Raju Jain, General Manager, Wonder Cement discusses how they optimise material handling by integrating advanced technologies, automation, and sustainable practices to enhance efficiency, reduce operational costs, and minimise environmental impact.

Material handling plays a crucial role in cement production. How is your company optimising material handling systems to ensure efficiency and reduce operational costs?
At Wonder Cement, optimising material handling is key to improving overall plant efficiency and reducing operational costs. We focus on integrating advanced technologies and adopting a systematic approach to streamline our material handling processes. To minimise waste and energy consumption, we deploy automated conveyor systems that transport raw materials like limestone and gypsum with precision and reliability. These systems help in reducing the need for manual labour, which not only lowers labor costs but also minimises the potential for
human error.
Our optimisation strategies include real-time monitoring systems to track material flow and storage levels, ensuring that materials are used efficiently and without delay. We also employ energy-efficient motors and equipment that cut down on energy consumption, further driving operational savings. By utilising advanced data analytics, we can predict material needs and adjust our handling systems accordingly, leading to better resource management. In addition, our material handling systems are designed for minimal downtime, allowing us to maintain continuous operations and avoid costly interruptions. Regular maintenance protocols and use of high-quality equipment ensure long-term durability and performance, contributing to the overall cost-efficiency of our cement production processes.

What technologies or innovations has your organisation adopted to improve the safe and efficient transport of raw materials like limestone, gypsum, and clinker within the cement plant?
At Wonder Cement, scientific mining methods are utilised during limestone excavation. Our team of experts and experienced technical professionals oversee mining operations. To control dust generation, we employ wet drilling system that eliminates dust at its source. We adopt controlled blasting techniques to minimise noise, vibrations, and NOx emissions during blasting operations. Well-maintained mining equipment is used to reduce dust during loading and transportation. Additionally, water sprays are deployed on haul roads for effective dust control. We have embraced a variety of cutting-edge technologies to enhance the safe and efficient transport of raw materials within our plant. One of the primary innovations is the implementation of automated conveyor systems with high-efficiency motors and smart controls, which ensure smooth and consistent transportation of materials such as limestone, gypsum, and clinker. These conveyors are equipped with sensors that detect material flow rates and prevent overloading or spillage, which not only enhances safety but also minimises material waste.
We have also integrated dust suppression systems that mitigate dust generation during material transport. These systems help us maintain a cleaner and safer work environment while reducing the environmental impact of our operations. Additionally, the use of enclosed conveyors and fully automated bulk material handling systems prevents material exposure to the environment, reducing the risks associated with air contamination. Another key innovation is the incorporation of real-time monitoring and data analytics. Through the use of IoT (Internet of Things) sensors and AI-driven data platforms, we can monitor the health of our equipment and anticipate potential failures, enabling proactive maintenance. This reduces the risk of accidents, ensures continuous operation, and enhances overall efficiency in transporting raw materials throughout our cement plant.

How are you addressing the challenges of dust control and material spillage in your material handling processes, especially in bulk transport and storage?
At Wonder Cement , to reduce dust, spillage, and carbon emissions during heavy-duty vehicle transportation, we implemented a wagon and truck tippler system equipped with stackers and reclaimers, exceeding EPA standards and reducing carbon emissions. This setup facilitates efficient material transfer through enclosed conveyor systems. Controlling dust and preventing material spillage are critical priorities in our material handling processes, particularly during bulk transport and storage. To address dust control, we have deployed several advanced dust suppression technologies. Our primary approach involves using enclosed conveyor systems, which significantly reduce the amount of dust generated during the transport of raw materials like limestone, gypsum, and clinker. Additionally, we have installed misting and fogging systems that trap dust particles before they can become airborne, ensuring a cleaner and safer environment within the plant.
We have also incorporated dust collection systems, such as bag filters and electrostatic precipitators, at key material transfer points. These systems capture dust at the source, preventing it from escaping into the atmosphere. Regular monitoring and maintenance of these systems ensure their optimal performance, helping us meet stringent environmental regulations. Material spillage is minimised through the use of spill-resistant conveyor belts and properly designed transfer chutes. We ensure that our handling equipment is properly aligned and calibrated to avoid any unnecessary material loss. Furthermore, our real-time monitoring systems allow us to detect and address any material handling inefficiencies promptly, ensuring that spillage is kept to a minimum. By combining these efforts, we maintain a high level of operational efficiency while adhering to safety and environmental standards.

