Kesoram Industries Limited

Cement Division

Company Profile
Company Profile
Kesoram Industries Limited is part of the prestigious B.K. Birla Group of companies, started by Syt. G.
D. Birla, a legend in the history of the Indian Industry and Business. A man, who was committed to the
cause of Swadeshi Movement, was a close associate of Mahatma Gandhi and also one of the leading
philanthropists of his time. The legacy grew by leaps and bounds over time & the mantle is being
continued by his son Syt. B. K. Birla.

Kesoram Industries Limited: Cement Division, is an award-winning cement manufacturer and is one of
the nation's largest producers providing high quality cement products and reliable services to our
clients and communities across India under the flagship brand Birla Shakti Cement.

Founded in 1969, Kesoram Industries is one of the global leaders in cement technology. Besides being
a leading supplier of cement and aggregates, we also offer consulting, research, engineering, technical
and other services to complement our customers' business needs.

Cement division is headquartered in Hyderabad, Telangana. With two production sites, one located in
Sedam, Karnataka as Vasavadatta Cement Unit and the other Kesoram Cement Unit in Basantnagar,
Telangana. The plants are strategically located near our leased limestone deposits in the states of
Karnataka and Telangana.

For over 40 years, Kesoram Industries has been catering to the regional demands predominantly in
Karnataka, Telangana, Andhra Pradesh, Maharashtra, Madhya Pradesh, Chhattisgarh, Goa, Tamil
Nadu & Kerala. Presently, we have a combined total installed capacity of 9 million MT.

At Kesoram Industries, we have developed and nurtured our customer relationships by manufacturing
superior quality cement as per the industry standards. The promise of quality and commitment is
embodied in our products.

Vision & Mission

• We endeavour to shape tomorrow's urban landscape and provide a better quality of living for
the mankind.

• To inspire and touch lives through our services and products.

We, at Kesoram Industries Limited, Cement Division are committed to:

• Quality, strength and technology, which has enabled us to build strong working relationships
and gain the trust of our customers and builders over the years.

• Efficient management, continuous improvement in quality, health, safety & environmental

friendliness. Our compliance has been recognized & we have been certified an ISO 9001
company.

• Compliance of all applicable legal and other requirements

State-of-the-Art Manufacturing Plants
• Since the very beginning, we have been technologically competent. Vertical Roller Mill, Raw
Mill and Coal Mill were installed in the year 1986.

• Installation of additional Ball Mill to unit - 2VRM has significantly increased production by 50
TPH.

• Modern Polycom machines have been installed for finished grinding of limestone. It is
maintenance free and energy efficient (consumes 4 units of less power) and does not require
a water spray system.

• Latest Reverse Air Bag House has been installed in Raw Mill circuit to keep emissions less
than 40 mg/Nm3.

• Coal Mill supplied with the latest X win tyres and table liners have enhanced life to 6500 run
hours.

• Our Rotax kiln is friction driven and it does not require Girth gear drive like conventional
kilns.

• Hot Disc results in lower consumption of coal, thus, reducing CO2 emission, by consuming
municipal waste tyres and other organic waste.

• Our latest Pipe conveyors, which transports cement to the silo is energetically more efficient
than pneumatic systems. Installation of Maximum Belt Elevator has also resulted in reduced
power consumption.

• Our double Rotor Hammer crusher is running at more than the rated output and producing
particles of the desired size range.

• Five Thermal Power plants with a total capacity of 77.5 MW has sufficed 100 % of our total
power requirement.

Technology
Our plants with captive mine of superior grade limestone, is well suited to produce superior grades
and types of cement. CB OMNI ANALYSER (GAMA MATRIX) – THERMO FISHER-USA installed at
limestone crusher discharge belt, analyses the entire quality of crushed Limestone. The results are
displayed at the laboratory and the mines department, for close monitoring of output.

We have closed circuit electronic automatic roto packers for packing of cement with complete
accuracy to supply the right quantity of cement to our customers.

