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The Code on Wages 2019: Impact on cost to company

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The Code on Wages, 2019 has defined ??ages??in great detail. The same definition is quoted in the subsequent three labour codes passed by Parliament in 2020. According to Section 2 (y) of the code, ??ages” mean the entire remuneration paid to an employee while in employment and include: (i) basic pay; (ii) dearness allowance; and (iii) retaining allowance, if any.

However, ??ages??do not include:

(a) any bonus payable under any law for the time being in force, which does not form part of the remuneration payable under the terms of employment;

(b) the value of any house-accommodation, or of the supply of light, water, medical attendance or other amenity or of any service excluded from the computation of wages by a general or special order of the appropriate government;

(c) any contribution paid by the employer to any pension or provident fund, and the interest which may have accrued thereon;

(d) any conveyance allowance or the value of any travelling concession;

(e) any sum paid to the employed person to defray special expenses entailed on him by the nature of his employment;

(f) house rent allowance;

(g) remuneration payable under any award or settlement between the parties or order of a court or tribunal;

(h) any overtime allowance;

(i) any commission payable to the employee;

(j) any gratuity payable on the termination of employment;

(k) any retrenchment compensation or other retirement benefit payable to the employee or any ex-gratia payment made to him on the termination of employment.

However again, for calculating the ??ages??under this clause, if payments made by the employer to the employee under clauses (a) to (i) exceed one-half, or such other per cent as may be notified by the central government, of all the remuneration calculated under this clause, the amount which exceeds such one-half, or the per cent so notified, shall be deemed as remuneration and shall accordingly be added to the ??ages??under this clause.

This clause defines ??ages??as consisting of the basic pay, the dearness allowance and the retaining allowance if any. However, if these three components were to add up to less than 50 per cent of the total defined remuneration, then the 50 per cent figure arrived at will be regarded as ??ages??

Following the enactment of the Code on Wages, 2019, four existing Acts stand repealed. The concerned acts are: The Payment of Wages Act, 1936, The Minimum Wages Act, 1948, The Payment of Bonus Act, 1965 and The Equal Remuneration Act, 1976.

The Code on Wages, 2019 is applicable to all the employees of every establishment. This means the code applies not only to workers but to the supervisors and executives as well. The new definition of ??ages??will ensure that the minimum wages as prescribed by the the Government from time to time would strictly be complied with, while eliminating the scope for reducing the contribution to terminal benefits, because of the bifurcation method applied by employers in the past. Admittedly, once the code becomes operational, the new definition of ??ages??is likely to add to the financial burdens of several companies.

Evolution of wage structure with allowances

When I commenced my corporate career in 1970 as an Assistant Engineer with Mukand Iron & Steel Works (now called Mukand), there was nothing like the concept of cost to company (CTC). The appointment letter given to me merely carried details of the monthly basic pay, the Grade in which I was placed, and the annual increment applicable to that grade. There was also mention about the monthly dearness allowance that I would receive based on the consumer price index. In my first payslip, the total of these two items ??basic pay and dearness allowance ??amounted to a princely sum of Rs 1,050 per month.

No other allowances were payable to me, either monthly or annually, during the first two years of my service, except the annual bonus declared by the company before Diwali based on the earnings for the previous year. This pattern of monthly wages continued largely in the same manner as I moved up the organisational hierarchy by way of promotion, as well as movement from one organisation to another in my corporate career. Just to reiterate, the basic pay and for certain years the Dearness Allowance continued to be the most important components of my monthly remuneration.

In India, the concept of CTC had its origins in the information technology (IT) companies from around mid-1980??. Alongside, consulting firms began to undertake surveys of executive remuneration for providing a comparative picture of a company?? standing in respect of its compensation levels and for determination of industry wise benchmarks. Some select companies formed remuneration clubs for similar purposes, primarily for exchange of salary details and compensation practices. These new developments necessitated having to assign cash value to perquisites extended to executives especially in multinational companies. Later, when the income tax rates were rationalised and the tax-free perquisites came up for scrutiny, companies began to treat all items of compensation as taxable. This automatically led to the legitimisation of the concept of CTC.

Simultaneously, there were other developments. The practice of including dearness allowance in the monthly salary of executives was abandoned by most companies. Also, in negotiations of long-term wage settlements with trade unions, organisations tried to introduce new allowances. This was done mainly to limit the rise in basic pay and monthly dearness allowance, as these two items had an impact on several other payments such as overtime rate, annual bonus, leave encashment, contribution to provident fund and gratuity.