With sustainability becoming a key focus in the cement industry, what steps is your organisation taking to reduce the environmental impact of material handling, such as energy consumption and emissions?
Wonder Cement is deeply committed to reducing the environmental impact of its material handling operations. One of the primary steps we’ve taken is the integration of energy-efficient technologies across our material handling systems. We utilise high-efficiency motors, variable frequency drives (VFDs), and energy-optimised conveyor systems, which help us reduce energy consumption while maintaining operational efficiency. In terms of emissions, our focus is on minimising dust emissions through advanced dust suppression systems and using enclosed conveyors. We have also implemented real-time emissions monitoring systems to track and control particulate matter generated during material handling, ensuring compliance with environmental regulations. The installation of dust collectors, such as bag filters and electrostatic precipitators, helps capture and recycle dust back into the production process, reducing waste and emissions.
Furthermore, we are actively exploring alternative raw materials and fuels that have a lower carbon footprint. By integrating materials like fly ash and slag into our cement production process, we reduce the need for virgin raw materials, which in turn lowers the environmental impact of their extraction and transport. Our commitment to sustainability also includes efforts to optimise logistics and transportation. By streamlining material transport within the plant, we reduce fuel consumption and associated greenhouse gas emissions. These initiatives align with our broader sustainability goals, contributing to a greener, more responsible cement production process.

Automation and digitalisation are transforming material handling systems. How has your company integrated Industry 4.0 technologies like IoT, AI, and robotics to enhance material handling efficiency?
Wonder Cement has embraced Industry 4.0 technologies to significantly enhance the efficiency of our material handling systems. The integration of IoT (Internet of Things) devices throughout our plant allows us to gather real-time data on material flow, equipment performance, and operational conditions. This data is crucial for optimising our processes, as it enables us to monitor and adjust material handling systems dynamically based on demand and production needs. AI (Artificial Intelligence) plays a vital role in predictive maintenance and process optimisation. By analysing data from IoT sensors, AI algorithms can predict potential equipment failures and recommend preventive actions. This reduces unplanned downtime and prolongs the life of our machinery, ensuring smooth and continuous material transport. Additionally, robotics has been implemented in certain areas of our material handling processes, particularly in packaging and palletising operations. Robots handle these tasks with precision and speed, reducing the need for manual labor and minimising the risk of human error.
We also leverage digital twins—virtual models of our material handling systems—to simulate different scenarios and optimise performance. This helps us identify bottlenecks and inefficiencies before they impact production. The adoption of these Industry 4.0 technologies not only improves operational efficiency but also enhances safety, reduces costs, and contributes to the overall sustainability of our cement manufacturing process.

What are the primary challenges you face in handling alternative raw materials or fuels (such as waste, biomass, or fly ash), and how have you adapted your material handling infrastructure to manage these new inputs?
Handling alternative raw materials and fuels, such as waste, biomass, and fly ash, presents unique challenges due to their varying properties compared to traditional inputs. At Wonder Cement, we have adapted our material handling infrastructure to manage these challenges effectively. One of the main issues is the irregular particle size and moisture content of alternative materials, which can affect the flow and handling efficiency. To address this, we have implemented specialised conveyors and storage systems designed to accommodate the diverse characteristics of these materials. For example, we have modified our storage silos and hoppers to ensure smoother material flow and prevent blockages or clumping. In addition, we utilise advanced weighing and dosing systems to ensure precise control over the input of alternative materials, maintaining the consistency and quality of our cement.
Another challenge is the higher tendency of alternative fuels, such as biomass, to produce dust and emissions. To counter this, we have upgraded our dust suppression systems and installed filters at key transfer points. This ensures that the environmental impact of using alternative materials is minimised. Furthermore, we continuously monitor and fine-tune our material handling processes through data analytics and IoT-based systems, enabling us to adapt to the specific requirements of alternative materials. By investing in this infrastructure, we are able to incorporate sustainable materials into our production processes without compromising efficiency or
product quality.

