Displaying items by tag: efficiency

India: FLSmidth has signed a contract with UltraTech Cement to supply two new Cross-Bar coolers with HRBs to upgrade the pyroprocessing lines at its Dalavoi and Sankar Nagar plants in Tamil Nadu. The upgrades aim to increase efficiency and productivity at both facilities.

Bangladesh: Most cement plants are operating at less than 30% capacity, far below the global benchmark of 70–80%, according to the Bangladesh Cement Manufacturers Association (BCMA) via The Business Standard. National consumption fell to 38Mt in 2024, less than 40% of total capacity, and has declined further in 2025, forcing producers to cut output and lay off workers.

BCMA president Amirul Haque said “After Covid-19, we began recovering in 2021, driven by renewed construction. But since 2023, the situation has worsened drastically. Entrepreneurs expanded based on government demand. When projects slowed, we faced a severe cash flow crisis. Several small plants have already shut down.”

Bashundhara Cement, which has a capacity of 7.3Mt/yr, is reportedly running at 20% utilisation, while Mir Cement has reduced output to a quarter of capacity. Premier Cement is operating at around 40% capacity and Crown Cement has 60% of its capacity idle. Only Meghna Group of Industries reports growth, though utilisation remains 65%.

Nigeria: Lafarge Africa recorded sales of US$533bn in the first nine months of 2025, up by 63% year-on-year from US$327m. Its operating profit more than doubled to US$204m, from US$88.9m in the first nine months of 2024. The company grew its profit after tax to US$142m, more than triple its nine-month 2024 figure of US$41.1m. The producer attributed the growth to an increase in sales volumes and operational efficiency gains.

CEO Lolu Alade-Akinyemi said "Building on the performance from previous quarters, the third quarter of 2025 showcased our cost discipline, strategic market positioning, unwavering commitment to value creation and strong operational efficiency – demonstrated by a 7% year-on-year improvement in capacity utilisation."

Egypt: Deputy Prime Minister for Industrial Development and Minister of Industry and Transport Kamel El-Wazir met with cement producers to discuss production trends, recent price declines, and ways to increase capacity and restart idle production lines, according to a ministry statement. The meeting forms part of the Ministry of Industry’s plan to enhance efficiency in the cement sector and ensure sufficient supply to the local market. Officials reviewed recent price movements, local production levels, and reasons for the shutdown of certain production lines, with a view to their reactivation, according to Zawya news. Cement manufacturers continue to submit monthly production reports to the General Authority for Industrial Development (IDA), including data on licensed capacities, actual output and exports. The review showed that several companies have the technical ability to exceed their currently licensed production limits.

In response, the IDA will study applications from these producers to expand permitted capacities, aiming to optimise resource use, increase supply and stabilise market prices. The meeting also addressed the causes of plant shutdowns, including spare part shortages and ongoing renovation of production units. Some companies are upgrading their systems to align with production and efficiency standards. El-Wazir reaffirmed the Ministry’s commitment to supporting plants in overcoming technical or administrative obstacles and restoring full operational capacity. The meeting further discussed expanding the use of alternative fuels derived from agricultural and household waste to reduce production costs and environmental impact. Cement companies reportedly expressed interest in this transition, viewing it as a way to enhance competitiveness and sustainability.

Greece: As of 10 September 2025, Heracles Group will permanently discontinue its 50kg cement bag, becoming the first company in the Greek construction sector to fully transition to smaller bag sizes, according to a press release. The company said that the decision ‘responds to market needs,’ while setting new standards for healthy and safety and efficiency on site.

The company said that the move is expected to ‘significantly improve’ daily operations across construction sites, creating better working conditions and boosting productivity. According to the company, key benefits of the new packaging include reduced strain and fewer injuries on site, easier handling and transport, compliance with European occupational health and safety standards and minimised waste.

US: Ash Grove Cement, part of CRH, has deployed Boston Dynamics’ autonomous robot ‘Spot’ at its cement plant in Washington in a year-long pilot to boost efficiency and safety. Operating more than 80 hours a week, the four-legged robot conducts routine inspections using a 4K camera and laser scanning, detecting anomalies and alerting teams before failures occur.

The company said that the robot can measure refractory bricks inside cement kilns, reducing risks by keeping employees out of hazardous environments. During the trial, Spot detected a failing bearing in rotating equipment, preventing unplanned downtime. Ash Grove said that the technology improves site safety, frees skilled teams for complex work and enables real-time monitoring in the hot and dusty conditions at the plant.

Plant manager Andy White said “Our aim for Spot is that, at the moment, we don’t have preventative or proactive maintenance routines on night shifts and the weekends. And, also, our labour force has to spend a lot of time recording data rather than analysing it… Spot can do this for us. When we come in the mornings, we already have reported generated, so we can proactively fix those issues thather than spending eight hours trying to find them.”

UK: Holcim UK will roll out Fuelre4m’s Re4mx fuel reforming technology across more than 200 sites nationwide, following three years of testing that the company says improved fuel efficiency and helped reduce emissions across operations.

Holcim UK supply chain director Edern Lalanne said “This agreement is the result of meticulous testing, collaboration and operational learning. We have seen consistent results with Re4mx across a wide range of use cases, and it aligns directly with our commitment to sustainable innovation and operational excellence. This is about measurable outcomes, not promises, and Fuelre4m has delivered both the data and the support to back it up. This is part of our mission to make sustainable construction a reality and continues our journey to achieve net-zero by 2050.”

Re4mx will be delivered in pre-measured containers and dosed directly into on-site fuel systems. Holcim says that the rollout has been designed for ease, speed and zero disruption to infrastructure or workflows. Manufacturing is underway, with shipments to the UK beginning once production is complete. From there, Re4mx will be distributed site-by-site across Holcim’s network, through Fuelre4m’s VIRDIS (Virtual Distribution) system, in preparation for full dosing from 1 September 2025.

Russia: Katavsky Cement has modernised rotary kiln No. 4, raising clinker production capacity by 15% from 888,000t/yr to 927,000t/yr. According to Cemros, the project formed part of a corporate programme of improvements to increase production efficiency, valued at around US$760,000. Specialists reportedly encountered the problem of clinker defects when increasing the feed of raw meal due to insufficient heat exchange in the kiln system. To eliminate the problem, the plant updated the cyclone heat exchanger, stabilised the air supply and combustion of additional fuel, and improved the clinker cooling system.

General director Vyacheslav Lyubimtsev said “Modernisation of kiln No. 4 is a consistent step in the development of the plant. In 2024, similar work was carried out to increase the productivity of furnace No. 3 by 30%. The new result confirms the effectiveness of the chosen strategy.”

India: Wonder Cement’s managing director Kiran Patil led the inauguration of Line 5 at the Nimbahera plant in Rajasthan on 7 May 2025, according to a social media post by the producer. The project increased the producer’s clinker capacity by 2.8Mt/yr to 13.35Mt/yr and cement capacity by 2.5Mt/yr to 21.5Mt/yr. The company partnered with APBCO on the expansion, which also includes a 12MW waste heat recovery system to increase energy efficiency.

India: UltraTech Cement has increased its production capacity by 1.4Mt/yr through debottlenecking and ‘efficiency improvements’ at multiple sites across India.

It added 0.6Mt/yr of grinding capacity at Nagpur in Maharashtra and 0.8Mt/yr across Panipat and Jhajjar in Haryana. The company’s total domestic grey cement capacity now stands at 184.8Mt/yr, while its global capacity has reached 190.2Mt/yr.