In enterprises which have field force for supporting the sales and marketing effort, there has been a practice of negotiated tax-free daily allowance for local and out station working of the field force as the job entails travel, boarding and at times lodging expense. Here the tax-free daily allowance is normally paid without any supporting vouchers and at times higher than the normal expense. The eligible tax-free daily allowance is quite often part of a negotiated long-term wage settlement.

CTC

CTC is the nomenclature presently used by Employers while making an offer of employment to show case total remuneration. The final figure shared can be misleading as in some cases it includes items such as performance bonus payable at its maximum (for which amount limited number of persons qualify), monetary value of Subsidised snacks and meals, and gratuity (which again is payable only when an employee completes a minimum of five years of service). Many new employees get at first impressed with the CTC figures shown on the paper, but later feel disappointed when they realise that the monthly take home pay is very much lower, and not one twelfth of the CTC amount, as they had assumed that it would be.

Some companies offer an ? la carte system where employees can opt for allowances of their choice within the negotiated CTC limits. This is done for two purposes: 1) cash now as against deferred payment and 2) reduction of tax liability.

The CTC represents a company?? total annual expenditure on an employee. CTC computation includes all the payments, in cash and in kind, the direct payments and the money value of the welfare benefits and perquisites extended to an employee. Hence, to avoid any misunderstanding or subsequent disappointment, the CTC components should be explained clearly and carefully to a new joinee.

Elements of CTC

The items defined under section 2 (y) of the code fall into three categories of the CTC format in vogue among the companies. They are as follows:

A) Direct benefits to an employee ??(i) basic pay, (ii) dearness allowance, (iii) retaining allowance, (a) bonus, (d) conveyance allowance, (e) special expenses, (f) house rent allowance or reimbursement, (g) amount payable under an award, (h) over time allowance, (i) commission.

Allowances such as shift allowance, education allowance, dress allowance, and any other allowance which form part of the direct benefits but have not been defined anywhere in the Code, will have to be considered as elements of item (e) special expenses and be regarded as part of remuneration.

However, medical allowance or reimbursement, medical insurance premium and leave travel reimbursement, which are shown as part of CTC, may not have to be included in calculating the remuneration under the code.

B) Indirect Benefits to an employee include the item value of house accommodation. Which under Section 2 (y) (b) of the code is defined as: ??he value of any house-accommodation, or of the supply of light, water, medical attendance or other amenity or of any service excluded from the computation of wages by a general or special order of the appropriate Government?? House accommodation to employees plus supply of electricity, water is generally provided in the company?? township. In some cases, accommodation is provided to essential staff or persons in top management cadre. There is a method of computing the value of accommodation, if provided free, as per existing income tax laws.

There are organisations that hich provide also the following benefits: interest free loans for buying assets, food coupons in lieu of subsidised meals, payment of medical insurance premium, free transport to office and free uniform. All these items form part of indirect benefits, but they have not been defined anywhere in the Code. On the other hand, they are being shown as part of CTC by the organisations. These items stay as grey areas and there is a danger that they may become objects of arbitrary interpretation by the Labour & Employment Department.

C) Saving contribution to an employee refers to item 2 (y) (c) of the code contribution paid by the employer to any pension or provident fund, and the interest which may have accrued thereon. Organisations were including the contributions made by the Employer to the employee?? Pension and Provident Fund accounts under the existing law, in the employee?? CTC. However, the interest which may have accrued to the contribution in the year was never considered as part of CTC, as this is not paid by the employer. Be that as it may, for the first time ever, the interest accruing to the contribution has been made a part of remuneration under the new code. This is clearly a new development.

Many companies operate superannuation fund for their executives. The contribution to the superannuation fund, amounting to 15 per cent of an employee?? basic salary (plus dearness allowance, if any), is solely made by the employer. The Government of India has presently set an aggregate limit of Rs 7.5 lakh for employer contributions to the Provident Fund (PF), National Pension System (NPS) and superannuation fund (SF), any contribution beyond which is taxable for the beneficiary, otherwise this amount does not at present attract any liability. In fact, the code seems silent about SF. The SF is, no doubt, a pension fund, and the code does make a mention of pension fund. But the pension fund referred to under item 2 (y) (c) in the Code is about the pension scheme which forms part of the PF. SF does not get discussed at all in the Code.

