Economy & Market

Failures of ?Gearbox and Drives?

Published

11 years ago

August 31, 2015

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It is a pain area for the plant management team when the gear drive fails and it is more difficult to arrive at the correct cause of failure. S Sengupta & A Ray Chowdhury from Sprat Consultancy elaborates on some of the common causes of failures, also suggests remedial measures.

The idea of putting pen to paper regarding gear drives seems to be a daunting task. One is apprehensive as to where to begin and to what degree to write is a nerve racking proposition as majority of the readers are qualified, sound practical engineers who are associated with industrial plants such as cement, power, metals, etc. Experience confirms that a meaningful insight on the subject requires around three working days and if fourth day could be added by way of site visit with discussions on practical problems, works out a ?win-win? situation for all.

An endeavour is however being made to jot down some thoughts that may serve as pre curser from selection to use of drives. The order of narration is not sacrosanct and not all encompassing. It is just a brief write up on few attributes hoping it will provoke the mind of concerned personnel be it users or project/technical personnel. Use of gear drives in a system does not imply just operational; it encompasses what happens within a drive train and requirements to achieve desired performance life hence design life.

In many instances over the past 38 years, we have come across failures in drives caused by lack of insight or foresight or lack of correct data or its understanding during selection of drive. A common failure, but not frequent, is lack of perception of what all is to be handled &/or power required to drive the system.

An example that readily comes to mind is in a greenfield cement plant around early 1980s: the external consultant confirmed motor power, application, operating hours per day, etc. and wanted a drive with a safety factor (SF) of 2.5. This particular gear drive was 1 amongst 65 others. It was the only one that was prone to frequent failure to the tune of once every three months. Review of actual operating data confirmed actual power consumed was 40 per cent higher than confirmed during project design & planning leading to premature failures.

Another instance of premature failures observed in a cement plant in Western India of a twin drive bucket elevator where input drive was through fluid coupling. After a year of satisfactory operation failures commenced with regularity in one of the gear drives in the arrangement. As they were imported gearboxes not much hue and cry was raised initially. Replacements from two indigenous producers also failed in the same manner and frequency leading to a pantomime at the plant. Analysis of the drive arrangement confirmed power consumed by individual drives differed by over six per cent. In such a scenario, failure was inevitable and plant further confirmed that after a year one drive motor had burnt out requiring rewinding. Rewinding is common accepted process but what is equally important is that in a twin drive synchronisation of input power is of utmost importance of within two per cent variance. Since synchronise of input power no further failures occurred over a decade.

There are many other instances of failures we often recollect as observed over the last four decades. In all instances failures have taken place for:

Incomplete or inadequate clarity of specification at initial stage.
Lack of appreciation of specification, which is more dangerous.
Hypothesis by OEM of likely operational parameters viz a viz specification thus incorrect supply.
Augmenting capacity after year/s of use and not sharing data with supplier or supplier not appreciating information conveyed which must be well defined.

In short whatever are the circumstances in life (we consider gear drives also a form of life) it takes two to speak the truth to form an understanding and thus realisation. In the field of machine dynamics the same applies; dialogue between user and supplier must be continual and without inhibition or prejudice. In other words partnership is required with frank exchanges, irrespective of how insignificant the information may appear, to eliminate misgivings consequently failures.

The more this realisation dawns on all in a B2B scenario and quicker the better for all concerned resulting in reliability of operations. Failures are phenomena that cannot be totally ruled out even with best intentions of user and supplier. Any failure, irrespective of its occurrence, within or beyond the warranty period or after extended period of use is relevant at all times towards better and improved designs unless failure occurs beyond design life of rolling elements. This information should be shared with factual details unambiguously.

It is common for most designers to design critical drives, irrespective of type/size &/or application considering a life of 100,000 hours for gears/pinions and around 60,000 hours for bearings. Indirectly, to a large extent, bearing life sets the set point for case hardened and ground gears/pinions although theoretically it has an infinite life.

The question therefore arises why premature failures occur within warranty period or shortly thereafter. One of the primary reasons for failure beyond warranty period is governed by the quality of lubricating oil being used. Often quality is misunderstood with viscosity grade. Quality per ?say? has no relation to viscosity grade; it refers to the cleanliness of the oil.

