director; Ravi T Katwa, Managing Director, who is also involved in R&D activities at KCPL.

How has KCPL performed in last 5 years in terms of growth and product launches?
KCPL has nearly doubled its production and sales capacity in the last 5 years. There was a strong demand for PPC grade cement indicated by our dealer network. To meet the demand we have launched ?Katwa Suraksha,? a PPC product in the market.

How is the cement industry performing and what are the challenges faced by the sector?
Overcapacity is affecting the cement industry badly for more than half-a-decade now. Rapid expansions worth more than Rs 50,000 crore that were done during 2007-12 have doubled the production capacity from 180 mtpa to 360 mtpa, the fastest in the sector?s history. This is serving as a self-made trap for the cement makers as the demand is very weak, far from the expectations that had driven the expansions.

The cement demand from the infrastructure and real estate sector is very low in comparison to what we expect it to be in a typical summer season. Also, the industry has been grappling with cost pressures due to rise in raw material costs and freight charges.

How are you dealing with these issues?
Though the cement prices have been reduced to stay competitive, we have been able to maintain our sale volumes at good levels. Our volumes are keeping us in profits. One of our business strategies is to remain focused on rural markets. We regularly conduct on-site social gatherings with our customers and run loyalty reward programs to keep them bonded to Katwa Cements. Apart from this, we also keep introducing several annual target-based schemes for our dealers.

We do not compromise on quality and delivery, and make the product available to our customers at an affordable price, which is why our customers keep coming back to us.

Are you planning for any capacity additions or product launches?
Yes. We have identified a few locations and are planning to set up facilities there. We are also planning to introduce Portland Slag Cement (PSC) in the market.

Tell us about your company?s CSR activities
The three thrust areas of our CSR initiatives at KCPL are clean drinking water, health & medical care and good education. Some of our initiatives in these areas include; Clean drinking water: We have installed hand pumps, tube wells, submersible pumps and have constructed elevated water tanks. We have also made provision for water connection; and have installed aqua guard water purifiers, water coolers at schools and community centres, etc.

Health & medical care: Katwa has organised camps to create awareness about several diseases in the region. We also arrange for free medical consultation and medicine for the needy employees at the plant.

Education: We have set-up a nursery for the kids staying at the plant quarters and are providing them with free education.

In today?s market where cement companies are going ahead with mergers and acquisitions to maintain economic viability, what are the challenges faced by a mini plant?
The only problem in being a mini-cement plant is the high cost of production, since a mini plant is highly labour intensive. And nowadays getting labour and skilled manpower is a big challenge due to competition. Labour is in short-supply and has become costly.

In current market conditions, it is advisable to have a cement plant to the minimum at small scale level. With cement prices dropping rapidly and with larger organisations joining hands to take advantage of scale, newly set up mini plants are finding it very tough to sustain themselves. Some of them, which are surviving, are bearing huge debts on their assets. Today, setting up a mini plant is no longer economically viable.

So how is your plant holding up in this tough scenario?
We are free from all bank loans and liabilities, etc., for more than a decade now. This is mainly because of our early start in this business. Katwa brand is pretty old and well recognised in this region. We have focused on quality and quick delivery at affordable prices right from the beginning. Quick delivery and availability is very important for consumers. So, we have maintained strong relations with our dealers and have retained even those who had joined us right from the inception of our plant. Our dealer network and brand recognition has helped us to manage the business profitably.

The other significant factor is we have based our unit closer to the limestone deposits. This has helped in cutting down the cost of logistics, which is a major expense for any cement plant.

Of course we do feel the need to expand, hence looking at boosting our capacity and introducing new products to fuel our growth further.

Are there any benefits of having a mini plant?
Yes, you do get some tax subsidies. Central government offers excise cuts to the mini-cement plants. Besides, the technology applied in mini-plant is simple; we don?t need highly skilled manpower. That helps in keeping overhead costs low.

We do not compromise on quality and delivery, and make the product available to our customers at an affordable price, which is why our customers keep coming back to us.

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Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

Dalmia Bharat Acquires Jaiprakash Associates Cement Assets for ₹2,850 Crore

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Dalmia Cement executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra, to acquire 5.2 MnTPA of cement capacity across Madhya Pradesh and Uttar Pradesh.

Dalmia Cement (Bharat) announced on May 22, 2026 that it had signed a Business Transfer Agreement with Jaiprakash Associates Limited and Adani Infra (India) Limited for the acquisition of cement plants located at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh. The deal was struck at an enterprise value of ₹2,850 crore and is expected to close within two weeks of execution.

The acquired assets from Jaiprakash Associates include 5.2 MnTPA of cement capacity and 3.3 MnTPA of clinker capacity. The package also covers 99 MW of thermal power capacity and railway sidings at Rewa, Chunar, and a common siding at Churk. This infrastructure gives the acquisition immediate operational utility beyond just production tonnage.

The transaction has a long backstory. Dalmia Cement had originally entered into a framework agreement with Jaiprakash Associates in December 2022, covering the sale of these business assets along with a long-term clinker supply arrangement. However, before the deal could be completed, Jaiprakash Associates was admitted to insolvency proceedings under the Insolvency and Bankruptcy Code. The earlier agreements could not be consummated as a result.

In an official statement, Puneet Dalmia, Managing Director & CEO, Dalmia Bharat, said, “I am very excited about addition of these assets in our portfolio. This serves as a great strategic fit for Dalmia. It helps us move forward in our journey to be a pan India player and provide a strong head start to serve the high potential markets in Central region. I am optimistic that the expansion potential of these assets along with close proximity with Dalmia’s captive mines will help us create a capacity hub for the future”.

Following the approval of Adani Group’s resolution plan for Jaiprakash Associates under the IBC framework, Dalmia approached the new management to revive discussions. The fresh Business Transfer Agreement was executed to settle all pending disputes, legal proceedings, and arbitration matters arising from the original framework agreement with Jaiprakash Associates.

Expanding market reach

Dalmia added, “Our familiarity with these assets under the earlier tolling arrangement gives us a deep understanding of the facilities and helps us establish strong connect with channel partners and vendors. We believe that this will help us in faster ramp up of capacities and quicker inroads into the market. As we look forward, I am very confident that we will be able to leverage the strengths of Dalmia to operate these assets in a manner where we can maximise value creation for all our stakeholders.”

With the addition of these plants, Dalmia Bharat’s total installed cement capacity will rise to 54.7 MnTPA upon consummation. The company has further expansion projects underway at Belgaum, Pune, and Kadapa, which are expected to take overall capacity to 66.7 MnTPA by Q2 to Q3 FY28.

The Central India location of the Jaiprakash Associates plants gives Dalmia Bharat faster access to markets in Madhya Pradesh and Uttar Pradesh than a greenfield build would have allowed. The company also cited debottlenecking and brownfield expansion as near-term opportunities at the acquired sites. Dalmia Bharat said the assets were expected to contribute positively to EBITDA and overall returns, given the pricing environment in the region and the company’s cost structure.

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