This is yet another grey area. It would, therefore, be advisable to include the employer?? contribution to the superannuation scheme as part of remuneration. There are companies that have stock options for certain category of employees and this could be a grey area for it to be considered as remuneration based on the Income Tax Act.

Impact on companies

The two items, that pose a problem in computing an employee?? remuneration for a financial year, are overtime and annual bonus. In the case of workers, over time earnings are a part of remuneration. However, the payments are likely to vary from month to month and the exact amount will only be known at the end of the year. Similarly, the annual bonus payable to employees could vary from year to year as the final amount is based on the available allocable surplus. Of course, it is entirely a different matter that in quite a few companies, the quantum of bonus is negotiated and settled with the trade union and is in no way related to the allocable surplus.

All organisations have to calculate the ??ages??as defined under the cde and see whether the existing basic pay, dearness allowance and retaining allowance together amount to more than 50 per cent of the remuneration for every one of their employees, whether they are executives, supervisors, workers or even contract workers. If it does, there would not be any additional financial liability to the company when the code becomes operational.

But in organisations where the ??ages??do not add up to 50 per cent of the remuneration, extra provision will have to be made for leave encashment and gratuity payments. As for the employer?? contribution towards PF, as long as the present limits are in force at ??12 per cent of the wages subject to a present wage ceiling of Rs 15,000 pm ??the additional financial impact is likely to be marginal. If, however, the wage ceiling of Rs 15,000 were to be enhanced or removed, then there is bound to be additional liability, once the code becomes operational.

Conclusion

In cases where the wages paid amount to less than 50 per cent of the total remuneration, organisations need to take corrective measures to remove the anomaly forthwith. The easiest way is to enhance the basic pay gradually while granting annual increments.

Organisations should also institute reasonable limits to leave accumulation and urge their employees to avail of their annual leave regularly. This will reduce a company?? liability considerably when it comes to leave encashment.

There is a provision in the code that the full and final settlement of a departing employee will have to be completed within two working days. This may not pose a problem in the cases of retirement, retrenchment or dismissal of an employee. However, in the cases of resignation

without advance notice, making full and final settlement of the dues within two working days can be a big challenge, as processing of the monthly payroll in most enterprises is outsourced. Hopefully, this issue can be resolved by ensuring that the departing employee has to serve the notice period.

Confusion still persists among the professionals of most companies as to which components of the CTC are to be included in computing the remuneration, to determine the quantum of ??ages?? It would hugely benefit organisations, trade unions and employees, if the Ministry of Labor & Employment, Government of India can release question and answers by sharing real life examples to explain how the ??ages??are to be calculated. This will help the organisations to duly comply with all the provisions of the new code and spare them from being harassed at a later date by government agencies for non-compliance, which, in many cases, could be merely due to ignorance or misunderstandings.

ABOUT THE AUTHOR:

Dr. Rajen Mehrotra is Past President of Industrial Relations Institute of India (IRII, Former Senior Employers??Specialist for South Asian Region with International Labor Organization (ILO) and Former Corporate Head of HR with ACC Ltd. and Former Corporate Head of Manufacturing and HR with Novartis India Ltd. E-Mail: rajenmehrotra@gmail.com

Published in April 2021 issue of Current Labour Reports.

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Economy & Market

SEW-EURODRIVE India Opens Drive Technology Centre in Chennai

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The new facility strengthens SEW-EURODRIVE India’s manufacturing, assembly and service capabilities

SEW-EURODRIVE India has inaugurated a new Drive Technology Centre (DTC) in Chennai, marking a significant expansion of its manufacturing and service infrastructure in South India. The facility is positioned to enhance the company’s responsiveness and long-term support capabilities for customers across southern and eastern regions of the country.

Built across 12.27 acres, the facility includes a 21,350-square-metre assembly and service setup designed to support future industrial growth, evolving application requirements and capacity expansion. The centre reflects the company’s long-term strategy in India, combining global engineering practices with local manufacturing and service capabilities.

The new facility has been developed in line with green building standards and incorporates sustainable features such as natural daylight utilisation, solar power generation and rainwater harvesting systems. The company has also implemented energy-efficient construction and advanced climate control systems that help reduce shopfloor temperatures by up to 3°C, improving production stability, product quality and working conditions.