Lubricating oil needs to be maintained clean and the desired level is NAS6 for industrial application other than turbine drives. This value of NAS6 also applies to wind mill drives and speed increasers as opposed to high speed drives. The cleanliness value of NAS6 does not readily register with users and to some extent with suppliers of gear drives. To put it mildly, check oil directly from a sealed barrel supplied by OEM for its NAS value and you will invariably find it anywhere around NAS10 or worse. Do not assume it happens only with indigenous supplies as it is far from the truth. Checks conducted with top brand sealed oil drums, indigenous or imported, confirm this is normal and common.
The onus thus lies with users to appreciate why oil cleaning is required and how does it improve the performance as well as life of the gear drive. It is safe to conclude, which concurs with our observation, that organisation which maintains lubricating oils health is less prone to premature failures. They invariably enhance the life of their drives by any where up to 30% higher than others for same drive conditions. This phenomena can be observed in an organisation &/or plant to plant operations but sadly data and findings are rarely pooled.
Another disturbing fact is often lubricating oil is procured on price consideration only and neglect issues such as scuffing, scoring, wet-ability etc properties.
Cost differential between normal mineral oil containing higher levels of sulphur and phosphorous in relation to vacuum distilled mineral oils is around 75-80 per cent more but the usable life of oil, if cleanliness maintained around NAS6, will justify the extra cost as life will be minimum double of normal mineral oil. A cement plant in Eastern India has continually achieved life of three times that of normal mineral oils there by not only resulting in huge savings to the organisation by way of less oil consumption and frequent shutdowns for changing oil.
Do note, normal mineral oils with higher levels of sulphur and phosphorous have an greater affinity to absorb moisture from the atmosphere leading to formation of sulphuric & phosphoric acids; both are very harmful towards life of bearings, seals and last but not least internal preservative paints applied to gearbox housing walls adding to further contamination.
A question we need to ask our self, as buyers we seek guarantee and warranty at the drop of a hat then why not for lubricants used?
Another cause of failure beyond warranty period is the upkeep of breathers, seals, etc. along with external surface of the gear drive. Often it is neglected resulting in breathers getting choked &/or become an ingress point for dirt when drive is stopped. As a result we have oil seal leakages and oil contamination leading to premature failures. Such instances are quite common in conveyor drives of cement grinding section or packing plant, coal handling conveyors, etc. An excuse we at times come across for not maintaining minimal level of cleanliness is, it is not a critical drive! The same excuse is also conveyed when the gearbox is covered with dust. What fails to be appreciated by the user is damage is taking place to investments and it can has a cascading effect.
There are numerous other instances of failures beyond warranty period but this is nether the forum or place to address these issues.
Failures during warranty period can be generally summed up under following heads as trends prevailing in gear design are to raise power levels till it does not result in a failure while decreasing volumes thus weight leading to increasing problems of heat dissipation:

Faulty or inadequacy of design
Incorrect selection & use of materials for manufacture
Incorrect selection of bearing
Manufacturing errors
Heat treatment errors
Assembly errors
Fluctuating or incorrectly defined operating parameters
Variants from original specification supplied &/or contaminates
Use of improper or incorrect quality of lubricant

Very rarely only one of the above mentioned causes account for failure to gear drives thus understanding and assessing gear damage requires in-depth knowledge of:

Gear contact patterns
Gear tooth failure types and probable causes
Bearing failure types with probable reasons
Lubricating oils
Oil flow within the gear drives be it splash or forced lubrication, etc.

It is not feasible to go through all these aspects in depth through this short article but to create awareness towards minimising risks of premature failures. We as such recommend use of following documents as a starting point to improve performance of gear drives thus overall operations of a plant. The documents relate to what needs to be communicated to the prospective seller and what in return you must get from them without fail.

Info. to be given By gearbox manufacturer

1.With offer for critical drives:
Design calculation in details for safety wrt wear & strength confirming material grade, etc.

2.Along with general arrangement (GA) drawing after placement of order:

GA drawing for all gear units, unless otherwise agreed upon, that gives full details of all manufactured part numbers and full nomenclature of proprietary parts including prefix and suffix, if any.
Number of teeth of each pinion and gear to facilitate vibration analysis. ?Spare parts list that can be correlated with GA drawing & the part number.
Approximate weight of gearbox.
Direction of rotation of input and output shafts.
GD? value of critical drives.
In case of pressure lubrication system water and oil flow rates with pressure range. Should also specify water and oil temperature gradient envisaged between inlet and outlet.
In case of cooling coil water flow rate and temperature gradient envisaged between inlet and outlet.
Details of interlocking, if any required to be ensured.

Note:

Your requirements of above data should be incorporated in your tender or enquiry or most major manufacturers will refuse to comply with the request at a later date.
Data of number of teeth will not only facilitate vibration analysis personnel but may facilitate in rationalising spares inventory if similar gearboxes are available in the plant or if same series gearboxes are installed of sizes that are just smaller or bigger than that on order.
Information to be given By a client

Following information are required to be furnished along with enquiry to finalise drive:

1. Prime mover – confirm type with full details like kW, rpm, Hz, type etc:

Motor
Turbine
I.C. engine

2. Input coupling – specify which:

Pin bush type flexible
Geared coupling
Fluid coupling
Bibby coupling
Tyre coupling
Any other than that mentioned above?

Note:

If coupling is not in the scope of gearbox supplier then its type, make, bore with tolerance of half to be mounted on gearbox are to be furnished.
Coupling in scope of gearbox OEM then confirm motor shaft diameter & tolerance.

3. Input through belt pulley drive – confirm following:

Pitch circle diameters of pulleys?
Direction of rotation of input shaft looking towards it?
Type of pulleys?

Note:
Provide sketch showing disposition of pulleys with respect to gearbox with dimensions in vertical and horizontal plane.

4. Type of gear drive:

Configuration of gearbox required i.e. helical, bevel/helical, RH, LH etc.
Operating hours per day?
Minimum and maximum ambient temperature where it is installed?
Place of installation i.e. open space, small confined area or large workshop?
Environmental condition e.g. normal, dusty, etc.

Note:
Mention if any other speciality is required in the drive.

5. Output coupling – specify which:

Pin bush type flexible
Geared coupling
Any other than that mentioned above?

Note:

If coupling is not in the scope of gearbox supplier then its type, make, bore with tolerance of half to be mounted on gearbox are to be furnished.
Coupling in scope of gearbox OEM; confirm machine shaft diameter & tolerance.

6. Output through Sprocket Drive:

Pitch circle dia of sprockets?
Direction of rotation of output shaft looking towards it?
Maximum pull of chain?

Note:
Provide sketch showing disposition of sprockets with respect to gearbox with dimensions in vertical and horizontal plane.

7. Driven machine details:

Cement mill, coal mill, sugar mill, belt conveyor, kiln, etc.
Confirm if it is twin drive, etc.
If possible specify OEM details of equipment manufacturer.

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.