What role do preventive maintenance and condition monitoring play in your material handling operations, and how does this contribute to minimising downtime and enhancing equipment lifespan?
Preventive maintenance and condition monitoring are integral to Wonder Cement’s approach to material handling operations. We employ a proactive maintenance strategy that focuses on regular inspections, timely servicing, and the early detection of potential issues to ensure the longevity and efficiency of our equipment. Condition monitoring systems, such as vibration analysis, temperature sensors, and oil analysis, are used to track the health of our material handling equipment in real time. By continuously monitoring the performance of critical components like conveyor belts, motors, and bearings, we can identify early signs of wear or malfunction. This allows us to schedule maintenance before a failure occurs, significantly reducing unplanned downtime and preventing costly breakdowns.
In addition, predictive maintenance tools, powered by AI and data analytics, enable us to predict when specific equipment will require servicing based on historical performance data. This not only enhances the lifespan of our machinery but also optimises maintenance schedules, ensuring that equipment is serviced only when necessary, thus avoiding unnecessary downtime. Preventive maintenance also improves safety, as it reduces the likelihood of accidents caused by equipment failure. Ultimately, by adopting these strategies, we can maintain a high level of operational efficiency, minimise production interruptions, and extend the service life of our material handling systems.

Looking forward, what future trends do you foresee in material handling for the cement industry, and how is your company preparing to adopt these advancements to stay competitive?
As the cement industry continues to evolve, several key trends in material handling are likely to shape the future. One of the most significant trends is the increased adoption of digitalisation and automation, driven by Industry 4.0 technologies. At Wonder Cement, we are preparing for this shift by investing in IoT, AI, and robotics to enhance the efficiency, safety, and sustainability of our material handling processes. Another emerging trend is the use of alternative raw materials and fuels, as the industry moves towards more sustainable production practices. We are adapting our material handling infrastructure to accommodate these new inputs, such as waste-derived fuels and biomass, which require specialised equipment and handling techniques.
Energy efficiency and emissions reduction will also be key focuses in the coming years. We foresee a greater emphasis on energy-efficient motors, renewable energy sources, and advanced dust suppression technologies to minimise the environmental impact of material handling. Our commitment to sustainability is evident in our continuous efforts to reduce energy consumption and implement cleaner technologies across our operations. Additionally, predictive maintenance and advanced analytics will play an increasingly important role in optimising equipment performance and minimising downtime. By staying at the forefront of these trends and integrating them into our operations, Wonder Cement is well-positioned to remain competitive in an evolving industry while maintaining our commitment to innovation and sustainability.

Shubham Choudhari, Chief Technology Officer, SBL Energy, explains how their technologies help reduce the environmental impact of the mining process.

Sustainable mining is increasingly critical across various industries. How does SBL Energy contribute to sustainability in mining, particularly with the use of industrial explosives in sectors like cement production?
At SBL Energy, sustainability is a core value, and we are committed to eco-friendly mining practices. Our contribution to sustainability is centred on developing and supplying high-quality, efficient explosives that optimise resource extraction while minimising environmental disruption. By utilising advanced bulk emulsion explosives and precision blasting techniques, we reduce over-blasting and material waste, which directly contributes to a lower environmental footprint in cement production. This approach supports sustainable mining by ensuring more efficient use of resources and reducing energy consumption.

What are the key environmental challenges associated with the use of industrial explosives in mining, and how is SBL Energy working to minimise the environmental impact of these explosives?
The use of industrial explosives presents key environmental challenges, including ground vibrations, air pollution from dust and gas emissions, and excessive material fragmentation. SBL Energy addresses these challenges by:

• Developing low-emission explosives, such as bulk emulsions, that reduce the release of harmful gases like NOx.
• Promoting the use of controlled blasting techniques to minimise ground vibrations and ensure precision in fragmentation, leading to less environmental disruption.
• Innovating non-electric detonators for more accurate blast timing, which reduces the risk of unwanted side effects such as excessive noise or ground instability (SBL version).