A key highlight of the centre is the 15,000-square-metre assembly shop, which features digitisation-ready assembly cells based on a single-piece flow manufacturing concept. The facility also houses SEW-EURODRIVE India’s first semi-automated painting booth, aimed at ensuring uniform surface finish and improving production throughput.

With the commissioning of the Chennai Drive Technology Centre, SEW-EURODRIVE India continues to strengthen its manufacturing footprint and reinforces its long-term commitment to supporting industrial growth and automation development in India.

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Concrete

Material Flow Efficiency

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We explore how material handling systems are becoming strategic assets in cement plants, enabling efficient movement of raw materials, clinker and finished cement. Advanced conveying, automation and digital technologies are improving plant productivity while supporting energy efficiency and sustainability goals.

Material handling systems form the operational backbone of cement plants, enabling the efficient movement of raw materials, clinker and finished cement across complex production networks. With India’s cement industry producing over 391 million tonnes of cement in FY2024 and possessing an installed capacity of around 668 mtpa, according to the CRISIL Research Industry Report, 2025, efficient material logistics have become critical to maintaining plant productivity and cost competitiveness. At the same time, cement production is highly energy intensive and contributes around 7 per cent to
8 per cent of global CO2 emissions, making efficient material flow and logistics optimisation essential for reducing operational inefficiencies and emissions states the International Energy Agency Cement Technology Roadmap, 2023. As plants scale capacity and integrate digital technologies, modern material handling systems, ranging from automated conveyors to intelligent stockyards, are increasingly recognised as strategic assets that influence plant stability, energy efficiency and environmental performance.

Strategic role of material handling
Material handling is no longer viewed as a secondary utility within cement plants; it is now recognised as a strategic system that directly influences production efficiency and process stability.
Cement manufacturing involves the continuous movement of large volumes of limestone, clay, additives, clinker and finished cement across multiple production stages. Even minor disruptions in conveying systems or storage infrastructure can lead to kiln feed fluctuations, production delays and significant financial losses. According to Indian Cement Industry Operational Benchmarking Study, 2024, unplanned downtime in large integrated cement plants can cost between Rs.15–20 lakh per hour, highlighting the economic importance of reliable material handling systems.
Modern cement plants are therefore investing in advanced mechanical handling systems designed for high throughput and operational reliability. Large integrated plants can process over 10,000 tonnes per day of clinker, requiring highly efficient conveying systems and automated stockyards to maintain continuous material flow, suggests the International Cement Review Industry Analysis, 2024. Efficient material handling also reduces spillage, minimises dust emissions and improves workplace safety. As cement plants become larger and more technologically advanced, the role of material handling is evolving from simple transport infrastructure to a critical operational system that supports both productivity and sustainability.

From quarry to plant
The transport of raw materials from quarry to processing plant represents one of the most energy-intensive stages of cement production. Traditionally, limestone and other raw materials were transported using diesel-powered trucks, which resulted in high fuel consumption, dust generation and increased operational costs. However, modern plants are increasingly adopting long-distance belt conveyors and pipe conveyors as a more efficient alternative. These systems allow continuous material transport over distances of 10–15 kilometres, significantly reducing fuel consumption and operating costs while improving environmental performance, states the FLSmidth Cement Industry Technology Report, 2024.
Milind Khangan, Marketing Manager, Vertex Market Research & Consulting, says, “Efficient and enclosed handling of fine materials such as cement, fly ash and slag requires modern pneumatic conveying systems. By optimising the air-to-material ratio, these systems can reduce energy consumption by 10 per cent to 15 per cent while ensuring smooth material flow. Closed-loop conveying further minimises dust loading and improves the performance of bag filters, supporting cleaner plant operations. In addition, flow-regulated conveying lines help prevent clogging and maintain reliable dispatch performance. Overall, automation in pneumatic conveying delivers immediate operational benefits, including improved equipment uptime, lower energy use, reduced material spillage and more stable kiln and mill performance.”
Pipe conveyor systems are particularly gaining traction because they provide a completely enclosed transport system that prevents material spillage and dust emissions. According to global cement engineering studies, conveyor-based transport can reduce energy consumption by up to 30 per cent compared to truck haulage, while also improving operational reliability. Several cement plants in India have already implemented such systems to stabilise quarry-to-plant logistics while reducing carbon emissions associated with diesel transport.

