Operational Excellence
Shaping the
Highest Quality
The Company is focused on scaling its production capabilities to meet market demand, with a current cement capacity of 18,540 TPD (tonnes per day) and plans to expand to cement 51,000 TPD. This expansion aims to enhance its contribution to an improved market presence of Ambuja Cements while ensuring consistent, high-quality output.
Upgrading infrastructure to support higher capacity utilisation and addressing manufacturing challenges is a priority for the Company. Refractory issues are being resolved through kiln technology upgrades to improve performance and efficiency. To mitigate weather-related disruptions, the Company is strengthening material handling systems to ensure reliability and ability to withstand environmental variations. Improved material handling also translates to operational consistency, while kiln technology optimisation support efficiency and expanded capacity.
SIL demonstrates its commitment to sustainability and efficiency through targeted initiatives in energy management, operational improvements, and cost optimisation in alignment with the Group’s sustainability goals.
Management
Implementation of green energy contracts aligns with the Group’s Environmental, Social and Governance (ESG) goals.
Initiatives
Collaborations with institutions are underway to advance Carbon Capture Utilisation and Storage (CCUS) technologies.
Excellence
Cooler upgrades across its facility and strategic measures have significantly reduced fuel and alternative fuel costs.
Management
Fuel cost optimisation has been achieved through alternative fuel usage and strategic negotiations. Captive Power Plant operations have unlocked notable savings through efficient sourcing and transportation strategies. A streamlined approach to logistics and transportation has further enhanced cost efficiency.
Security
Securing coal mines ensures a stable and cost-effective fuel supply.
With the aim of reducing its logistics costs and environmental impact, SIL is shifting to CNG and electric transportation. Its parent company, Ambuja Cements, has implemented the ‘Go Direct’ programme to increase direct dispatch and has implemented the modern electronic proof of delivery (ePOD) system to enhance logistical efficiency and transparency. Ambuja Cements has also ensured real-time AI-enabled tracking with 98% GPS coverage, allowing customers to track shipments and receive estimated arrival times, thus enhancing customer satisfaction. Further, centralised logistics control tower for monitoring and integrated digital solutions for in-plant automation and advanced tracking is helping reduce truck turnaround times and strengthen dispatch capacity substantially.
SIL's parent company, Ambuja Cements, is increasing its investments in General-Purpose Wagon Investment Scheme (GPWIS), and Bogey Covered Fly Ash/Cement (BCFC) rakes to ensure safe and cost-effective transportation of fly-ash from thermal plants to facilities.
Ambuja Cements has also established DMCs at all manufacturing sites. These DMCs, staffed by dedicated safety professionals, prioritise defensive driver training, GPS monitoring, behaviour-based safety counselling and road safety awareness campaigns. The centres focus on driver well-being through regular health check-ups, nutritious food, clean rest shelters and sanitation facilities. SIL is expected to benefit from this initiative by creating a safer and efficient working environment.
Transformation
Strengthened centralised logistics control for real-time monitoring and proactive interventions. Expanded GPWIS and BCFC rake fleets for cost-effective clinker and fly ash transport. AI-enabled fleet management now ensures 98% GPS coverage for precise shipment tracking.
Infrastructure
Implemented in-plant automation and advanced vehicle tracking, reducing truck turnaround times and increasing dispatch capacity.
Excellence
Optimised freight and handling costs using advanced models, integrated electronic proof of delivery, and touchless billing for transparency and efficiency.
Energy Transition
Shifted from diesel to CNG, LNG, and electric, cutting carbon emissions and improving cost efficiency.
Supply Optimisation
Integrated digital tools and a Cement Network Operating Centre (CNOC) to streamline order processing and enhance operational efficiency.