In the context of cement manufacturing, which relies heavily on raw material extraction, how can innovative blasting techniques help reduce the environmental footprint of quarrying operations?
Innovative blasting techniques play a significant role in reducing the environmental footprint of quarrying for cement manufacturing. At SBL Energy, we provide customised blasting solutions that:

• Optimise fragmentation to ensure that the extracted material is of the required size, which reduces the need for secondary crushing and lowers
  energy consumption.
• Reduce waste by minimising over breaks and ensuring that the maximum amount of usable material is extracted, decreasing the environmental burden of discarded materials.
• Lower emissions by using advanced bulk explosives that reduce the release of harmful gases and by employing more precise timing through electronic detonators, minimising the total number of blasts needed.

Could you elaborate on the role of non-electric detonators and bulk emulsion explosives in optimising energy efficiency and reducing emissions in mining operations for cement production?
Non-electric detonators provide precise timing control, ensuring that the blast sequence is synchronised, which helps achieve better fragmentation and reduces energy usage in post-blast processing like crushing and milling. They also reduce the need for complex wiring, making operations more efficient and reducing the risk of misfires.
Bulk emulsion explosives are another critical component. These explosives have a higher energy output compared to traditional explosives, enabling more effective blasts with less explosive material. This reduces the number of blasts required and thus cuts down emissions from multiple detonations. Additionally, bulk emulsions tend to be more environmentally friendly, as they produce fewer toxic gases and dust emissions.

The cement industry is a significant user of raw materials from mining.
How does SBL Energy’s technology improve resource recovery during blasting, ensuring more efficient extraction for
cement production?
At SBL Energy, we leverage advanced technology to improve resource recovery during blasting. Our precision blasting techniques ensure optimal rock fragmentation, minimising the need for re-blasting and ensuring that a higher proportion of extracted material is of high quality and ready for processing. This approach delivers several key benefits:

• Higher recovery rates: Less material is left in the ground, and more is recovered for cement production.
• Reduced material loss: By controlling the blast size and reducing overbreak, we minimise the amount of unusable material, ensuring that raw material extraction is more efficient and cost-effective.
• Increased operational efficiency: More accurate blasting translates to reduced transportation and processing costs, further lowering the environmental impact.What role does SBL Energy’s R&D play in innovating eco-friendly explosives or reducing the carbon footprint of mining operations in sectors like cement manufacturing?
  SBL Energy’s R&D division is deeply committed to the development of eco-friendly explosives and techniques that reduce the carbon footprint of mining operations. Our focus areas include:
• Developing biodegradable and low-toxicity materials in explosives to reduce environmental contamination.
  Advancing emulsion-based explosives that are more energy-efficient and produce fewer harmful by-products.
  Collaborating with our clients to integrate blasting optimisation software that calculates the most effective blast design, reducing fuel use, emissions, and overall environmental impact. Our R&D efforts continuously explore innovative materials and methods that contribute to greener mining practices

Sustainability often requires a holistic approach. How does SBL Energy assist its clients in developing comprehensive strategies for sustainable mining practices, from product usage to waste management, particularly in industries like cement?
At SBL Energy, we partner with our clients to create customised, sustainable mining strategies that extend beyond product application. We assist in:

• Optimising blasting operations to reduce waste, conserve energy, and enhance resource recovery.
• Implementing best practices for waste management, focusing on minimising the generation of unusable material during blasting.

This comprehensive approach helps our clients achieve greater sustainability throughout their operations, from raw material extraction to waste management.

Looking forward, what are some of the most promising trends or innovations in sustainable mining that SBL Energy is exploring, and how do you foresee these benefiting the cement industry?
SBL Energy is actively exploring several promising trends in sustainable mining, including:

• Electronic detonators: We are advancing the use of electronic detonators that enable more precise blast control, resulting in reduced energy consumption and improved blast efficiency.
• Automation and smart blasting: Utilising data analytics and machine learning to optimise blast designs for efficiency and environmental impact reduction. These innovations are expected to greatly benefit the cement industry by reducing operational costs, lowering emissions, and enhancing the overall sustainability of quarrying operations.

