The cement industry today faces diverse challenges that affect operational efficiency, digital transformation, and sustainability practices. Adding to this, many companies lack digital infrastructure and they still rely on inefficient manual processes with limited use of advanced technologies such as IoT or Artificial intelligence. Furthermore, the cement industry faces pressure to reduce its carbon footprint and adopt sustainable manufacturing practices. While implementing low-carbon alternatives, the process is hindered by inconsistent material availability and a limited market.
To address these aforementioned challenges, Nextcem Consulting comes with a broader vision to offer strategic solutions with a 360-degree health assessment covering design, operations, energy, maintenance, emissions, and digital infrastructure be it Grinding Mills or Pyroprocess Systems. It also incorporates WHRS retrofits or repowering, along with burner and preheater/calciner upgrades and clinker cooler optimization, thereby fostering an effective approach to tackle outdated infrastructure and to improve energy efficiency.
The company transforms cement factories into intelligent, connected ecosystems with a complete digital thread of DCS, IIoT lab, and ERP systems. Also to note, Nextcem Consulting implements AI/ML models for plant health prediction, anomaly detection, and energy loss analytics, while piloting generative AI to auto-generate SOPs, shift reports, and diagnostic workflows. The company’s real-time digital cockpits empower plant heads and CXOs with a single view of productivity, emission, and downtime.
Nextcem Consulting offers innovative solutions to decarbonize the cement industry.
The company pomotes manufacture of low-carbon cement (LC3, PPC, and Composite cements) and facilitates AFR (Alternative Fuel and Raw Material) usage. The company promotes 7R (Rethink, Redesign, Reduce, Reuse, Repair, Recover, and Recycle) principles.
Boosting Efficiency, Enabling Net Zero Goals
Nextcem Consulting aligns with evolving regulations and government’s frameworks for decarbonization with PAT schemes, ESG reporting norms, and Net Zero declarations. “We act as owner’s engineers and strategic partners, and not just traditional PMC players. Our differentiator lies in our ability to link design decisions to operational performance from day one”, says Ashwini Pahuja, Chairman & Managing Director, Nextcem Consulting.
The company believes true value engineering goes beyond cost-cutting, and it’s about unlocking long-term operational potential. The process of optimization framework includes plant-wide energy and mass balance audits, identification of bottlenecks and process instabilities. The company incorporates the process of standardization of control loops and operator dashboards for maintenance. All recommendations are backed by a cost-impact-effectiveness matrix that allows clients to prioritize with clarity and confidence.
“Nextcem Consulting believes true value engineering goes beyond cost-cutting, and it’s about unlocking long-term operational potential & long term sustainability and improving resilience to overcome climate challenges, cost reduction and project effectiveness”, says PVR Murty, Chief Executive Officer, Nextcem Consulting.
Nextcem Consulting believes true value engineering goes beyond cost-cutting, and it’s about unlocking long-term operational potential & long term sustainability and improving resilience to overcome climate challenges, cost reduction and project effectiveness
Empowering Cement with Innovation & Skilled Talent
Nextcem Consulting’s role in skill development and workforce transformation includes Role-specific technical training (Kiln, Mill, WHRS, QC), Digital enablement programs (IIoT, GenAI, ERP modules), Leadership workshops for plant heads and CXOs, and LMS and digital academies tailored for cement operations. Currently, the company is building tailored future roadmaps which are aligned with India’s PAT targets, ESG mandates, and Net Zero ambitions.
Going forward, it envisions to empower cement manufacturers to achieve unparalleled levels of operational excellence, embrace true sustainability, and harness the full potential of innovation. The company directs the client to unlock latent value, from existing capex, ensuring every asset delivers peak performance.
The company focuses on building internal ‘Innovation Cells’ and fostering a culture of continuous improvement and new product development. Additionally, developing future-ready talent and upgrading the workforce with the skills needed to thrive in the digital and sustainable era.
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