Case Study
SIL’s parent, Ambuja Cements’ Digital In-plant Automation initiative aims to enhance logistics and safety across operations by equipping over 60,000 trucks with GPS technology and implementing a safety dashboard. Initially launched at one of the parent company's sites and later expanded to other cement sites, the initiative aligns with the Group’s 'Growth with Goodness' motto, focusing on system hygiene and stakeholder well-being. By integrating advanced technology, the initiative ensures safer, more efficient, and cost-effective logistics, with estimated annual savings of ` 7 crore while promoting stakeholder value and system improvements.
The initiative was designed to overcome challenges in fleet owner adoption and transporter union acceptance. Extensive collaboration with stakeholders demonstrated the benefits of GPS and RFID technology, enabling a win-win situation for all parties. Cost concerns were addressed by providing GPS devices at minimal or no cost, fostering wide-scale acceptance.
The safety dashboard offers features such as real-time fleet monitoring, customised parking zones, incident reporting, and accurate data capture using AI, ensuring seamless operations even in remote areas. The system links sales, logistics, plants, dealers and customers, enhancing coordination and efficiency.
Real-time GPS monitoring ensures drivers follow safe routes, reducing accidents and improving road safety.
Optimised routes reduce fuel consumption, travel time, and operational costs.
Detailed truck performance insights support proactive maintenance and minimise downtime.
Real-time tracking aids in recovering stolen vehicles and safeguarding assets.
Automated reporting on routes, driving hours, and other data improves regulatory compliance and transparency
Accurate tracking allows timely communication with customers about delivery schedules, enhancing trust and satisfaction.
The Company owns one of India’s largest limestone reserves (~1 Bn MT) with high-grade (>90% purity) marine limestone. Its eco-friendly surface mining practices include raw material transportation via a 3 km conveyor belt, minimising dust and fuel usage. Advanced systems enable 24/7 monitoring, earning recognition for exemplary mining operations from the Indian Bureau of Mines and Directors of Mines Safety.
A multi-modal distribution system ensures timely supply to domestic and international markets. The Company is one of India’s largest exporters of bagged cement, offering cost-efficient distribution.
The Technical Centre of Excellence (CoE) has been established to advance Chairman Gautam Adani’s commitment to achieving Zero Carbon emissions in the Cement Business. The CoE is dedicated to enhancing reliability, productivity, and efficiency across manufacturing processes. By integrating best-in-class processes and systems, the CoE will play a pivotal role in new product development and the technical evaluation of upcoming projects and potential acquisitions, ensuring alignment with the overall business strategy.
The Company ensures superior product quality through advanced automation and precision-driven operations. Rigorous quality checks are undertaken at every stage, guaranteeing consistency and excellence. Stackers and reclaimers are employed to achieve uniform homogenisation of raw materials, while centralised manufacturing controls ensure seamless production workflows.
- Automated processes for enhanced efficiency and precision
- Stringent quality checks at every stage of production
- Use of stackers and reclaimers for raw material homogenisation
- NABL-accredited physical and chemical testing labs for rigorous quality assurance
- Accreditation by BIS and BS-EN standards, reflecting adherence to industry benchmarks and excellence
ISO Certifications
National Accreditation Board for Testing and Calibration Laboratories' accreditation for chemical and mechanical testing
The Company’s parent, Ambuja Cements has undertaken several initiatives to improve its manufacturing processes through digitalisation and innovations.
Integrating calorific value measurements with Laboratory Information Management System (LIMS)
Coal testing methods (CTM) were automated, improving reliability and reducing testing time
A heat accounting application application was developed and implemented to track coal heat value
A cement bag tracking system was implemented to monitor bag movement, and improve inventory management
Internal material movement was optimised through automation and real-time tracking
CCTV-AI was introduced to monitor print quality on bags, ensuring high standards
Bag counting was automated to provide accurate inventory data and improved efficiency
Sensors were deployed to monitor equipment vibrations in real-time
An application-based WBI (Web-Based Interface) Reporting system was launched for real-time maintenance reporting and enhancing productivity
AI was deployed to support operators with real-time guidance
Advanced control systems were implemented to optimise kiln mill performance