Stockyard management and homogenisation
Stockyards play a critical role in maintaining raw material consistency and stabilising kiln feed quality. Modern cement plants use advanced stacker and reclaimer systems to ensure efficient storage and blending of raw materials before they enter the grinding and pyroprocessing stages. Automated stacking methods such as chevron or windrow stacking enable uniform distribution of materials, while bridge-type or portal reclaimers ensure consistent extraction during kiln feed preparation. These systems are essential for maintaining stable chemical composition of raw meal, which directly influences kiln efficiency and clinker quality. The Cement Plant Operations Handbook, 2024 indicates that advanced homogenisation systems can reduce raw mix variability by up to 50 per cent, significantly improving kiln stability and energy efficiency. Integrated stockyard management systems also incorporate sensors for monitoring bulk density, moisture levels and stockpile volumes, enabling real-time control over material blending processes.

Clinker and cement conveying technologies
Once clinker is produced in the kiln, it must be efficiently transported to storage silos and subsequently to grinding and packing units. Modern cement plants rely on high-capacity belt conveyors, bucket elevators and pneumatic conveying systems to manage this stage of material flow. Steel-cord belt bucket elevators are now capable of lifting materials to heights exceeding 120 metres with capacities reaching 1,500 tonnes per hour, making them suitable for large-scale clinker production lines, states the European Cement Engineering Association Technical Paper, 2023.
For fine materials such as cement, fly ash and slag, pneumatic conveying systems provide a reliable and dust-free solution. These systems transport powdered materials using controlled airflow, ensuring enclosed and contamination-free movement between grinding units, silos and packing stations. Optimised pneumatic systems can reduce energy consumption by 10 per cent to 15 per cent compared to older conveying technologies, while also improving plant cleanliness and environmental compliance, according to the Global Cement Technology Review, 2024.

Automation and digitalisation
Digitalisation is transforming material handling systems by introducing real-time monitoring, predictive maintenance and automated control. Advanced sensors and Industrial Internet of Things (IIoT) platforms enable plant operators to track conveyor health, stockpile levels and equipment performance in real time. Predictive maintenance systems analyse vibration patterns, temperature fluctuations and equipment load data to detect potential failures before they occur. According to McKinsey’s Industry 4.0 Manufacturing Report, 2023, for heavy industries, digital monitoring and predictive maintenance technologies can reduce equipment downtime by up to 30 per cent and increase productivity by 10 per cent to 15 per cent. Digital control centres also integrate data from conveyors, stacker reclaimers and dispatch systems, enabling centralised management of material flows from quarry to dispatch.

Handling of AFR
The growing adoption of Alternative Fuels and Raw Materials (AFR) has introduced new challenges and opportunities for material handling systems in cement plants. AFR materials such as refuse-derived fuel (RDF), biomass and industrial waste often have irregular particle sizes, variable moisture content and lower bulk density compared to conventional fuels. As a result, specialised storage, dosing and feeding systems are required to ensure consistent kiln combustion. According to the Cement Sector Decarbonisation Roadmap published by NITI Aayog in 2026, increasing the use of AFR could enable India’s cement sector to achieve thermal substitution rates of around 20 per cent in the coming decades. To support this transition, plants are investing in automated receiving stations, shredding units, drying systems and precision dosing equipment to stabilise AFR supply and combustion performance.

Energy efficiency and dust control
Material handling systems also play a crucial role in improving plant energy efficiency and environmental performance. Modern conveyor systems equipped with variable speed drives and energy-efficient motors can significantly reduce electricity consumption. Permanent magnet motors used in conveyor drives can deliver 8 per cent to 12 per cent energy savings compared to conventional induction motors, improving overall plant energy efficiency according to the IEA Industrial Energy Efficiency Study, 2023. Dust control is another major concern in cement plants, particularly during material transfer and storage operations. Enclosed conveyors, dust extraction systems and advanced bag filters are widely used to minimise particulate emissions and improve workplace safety.

Future trends in material handling
The future of material handling in cement plants will be shaped by automation, digitalisation and sustainability considerations. Emerging technologies such as AI-driven logistics optimisation, autonomous mobile equipment and digital twins are expected to further improve plant efficiency and operational visibility. Digital twin models allow engineers to simulate material flow patterns, optimise stockyard operations and predict equipment performance under different operating conditions. According to the International Energy Agency Digitalisation and Energy Report, 2024, the adoption of advanced digital technologies could improve industrial energy efficiency by up to 20 per cent in heavy industries such as cement manufacturing. As cement plants expand capacity and adopt low-carbon technologies, intelligent material handling systems will play a critical role in maintaining productivity and reducing environmental impact.

