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Friction-free conveyors are the way to go

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Sagta Engineering, a Shanghai, China, based engineering consulting company, is trying to introduce air cushion technology in conveyor systems in India. Frank Wang, General Manager, and U.K. Mullick, Chief Consultant of Sagta, say it is a maintenance free and environment friendly technology.

Material transportation equipment plays an important role cement plants. What are the innovative products you have?
Frank Wang (FW):
Roller and tubular conveyor systems are well known among user. But both of them require a lot of maintenance because of friction they generate. We are in the process of introducing air cushion conveyor in India. Air cushion lifts up the rubber belt, removing friction in air cushion conveyors (ACC). It brings in several advantages – energy saving, environment-friendly and requiring minimal maintenance. We have introduced air cushion technology to Tata Steel, NTPC and MECON, an engineering and consulting company, etc., in India.

What are the key differences between belt and air cushion conveyor systems?
UK Mullick (UKM): In a conventional belt conveyor, where belt is running on rollers, a number of rollers appear along it. Basically the concept of ACC is very much similar to that of conventional belt conveyor, but the difference is there are no rollers in the new technology. Instead of rollers there are certain modules and on the surface of the modules there are a number of small holes through which pressurised air comes and keeps the belt afloat, so that the material loaded onto the conveyor belt moves on the airfill. A very thin airfill is generated due to high pressure air jet that comes from the module.

What are the advantages an air cushion conveyor user can expect?
UKM:
The majority of power consumption of a conveyor is for overcoming the frictional resistance of number of rollers present in the system. If there are no rollers, then there is no friction due to which the power consumption will come down drastically. And this reduction is seen to be in the range of 20-70 per cent, which is really a great phenomenon- we are not only saving money, but also saving costly energy. Secondly, this 20-70 per cent saving depends on the length of the conveyor, longer the more.

FW: The lifespan of rubber belt in a conveyor is very important. Generally, due to friction the rubber belt lasts about three or four years and needs replacement. Sometimes it gets broken. There is a lot of downtime that goes into repairing the belt. Due to friction-free air cushion the lifetime of the rubber tends to be much longer. To our surprise, the rubber belt of our first project is still there even after 15 years, and no replacement needed anytime soon.

Is there any advantage in installation cost?
UKM:
Cost is generally based on length of the conveyor – if it is less than a kilometre, the cost of ACC is slightly more compared to the conventional one. In a long distance conveyor, say 10-20 km, the installation cost is more or less the same. Simple reason is, say for a 15-km conventional conveyor’s power installation needed is 4,200 kW, while for ACC technology the installed capacity required is 2,500 kW. That is a drastic difference due to absence of rollers. So, this is definitely an innovation so far not tried out in India and they are the way to go.

Are there any disadvantages or limitations for ACC when compared conventional conveyor…
UKM:
If you ask me, is it possible to convey big boulders? The answer is simply "no." The maximum weight that can be conveyed by ACC is approximately 50 milli meters (mm). As for angle of inclination, it can take a very good angle of inclination up to 35-40 degrees. But one should be conscious about a thing – it cannot take right or left turn, and it has to be straight. As such this is very good for long distance material handling. For that purpose we have already approached JSW and they are planning to implement long distance conveyor and this technology is under their active consideration, subject to their visiting China and seeing it physically.

So it cannot be implemented in all terrains…
UKM:
If the conveyor route has to pass through hills and mountains and have to take several twists and turns, you may need to install different types of conveyors ? conventional conveyor for a portion of it, pipe conveyors where twists and turns are there, and ACC where the route is straight. Since Sagta Engineering is capable of supplying any kind of conveyors or a combination of all the three, it can offer the best solution to any terrain.

In India, the government follows L1 (least capital cost) method for choosing suppliers, though the trend is changing of late. How do you propose to pitch your product to them?
UKM:
If you want to adopt any innovative technology, at that point of time one cannot compare the initial investment cost. If it can pay back the additional cost incurred in about three years, that is great.

Any more innovative products in pipeline…
UKM:
Another innovative technology is friction-free coupling. Generally we have fixed coupling that is rigid coupling where bolts and nuts are used. Suppose if there is a little misalignment in drive and driven end, and if it is allowed to run at a very high speed, in no time the bolt or nut will shear and break, bringing the whole process/system to a standstill. Now for power transmission or stop transfers for motors of more than 30 kV we are using fluid coupling for different applications in power, mining, or cement sectors.

FW: But Sagta has come out with a new magnetic coupling which uses permanent magnet on either side – driver shaft side and driven shaft side. Suppose if the blower is installed, and between motor and blower if you put a magnetic coupling, and due to installation problem if there is some small misalignment, since these two items are not touching each other, (as they are held only by magnetic force), this is not going to hamper the driven or driven side operations. These particular couplings are available from 30 kW to 4500 kW. Friction-free coupling is also maintenance free and has a lifetime of 30 years, we can say. This product has been welcomed by the Chinese heavy industry, including steel plants.

Another product that is in the final stages of development is magnetic speed adjusting device used in motors and blowers. These can be used in the cement industry as well. It is also long lasting and maintenance-free.

– BS SRINIVASALU REDDY

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Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

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

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

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

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

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

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

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

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

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

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

 

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Concrete

Building a Greener Future Together

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

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

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

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

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

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

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

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

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

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Concrete

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

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

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

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

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

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

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

Expanding market reach

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

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

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

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