Pukhraj Sethiya, India Managing Director, and Jyotirmoy Saha, Senior Consultant, with guidance and inputs from Kumar Rajesh Singh, Global Managing Director, ReVal Consulting, discuss their approach to sustainable mining, environmental responsibility and innovative mine planning.

Can you define what sustainable mining means to ReVal Consultancy, and how it aligns with your core principles in the capital industry sector?
Sustainable mining focuses on enhancing recovery and resource life, minimising environmental impact, promoting social responsibility and ensuring economic viability in mineral extraction processes. Keeping these objectives in mind, at ReVal we firmly believe in the three pillars of innovation, sustainability, and trust, and our work is governed by this ethos in their true spirit. From the very onset we have prioritised integrating sustainability into our practices and ensuring the benefit of the same is passed on to our clients. A testament to this is our optimised mine plans and mine operational plans, which are conceptualised to maximise resource extraction by minimising waste generation and environmental footprint thus helping our clients in having an efficient and streamlined mining project.

How does Reval Consultancy integrate sustainability into mine planning, and what specific strategies are used to minimise environmental impact while maximising resource utilisation?
Mine planning is a complex job and requires extensive critical thinking along with technical competency. With a core focus on sustainability and resource recovery maximisation, our mine plans are built in ways that ensure long term gains for our esteemed clients. We deploy first principle thinking and create numerous design iterations which helps us in curating a comparative picture of the different ways of operating a particular mine. This involves defining the mine pit boundary first which is of prime importance to ensure optimum land requirement and utilisation.
Further, using advanced software’s like MINEX and SURPAC and others, we ensure an optimised mine design with smooth production sequencing that is viable, ensuring focus on dump balancing, staggered land possession and progressive mine closing activities reducing handling requirement, haul distances and avoid rehandling to the extent possible. To minimise environmental impact, our mine operational plans are formulated with a mix of both conventional fuels based and renewable battery powered equipment. Further we also include afforestation and garland drainage systems in all our mine closure plans ensuring a proper restoration of the site post mining.

What role does technology play in driving sustainability within the mining operations that you consult on? Are there any particular innovations that have been game-changers for your clients?
Technology has a paramount role to play in driving the sustainability initiatives in mining. The industry 4.0 revolution has pushed all the sectors to embrace automation on the backdrop of maximising productivity and achieving sustainable standards. Mining too has been positively impacted by the digitisation and rapid scale adoption of IoT based technologies. Continuous monitoring of emissions from operations, drone deployment for surveys, RFID based data collection and renewable energy-based equipment deployment to mention a few has helped champion both sustainability and operations in the sector. At ReVal, we remain committed in advising our clients on staying at the forefront of tech adoption. We formulate mine plans with advanced scheduling software’s like MINEX and SURPAC that helps clients in real-time visualisation of the mining progression. Besides that, our operational plans embed tech-enabled equipment and data stacks such as automated heavy equipment, GPS enabled truck dispatch systems and interactive KPI dashboards that ensure streamlined operations with real time data capture of all aspects of mining.

What are the biggest challenges that mining companies face when adopting sustainable practices, and how does ReVal Consultancy help them overcome these?
Mining entities face serious challenges regarding their environmental footprint, efficient resource utilisation and community engagement. While there are plausible solutions that exist to tackle these encumbrances, the real difficulty lies in implementing these solutions on the ground. Worldwide mining companies face challenges related to violations in air pollution, emissions, regulations and health and safety to mention a few, solely because of the lack of visibility of operations to stakeholders. Further, the demand of maintaining production and shareholder returns, several times such issues are overlooked and missed. However, the most significant challenge we have encountered in our tenure is the problem related to the availability of land in India. A very complex issue, posed by the communities, severely causes distress for mining companies, leading to the derailment of mining schedules and operational plans.
An uncertain yet a pre-emptive measure that we deploy to tackle this problem, is we work with clients on short term operational planning that can be altered in real-time without significantly hampering the production prospects while keeping a view of Life of Mine Plan. Further in cases where a breakthrough is bleak, we provide the requisite support to the client and prepare an alternative plan with minimum deviation, ensuring minimal hiccups in the project.
ReVal’s approach includes comprehensive mine design optimisation.