Conclusion
Material handling systems have evolved from basic transport infrastructure into strategic operational systems that directly influence plant efficiency, reliability and sustainability. From quarry transport and automated stockyards to digital dispatch platforms and advanced conveying technologies, modern material handling solutions enable cement plants to manage large production volumes while maintaining process stability.
As India’s cement industry continues to expand to meet infrastructure and urban development demands, investments in advanced material handling technologies will become increasingly important. By integrating automation, digital monitoring and energy-efficient systems, cement manufacturers can improve operational performance while supporting the industry’s long-term sustainability and decarbonisation goals.

  • Kanika Mathur

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Concrete

Modernise to Optimise

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Cement plant modernisation is reshaping the industry through upgrades in
kilns, energy systems, digitalisation, AFR integration and advanced material
handling. We explore these technologies that improve efficiency, reduce
emissions, strengthen competitiveness, while preparing the industry for India’s
next phase of infrastructure growth.

India’s cement industry, the world’s second-largest, is undergoing a rapid transformation driven by infrastructure demand, decarbonisation targets and technological advancement. The sector’s installed capacity stood at approximately 668 million tonnes per annum (mtpa) in FY2025 and is projected to reach 915–925 mtap by 2030, supported by large-scale capacity expansions and infrastructure investment cycles, suggests CRISIL Intelligence Industry Report, 2025. At the same time, cement production remains highly energy intensive and contributes about 6 per cent to 7 per cent of India’s total greenhouse gas emissions, making efficiency improvements and modernisation critical for long-term sustainability as stated in CareEdge ESG Research, 2025. As a result, cement manufacturers are investing in advanced kiln technologies, digital monitoring systems, waste heat recovery, alternative fuels, and modern material handling infrastructure to enhance productivity while aligning with global decarbonisation pathways.

Need for modernisation
The need for plant modernisation is closely linked to the sector’s rapid capacity expansion and rising operational complexity. India’s installed cement capacity has grown significantly in the last decade and is expected to exceed 900 mtpa by 2030, driven by demand from housing, infrastructure and urban development projects, as per the CRISIL Intelligence Industry Report, 2025. However, increasing scale also places pressure on energy efficiency, logistics, and production stability. The report also suggests that the cement plants must upgrade equipment and processes to operate at higher utilisation rates, which are projected to reach 75 per cent to 77 per cent by the end of the decade, compared to around 72 per cent to 74 per cent in FY2026.
Environmental imperatives are another major driver of modernisation. Cement manufacturing is responsible for a significant share of industrial emissions because clinker production requires high-temperature processes that depend heavily on fossil fuels. According to CareEdge ESG research, the cement sector contributes 6–7 per cent of India’s total greenhouse gas emissions, with approximately 97 per cent of emissions arising from direct fuel combustion and process emissions in kilns. Consequently, plant modernisation initiatives now focus not only on productivity improvements but also on reducing emissions intensity, energy consumption, and reliance on conventional fuels.
“One of the most impactful upgrades implemented at Shree Cement in the last five years has been the adoption of advanced data management platforms that provide real-time visibility across major process areas. This digital advancement has strengthened plant automation by enabling faster and more accurate responses to process variations while improving the reliability of control loops. Real-time dashboards, integrated analytics and automated alerts now support quicker, data-driven decision-making, helping optimise kiln and mill performance, improve energy control and detect deviations early. By consolidating data from multiple systems into a unified digital environment, the company has enhanced operational consistency, reduced downtime and improved both productivity and compliance. This shift towards intelligent automation and real-time data management has become a key driver of operational excellence and future-ready plant management,” says Satish Maheshwari, Chief Manufacturing Officer, Shree Cement.

