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Manufacturing process of Instamix Xpress is different as compared to wet concrete

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Nuvoco came in the light when it acquired L&T?? ready-mix concrete business in 2008. Since then it has established itself not only as a cement producer but a player with innovative construction materials. It has successfully transformed itself from cement manufacturer to a building material supplier with a wide range of products. Prashant Jha, Chief of Ready Mixed Business, Nuvoco, speaks on one of the innovations he has recently launched.


Prashant Jha

Explain the idea behind introducing a new product during the pandemic. What is the market size, and what kind of growth do you expect from this product?

Through our interactions with customers and market studies, we observed that the construction industry is facing challenges of manufacturing concrete at the site due to the non-availability of superior quality raw materials like cement, sand, and aggregates. In the current scenario, the majority of small concrete work is done by mixing cement, aggregates, and water at the site. Then there is the issue of wastage of raw materials.

Most of the sites are still using the volumetric batching method, which generally results in poor quality concrete at site. Further due to the pandemic situation, there is a shortage of labour, moreover getting labour to do small jobs is generally a problem. All these factors resulted in an increased demand for well-graded pre-mix bag concrete. Although there are no published records, we are estimating the all India market size is more than 10,000 tonne per month, and it would be growing at 15 per cent per annum.

What is the manufacturing process ??is it the same as wet concrete? What is the batch size?

InstaMix Xpress is a pre-blended mixture of cement, sand, and aggregates with special admixtures, requiring only the addition of water before pouring the concrete. It is produced in a controlled environment and is fast, easy-to-use, and ready-to-pour in just three steps ??open, mix, and pour.

One needs to do is open the bag in a pan or mechanical mixer as per the requirement; add four to five litres of potable water per bag and mix the concrete uniformly; and finally, pour the preparation without making a mess. The manufacturing process of Instamix Xpress is entirely different as compared to wet concrete. In InstaMix Xpress, we have to ensure that there is 0 per cent moisture at any stage of production till packaging of the product. It is available in 50 kg special moisture-proof sealed bags, which are tested for quality. Batch size depends on the transit mixer capacity, which varies from 500 kg to 2,000 kg.

Is there any shelf life for the product?

Yes, it is good for use till three months of production.

Is the product covered under any BIS code? OR is the code in the draft stage?

No at this stage it is not covered under any BIS codes; however drafting of code for dry concrete is under process.

What has been the response from the users?

Initially, we have launched InstaMix Xpress in East and Northeast markets and the response is very encouraging. Structural consultants and contractors prefer to use the M-30 and M-40 grade of concrete, which is not possible to produce at the site and ready-mix concrete is not available in remote areas. InstaMix Xpress is an ideal solution as it is a pre-mixed, ready-to-use, bagged, dry concrete, which can be easily transported to these far-flung areas. Looking at the response, we are planning to launch this product in Northern and Western India very soon.

Does any other cement manufacturer cater the consumers with a similar product?

Yes, a few cement manufacturers tried to produce at the local level ready-mix plants but they were not able to control the quality of the product.

To what extent the strength will be compromised if more water is used or if the product is used beyond stipulated period?

It all depends on how much excess water has been added or how long InstaMix Xpress has been stored beyond the three months shelf life. We recommend using four to five litres of water per 50 kg bag (depending on the grade of concrete). If the product is used beyond the stipulated period, [definitely] the compressive strength will reduce from 10 to 50 per cent.

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Concrete

Cement Makers’ Margins To Fall Rs 50-75 Per Tonne Amid West Asia Conflict

Crisil Sees Margins Easing Despite Steady Demand

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Crisil said operating margins of Indian cement manufacturers are expected to decline by Rs 50-75 per tonne (t) this fiscal to Rs 925-950 per t due to higher input costs triggered by the West Asia conflict. The analysis covered 18 cement companies accounting for nearly 90 per cent of India’s domestic cement capacity and noted margins had improved sharply to around Rs 1,000 per t in fiscal 2026.

Crisil noted that the reduction would be driven mainly by higher power and fuel costs, which account for about 30 per cent of total costs, as petcoke and imported coal prices have surged amid geopolitical uncertainties. Freight costs, which account for about a quarter of total costs, are also expected to remain elevated because of higher diesel prices. The impact on profitability is likely to be more pronounced in the first half of the fiscal year before easing commodity prices moderate cost pressures later.