How do you ensure that sustainability considerations, such as waste minimisation and environmental protection, are incorporated into mine design and operations?
Our mine plans are highly intuitive in nature and help clients envision the way the mining operations would progress over the mine life. As sustainability has become a norm, we ensure to integrate the same while designing every mine with prime focus on optimum resource recovery, minimum waste generation and less environmental impact. For achieving this we follow a meticulous approach that we have designed in-house. Rather than solely relying on documented data, we start with an on-ground survey of the site and take stock of the infrastructures such as densely populated villages, protected forest areas and other topographical encumbrances that exist. This helps in ensuring a highly optimised mine design when curated in MINEX or SURPAC with less challenges for the client in getting approvals and clearances thereby significantly reducing the time to operationalisation.
Further, we put an increased focus in mine sequencing during the designing phase which helps in regulating the overburden generation and land possession. With an entrenched focus on internal dumping and delayed land possession, we ensure mine operations remain optimised and profitable and communities remain undisturbed. The multiplier effects of these are enhanced ROM production, reduced expenditure and overall maximisation of value for stakeholders.

What is your view on the role of renewable energy in mining operations? How can the cement industry benefit from incorporating sustainable energy practices into their mining operations?
India is the second largest producer of cement in the world and is reliable in the mining sector for its raw material inputs. Big players in the cement manufacturing space adhere to the Sustainable Development Goals framed by the UN, however, implementing, practicing and upholding the standards become a challenge solely due to the uncontrollable ground situations. With the heightened advocacy on decarbonisation, the mining industry is gradually changing its way of operations.
Adoption of renewable energy-based power systems and battery-powered heavy mining equipment is slowly gaining traction and will pave the way for significant reduction in the sector’s carbon footprint, besides making it cost efficient. The cement industry being a part of the mining value chain will gain significantly by the adoption of these sustainable practices. Moreover, the industry is also embracing some of the newer strategies such as deployment of 3R methodology, installation of energy efficient kilns, and waste to energy processes for effectively handling byproducts, thereby propelling the sector towards becoming clean, compliant and efficient.

How does ReVal support mining companies in complying with global and local environmental regulations, particularly in the context of the cement industry’s mining activities?
At ReVal, we believe in providing end to end solutions to our esteemed clients. Our in-house technical team comprises capabilities in both technical and management consulting, which enables us to serve our clients with services ranging from mine planning and designing to project management services. Mining is a complex activity and requires stringent adherence to prevalent rules and regulations. And that’s where our contract management expertise comes into play, helping mining companies abide by the law of land.
We advise our clients periodically on the changing regulatory landscape and simultaneously conduct on ground audits to identify the gaps that exist in the operations. This we achieve by thoroughly checking the documents pertaining to operations, quality parameters and KPI achievements with regards to production, environment and safety and project timelines. Also, managing mine operations is a complex task and iterative in nature and we periodically frame new audit parameters to encompass all the necessary mandates set by the government.

Looking ahead, what are the key trends you foresee in sustainable mining, and how is Reval Consultancy preparing to support its clients in navigating these changes?
The mining sector is undergoing rapid digital transformation and each and every activity in the mines are getting interconnected. This helps in obtaining real-time data and helps stakeholders make strategic decisions efficiently. In recent years, we have witnessed Indian mines investing significantly in installing IoT devices such as robotic equipment and machines and GPS based devices to expand the visibility of the operations, culminating in a ‘borehole to boardroom’ concept.
At ReVal, aligning with this transition, we are dedicated to empowering our clients to navigate the evolving landscape of the mining industry. Our solutions are grounded in rigorous research and analytics conducted by our highly skilled team, enabling clients to have information about their projects at fingertips. Through advanced project management tools and interactive and customisable KPI dashboards, we ensure our clients experience an expansive view of the project anytime from anywhere, reaping the benefits of increased efficiency, reduced costs, less on-site exposure and a healthy work life balance.