For consistent and unparalleled quality, we have installed Stacker and Reclaimer in all stages like
limestone, additive, coal and incorporated blend export for raw material proportioning and Fuzzy
Logic for all unit operations to ensure better process control.
Traditionally, cement analysis was carried out by time consuming weight chemical techniques. We
have now replaced the obsolete technology with modern X-ray analysis which allows high quality
measurements and characterization. The data can be generated and analyzed in just a few minutes.

Our laboratories are well equipped with quality testing equipment’s like:

• Bruker-AXS X-Ray Machine (Bench Top) S-2 Ranger, Germany.

• Bruker-AXS X-RD (Bench Top), Germany.

• Bruker-AXS X-Ray Machine-S-8 Tiger, Germany.

• Particle Size Analyzer, Cilas Make.

• Alpine Particle Size Analyzer (Dry Siever).

• Bomb Calorimeter PARR-6300, Made in the USA.

To produce a consistent quality product, all above equipment’s are at the heart of the production and
quality control.

Advantages of Birla Shakti Cement - PPC

Birla Shakti Cement - PPC – for Durable Constructions:

BIRLA SHAKTI CEMENT - PPC is distinctly ahead of ordinary cements for the following reasons:

• The heat liberated during the hydration process of Birla Shakti Cement, is even lower than
Low Heat cement (Special Cement for Lower Heat of Hydration). This reduces the chances of
thermal cracks.

• High Reactive Silica (HRS) from Birla Shakti Cement converts soluble Calcium Hydroxide into
insoluble cementitious product resulting in a dense and impermeable concrete mass. Hence
concrete made with Birla Shakti Cement has more resistance to Sulphate Attack / Acid Attack
/ Chloride Ingression / Carbonation.

• The low density of fly ash, its high volume and fine spherical particle shape gives 'Ball Bearing
Effect', which makes concrete more workable at lower w/c ratio. This results in increased
compressive strength of concrete and improved bond strength between steel & concrete.

• Unique properties of Birla Shakti Cement (PPC) make concrete highly resistant to sea water,
chlorides, sewage and 'Alkali-Aggregate reaction'. Finer particle size in Birla Shakti Cement
gives denser & impermeable concrete, which protects steel reinforcement from corrosion &
better water proofing properties of concrete.

• Birla Shakti Cement is Environment-friendly cement because it contains reactive Silica- a

product from Thermal Power Stations, which, if released into the atmosphere, would despoil
our precious environment.
Product Range
Birla Shakti Cement (PPC) ----- conforming to IS 1489 (Part I) – 1991

Birla Shakti Cement 43 Grade ----- conforming to IS 8112–2013

Birla Shakti Cement 53 Grade ----- conforming to IS 12269–1987

Birla Shakti Cement - PPC conforming to IS 1489 (Part I) – 1991

• Blended with pozzolanic materials like power-station fly ash, burnt clays, ash from
burnt plant material or siliceous earths.

• High degree of cohesion and workability in concrete and mortar

• Smoother finish and high resistance to seepage

• Low heat-of-hydration leads to higher resistance to 'cracking'.

Birla Shakti Cement 43 Grade conforming to IS 8112–2013

• Most commonly used cement for a wide range of applications like dry-lean mixes, general-
purpose ready-mixes, high strength pre-cast and pre-stressed concrete.

• Suitable for sheet and pipes of asbestos/non-asbestos based products.

• Birla Shakti Cement 43 Grade is apt for general Civil Engineering construction works like
buildings, bridges, roads, etc.

• Compressive strengths are much higher than the BIS Standards.

Birla Shakti Cement 53 Grade conforming to IS 12269–1987

• Birla Shakti Cement 53 Grade strengthens faster than conventional grade cement &
facilitates quality constructions.

• Facilitates economical Constructions as it strengthens faster, saves in both cement

consumption and construction time.

• Durability: Fineness of cement, in terms of consistency, is an important factor in achieving

durability.