The rating agency said steady domestic demand and strong balance sheets should keep credit profiles stable despite the moderation in margins. Green energy currently accounts for 35-40 per cent of the sector’s total electricity consumption and is expected to partly cushion higher energy costs. Operating cash flows are likely to remain resilient, supported by projected 6-7 per cent growth in cement demand this fiscal.

Crisil highlighted that demand growth will be driven primarily by infrastructure spending, which meets about one-third of sector consumption, and by a nearly 18 per cent higher budgetary allocation for core ministries that should support project execution. Weaker rural housing demand amid pressure on agricultural incomes from a possible below-average monsoon may be offset by improved urban housing demand supported by favourable home-loan rates and a strong pipeline of Pradhan Mantri Awas Yojana-Urban projects. Ongoing capacity additions will keep capital expenditure elevated and may lift net debt to EBITDA to between 1.2 and 1.4 times from around 1.0 time last fiscal, though ratios are expected to remain healthy.

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Concrete

UltraTech Board Approves Rs 50 bn Fundraise Via NCDs

Company to issue half a million debentures for expansion plan

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UltraTech Cement’s board of directors has approved raising Rs 5,000 crore (Rs 50 bn) through non?convertible debentures issued in rupees.

The finance committee cleared a proposal to issue up to 500,000 fully paid, unsecured, listed, rated, redeemable, rupee?denominated, non?convertible, non?cumulative debentures of Rs 1 lakh each (Rs 0.1 mn each), aggregating to the Rs 5,000 crore programme.

As of June 2026 the firm reported net debt of Rs 15,875 crore (Rs 158.75 bn) and said its capacity expansion projects under execution are backed by capital expenditure of about Rs 17,000 crore (Rs 170 bn) over the next two to two?and?a?half years.

UltraTech spent Rs 9,500 crore (Rs 95 bn) on capital expenditure in financial year 2026 and in April the group crossed 200.1 mn tonnes per annum of domestic grey cement capacity and 205.5 mn tonnes per annum of global capacity.

The chief financial officer indicated the company would take consolidated capacity beyond 242 mn tonnes per annum, with grey cement capacity reaching 212.7 mn tonnes per annum by the end of financial year 2027. He noted the net debt?to?earnings before interest, taxes, depreciation and amortisation ratio stood at 0.87 times as of June 2026 and the company was confident of ending financial year 2027 with the ratio below one time.

In the first quarter of financial year 2026?27 UltraTech’s net profit attributable to owners rose 16.8 per cent year?on?year to Rs 2,599.3 crore (Rs 25.993 bn) and revenue from operations increased 15.9 per cent to Rs 24,648.20 crore (Rs 246.482 bn). The board approval is expected to complement internal cash flows as the company advances its expansion programme.

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Concrete

Lokesh Lays Stone For Rs 31 Billion Cement Unit In Kadapa

Line-2 expansion to make Kadapa a major cement hub

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Andhra Pradesh Education and IT Minister Nara Lokesh on Wednesday laid the foundation stone for the Line-2 expansion of Dalmia Bharat Cement at Chinnakomerla village in Mylavaram Mandal in Kadapa district. The project carries an investment of Rs 31 billion (bn) and is slated for completion by the third quarter of the financial year 2028. The expansion is intended to boost industrial growth and employment generation across the Rayalaseema region.

Once commissioned, the Kadapa facility will become Dalmia Bharat’s largest integrated cement manufacturing ecosystem in southern India, creating over 1,000 direct and indirect jobs and opening new business avenues for regional micro, small and medium enterprises and transport operators. Lokesh said the expansion signalled growing corporate confidence in the state and reflected the practical ease of doing business that secured repeat investment.

He placed the project within the government’s wider economic targets and recalled the Yuvagalam padayatra commitment to generate two million (mn) jobs within five years, noting that the state would cultivate talent while industry created opportunities. Lokesh highlighted Andhra Pradesh’s competitive pursuit of major manufacturing accounts, mentioning past successes and a personal initiative to engage global investors when persuading them to anchor expansion in the state.

The plant will leverage Kadapa’s abundant limestone reserves to scale production and sustainability. Clinker capacity is planned to rise from two point five million tonnes per annum (mn tpa) to six point one mn tpa, while overall cement output will increase from three point six mn tpa to nine point six mn tpa. The unit is designed to operate on over eighty per cent renewable energy and deploy waste heat recovery, zero liquid discharge, water recycling and advanced AI systems to optimise efficiency. Industries Minister TG Bharat, BC Welfare Minister S. Savitha and Jammalamadugu MLA C. Adinarayana Reddy attended the ceremony.

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