Integrated Manufacturing Unit
The Company boasts one of India’s largest single-location cement plants. Its fully integrated facility, equipped with multi-fuel technology, encompasses captive amenities such as captive mines, a thermal power plant, an all-weather port, and sea terminals in Gujarat and Mumbai. Besides this, due to the integrated nature of its operations, it has possibly one of the lowest costs of production in the country.
The Company is in the process of aggressively adding new capacity and in the process of commissioning a new clinker unit that will increase its total clinker production capabilities by 4 MTPA.
The Company’s capacity utilisation for the year under review was only 28%. However, due to the MSA, it is expected to shoot up significantly and reach ~80% levels, which is at par with the Adani Cement over the foreseeable future.
The Company proudly owns one of the largest limestone reserves in India, featuring ‘A grade’ marine limestone reserves of approximately 1 billion metric tonnes. The key attributes include:
High mineral-grade limestone with a purity level exceeding 90%
Implementation of eco-friendly surface mining practices
Utilisation of a 3 km long conveyor belt for raw material transportation from mines to the plant, ensuring near-zero dusting and substantial fuel savings
Adherence to best mining practices, including round-the-clock live monitoring of mining activities
Recognition through various awards for best mining operations and practices from the Indian Bureau of Mines and Directorate General of Mines Safety consecutively for multiple years
Striving to emerge as the most cost-competitive cement manufacturer in India, the Company consistently invests in lowering the clinker factor, improving energy efficiency, optimising raw material and fuel combinations, diversifying power sources, and increasing the utilisation of alternative fuels and raw materials in the Company’s production processes. Various measures have been taken to improve productivity and reduce energy consumption across operations. The mill internals have undergone modifications aimed at enhancing productivity and lowering energy usage. Inefficient coolers have been replaced to decrease thermal energy consumption. Initiatives focused on improving reliability have been undertaken, leading to increased overall productivity and efficiency.
Energy-intensive transportation equipment has been replaced with more efficient modes of material movement, further contributing to energy savings. Moreover, grinding aids have been optimised for maximum efficiency and productivity. Mills and kilns are now operated through automated processes using emerging technology, which has resulted in consistent operations and improved specific energy consumption levels. These combined efforts reflect a commitment to sustainable and efficient practices.
Emphasising efficiency and precision, the Company’s operations are driven by automated processes. Rigorous quality checks are conducted at every stage to ensure the superior quality of its products. The Company’s commitment to consistency extends to the use of stackers and reclaimers for the uniform homogenisation of each raw material.
Automated processes for enhanced operational efficiency
Stringent quality checks implemented at all stages
Utilisation of stackers and reclaimers to achieve uniform homogenisation of raw materials
Central manufacturing process controls to orchestrate seamless production workflows
NABL (National Accreditation Board for Testing and Calibration Laboratories) accredited physical and chemical testing labs to uphold rigorous quality standards
Accreditation by BIS and BS-EN (British standard implementations of English language versions of European standards), standards, highlighting the Company’s commitment to industry benchmarks and excellence
SIL’s integrated cement plants are directly linked to exclusive limestone mines, ensuring a secure supply of essential raw materials. The Company is implementing various measures to optimise and improve mine operations across different areas:
Diesel Usage: Proposed measures involve optimising operations through the utilisation of alternative fuels, improving lead and gradient optimisation, and enhancing productivity. Strategies also include incorporating electric pumps, negotiating contracts, and minimising stock rehandling by optimising the truck fleet.
Electrical Energy: Efforts to enhance electrical efficiency include reducing crusher idling time, optimising office lighting with solar solutions, and replacing HPSV (High Pressure Sodium Vapour) metal lights with energy-efficient LEDs. The Company also concentrate on optimising dewatering pump operations through the use of energy-efficient alternatives.
Explosives Management: In its explosive operations, the Company adopts innovative practices such as using stemming plugs, spacers, decking methods, and plastic bottles. Focus is also on optimising drilling and blasting patterns, exploring cost-effective explosives, minimising hole diameter, and improving fragmentation, all while integrating low-cost Nonel solutions.
Maintenance and Spare Parts: The Company optimises procurement by sourcing hoses, spares, and lube oil from non- OEM suppliers. Utilising used oil for top-ups and implementing cost-effective in-house solutions contribute to operational efficiency. Its focus on increasing tire life and achieving lubrication savings enhances mining KPIs.
Efficiency improvements: The Company has identified and is deploying on a regular basis across the process.
Miscellaneous: The Company has successfully eliminated land tax and implemented optimisation strategies for general and other expenses, enhancing overall financial efficiency.