Kiln and pyroprocessing upgradation
The kiln remains the technological heart of cement manufacturing, and modernisation efforts often begin with upgrades to pyroprocessing systems. Many older plants in India operate with four- or five-stage preheaters, while modern plants increasingly adopt six-stage preheater and pre-calciner systems that significantly improve heat efficiency and clinker output. These systems enhance heat transfer, reduce fuel consumption, and stabilise kiln operations under high throughput conditions.
Professor Procyon Mukherjee suggests, “Cement manufacturing is, at its core, a thermal process. The rotary kiln and calciner together account for energy consumption and emissions. The theoretical thermal requirement for clinker production is around 1700–1800 MJ per tonne, yet real-world plants often operate far above this benchmark due to inefficiencies in combustion, heat recovery and material flow. Modernisation, therefore, must begin with the
kiln system, and not peripheral automation or
isolated upgrades. The shift from wet to dry process kilns, combined with multi-stage preheaters and precalciners, has already delivered step-change improvements, making dry kilns nearly 50 per cent more energy efficient.”
Recent investment programmes across the industry have included kiln cooler upgrades, advanced burners, and improved refractory materials designed to increase operational reliability and reduce specific heat consumption. Such upgrades are essential because cement production remains highly energy intensive, and continuous efficiency improvements are required to meet global decarbonisation targets. According to the International Energy Agency (IEA) Cement Tracking Report, 2023, the cement sector must achieve annual emissions intensity reductions of around 4 per cent through 2030 to align with global net-zero scenarios.

Energy efficiency and WHRS
Energy efficiency remains one of the most important areas of modernisation in cement manufacturing, given the sector’s heavy reliance on thermal and electrical energy. Modern plants deploy advanced process controls, efficient grinding systems, and improved combustion technologies to reduce specific energy consumption. The adoption of energy-efficient technologies is particularly important in India, where energy costs account for a large share of production expenses. As demand grows and plants expand capacity, improving energy performance becomes essential to maintain competitiveness.
Waste Heat Recovery Systems (WHRS) have emerged as a key solution for improving plant energy efficiency. During cement production, large volumes of high-temperature gases are released from kilns and coolers. WHRS technology captures this waste heat and converts it into electricity, thereby reducing reliance on external power sources. According to energy benchmarking studies for the Indian cement industry, installed waste heat recovery capacity in the sector has reached approximately 840 MW, with an additional potential of around 500 MW states the Green Business Centre, Energy Benchmarking Report, 2023. Several leading producers have already implemented large WHRS installations; for example, UltraTech Cement has deployed systems with around 121 MW of waste heat recovery capacity, reducing carbon emissions by nearly 0.5 million tonnes annually according to the Energy Alternatives India Case Study, 2024.

Integration of AFR
The integration of Alternative Fuels and Raw Materials (AFR) is another critical dimension of cement plant modernisation. AFR refers to the use of industrial waste, biomass, refuse-derived fuel (RDF), and other non-fossil materials as substitutes for conventional fuels such as coal and petcoke. Increasing the use of AFR helps reduce fossil fuel consumption while simultaneously addressing waste management challenges. According to the NITI Aayog Decarbonisation Roadmap, 2026, scaling the use of RDF and other alternative fuels could enable the sector to achieve thermal substitution rates of around 20 per cent in the coming decades.
However, integrating AFR requires significant plant modifications and operational adjustments. Waste-derived fuels often have inconsistent calorific values, higher moisture content, and heterogeneous physical properties compared to traditional fuels. As a result, modern plants invest in advanced fuel preparation systems, dedicated feeding equipment, and automated dosing technologies to ensure stable kiln operation. These upgrades allow plants to maintain consistent clinker quality while increasing the share of alternative fuels in their energy mix.

Digitalisation and smart plant operations
Digitalisation is rapidly transforming cement plant operations by enabling data-driven decision-making and predictive maintenance. Industry 4.0 technologies such as IoT sensors, artificial intelligence (AI), and advanced analytics are now used to monitor equipment performance, optimise process parameters, and anticipate maintenance requirements. These digital tools enable plant operators to detect early signs of equipment failure, minimise unplanned downtime, and improve operational efficiency. Predictive maintenance systems, for example, analyse vibration, temperature, and acoustic signals from rotating equipment to identify potential faults
before they escalate into major breakdowns. Digital twins and integrated control systems further allow operators to simulate plant performance under different scenarios and optimise production strategies. Such technologies are becoming increasingly important as cement plants operate at larger scales and higher levels of process complexity.
Maheshwari also adds, “Plant modernisation is also increasingly central to the global competitiveness of Indian cement manufacturers. As cost pressures rise across energy, logistics and regulatory compliance, modern plants offer the structural efficiency required to operate reliably and competitively over the long term. Technologies such as AI-driven Advanced Process Control (APC) integrated with real-time data systems are emerging as essential investments for the future. These platforms use predictive algorithms, machine learning and live process inputs to optimise kiln, mill and utility operations with greater precision than traditional control systems. By continuously analysing variations in feed chemistry, temperature profiles, energy demand and equipment behaviour, APC enables stable operations, lower specific energy consumption, reduced emissions and improved product consistency. As regulatory expectations tighten and plants pursue higher efficiency with lower carbon intensity, AI-enabled APC will play a crucial role in strengthening automation, enhancing decision-making and ensuring long-term operational resilience.”

Modern material handling and logistics
Material handling systems play a critical role in ensuring smooth plant operations and efficient logistics. Modern cement plants rely on advanced conveying systems, automated stockyards, and digital dispatch platforms to manage the movement of raw materials, clinker, and finished cement. Long-distance belt conveyors and pipe conveyors are increasingly replacing truck-based transport between quarries and plants, reducing fuel consumption, dust emissions, and operational costs. Automated stacker-reclaimers ensure consistent blending of raw materials,
which improves kiln stability and clinker quality. Meanwhile, advanced packing and dispatch systems equipped with high-speed rotary packers and robotic palletisers enhance throughput and reduce manual labour. These technologies allow cement plants to optimise logistics efficiency while supporting higher production capacities.

Emission control and environmental compliance
Environmental compliance has become a central focus of cement plant modernisation as regulators and investors place greater emphasis on sustainability performance. Modern plants deploy advanced emission control technologies such as high-efficiency bag filters, electrostatic precipitators, and selective non-catalytic reduction systems to reduce particulate matter and nitrogen oxide emissions.
Sine Bogh Skaarup, Vice President, Head of Green Innovation and R&D, Fuller Technologies says, “One of our key focus areas is decarbonisation. We help cement producers reduce CO2 and overall carbon emissions. We offer alternative fuel solutions and calcined clay technologies to enable the production of LC3 cement, which play a significant role in decarbonising the cement industry. By combining alternative fuels and calcined clay solutions, CO2 emissions can be reduced by up to 50 per cent, making this a highly impactful approach for sustainable cement production.”
Continuous emission monitoring systems are increasingly used to track environmental performance in real time and ensure compliance with regulatory standards. In addition to air pollution control, cement companies are also investing in water recycling systems, renewable energy integration, and carbon reduction initiatives. These measures are essential for aligning the sector with national climate goals and improving the environmental footprint of
cement manufacturing.

Economic benefits and future outlook
Beyond environmental and operational advantages, cement plant modernisation also delivers significant economic benefits. Energy efficiency improvements, digital process optimisation, and advanced material handling systems reduce operating costs and improve asset utilisation. Waste heat recovery and alternative fuels help lower fuel expenditure and reduce exposure to volatile fossil fuel markets. As the industry expands capacity to meet growing demand, modernised plants are better positioned to achieve higher productivity and maintain profitability. The long-term outlook for the sector remains positive, with India expected to continue large-scale infrastructure investments in roads, housing, railways, and urban development.
Milan R Trivedi, Vice President – Projects, Prod & QC, MR, Shree Digvijay Cement, says, “The main focus in case of modernisation projects drives through the investment decision, which is mainly based on IRR and impact on overall efficiency improvement, cost optimisation and improvement in reliability. However, there are certain modernisation, which has high impact on environmental impact, statutory requirements, etc. has higher priority irrespective of ROI or payback period.”
“The energy efficiency and reliability investment projects generally provide fast return on investment whereas strategic, digitalisation and environmental investment projects provide long term and compounded benefits. Typical modernisation investment projects are decided with IRR of about > 20 per cent, payback period of typically 2-3 years for fast-track projects,” he adds.
In this context, modernisation will remain a key strategic priority for cement manufacturers seeking to maintain competitiveness in an increasingly sustainability-focused market.

Conclusion
The modernisation of cement plants is no longer a purely technical upgrade but a strategic transformation that reshapes how the industry operates. As India’s cement sector expands capacity toward the next growth cycle, improvements in energy efficiency, digitalisation, alternative fuels and advanced logistics will determine the competitiveness of individual plants. Modern technologies allow producers to operate at higher productivity levels while simultaneously reducing energy consumption and emissions intensity.
Looking ahead, the pace of technological adoption will play a decisive role in shaping the future of
the cement industry. Companies that successfully integrate modern equipment, digital systems, and sustainable production practices will be better positioned to meet rising infrastructure demand while aligning with global climate commitments. In this evolving landscape, plant modernisation stands as the cornerstone of both operational excellence and environmental responsibility.

  • Kanika Mathur

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