Birla Shakti Concrete

 We have a state of the art RMC unit successfully churning concrete in Pune and with expansion
plans in place, to improve capacity and geographical presence.
 A full-fledged PLC controlled liebherr plant is imported from Germony of capacity 120 m 3/hr
 We have 47 RMC vehicles serving the Pune market.
SPECIFICATION OF CEMENT MANUFACTURING
C o m p re ssive Stre n g th

PPC PPC
OPC-53 GRADE BIRLA SHAKTI OPC-43 GRADE BIRLA SHAKTI
TESTDETAILS BIS: 1489 BIRLA SHAKTI
BIS:12269-1987 OPC-53 GRADE BIS:8112-2013 OPC-43 GRADE
(PART-1): 1991 (BLENDED CEMENT)

3 Days Mpa Min. 27 Min. 36 Min. 23 Min. 32 Min. 16 Min. 30

7 Days Mpa Min. 37 Min. 46 Min. 33 Min. 42 Min. 22 Min. 38

28 Days Mpa Min. 53 Min. 60 Min. 43 Min. 54 Min. 33 Min. 54

Ph ysic a l A n a lysis

PPC PPC
OPC-53 GRADE BIRLA SHAKTI OPC-43 GRADE BIRLA SHAKTI
TESTDETAILS BIS: 1489 BIRLA SHAKTI
BIS:12269-1987 OPC-53 GRADE BIS:8112-2013 OPC-43 GRADE
(PART-1): 1991 (BLENDED CEMENT)

Setting Time

a) Intial (minutes) Min. 30 Min. 170 - Max. 200 Min. 30 Min. 170 - Max. 210 Min. 30 Min. 170 - Max. 200

b) Final (minutes) Max. 600 Min. 260 - Max. 290 Max. 600 Min. 260 - Max. 290 Max. 600 Min. 260 - Max. 295
Fineness m2/kg Min. 225 Min. 300 - 320 Min. 225 Min. 265 - 280 Min. 300 Min. 340 - 380

Soundness
a) Le-cha Eap.mm Max. 10.0 Max. 1.0 Max. 10.0 Max. 1.0 Max. 10.0 Max. 1.0

b) Auto Clave % Max. 0.8 Max. 0.15 Max. 0.8 Max. 0.2 Max. 0.8 Max. 0.08

Drying Shrinkage % Max. 0.15 Max. 0.05

C h e m ic a l A n a lysis

PPC PPC
OPC-53 GRADE BIRLA SHAKTI OPC-43 GRADE BIRLA SHAKTI
TESTDETAILS BIS: 1489 BIRLA SHAKTI
BIS:12269-1987 OPC-53 GRADE BIS:8112-2013 OPC-43 GRADE
(PART-1): 1991 (BLENDED CEMENT)

Loss on Ignition % Max. 5.0 Less than 1.5 Max. 5.0 Less than 1.5 Max. 5.0 Max. 2.0
Max. X+ 4(100-X) Depending on X
Insoluble Residue % Max. 3.0 Less than 1.5 Max. 4.0 Less than 1.8 100
Lime Saturation - -
0.80 - 1.02 Min. 0.88 0.80 - 1.02 Min. 0.86
Factor
Alumina : - -
Min. 0.66 Min. 1.1 Min. 0.66 Min. 1.1
Iron Ratio
Sulphuric
Max. 2.5/3.0 Max. 2.0 Max. 3.5 Max. 2.0 Max. 3.0 Max. 2.0
Anhydride %

Alkalies Max. 0.6 0.4 Max. 0.6 0.4 - -

Chlorides Max. 0.1 Max. 0.02 Max. 0.1 Max. 0.02 Max. 0.1 0.02

Min. -minimum, Max.-maximum

Sustainability
The key to sustainable economic growth lies in our belief, where we value our employees and their
families, the environment we do business in, our esteemed customers, as well as the local
communities we are surrounded by. We are convinced that social progress should be shared and
enjoyed by all the stakeholders of Kesoram Industries Limited.

Wet Drilling Technology

Water sprays nozzles are attached to reduce the dust emission during the drilling.

Thermal Power Plants

Five thermal power plants with a total capacity of 77.5 MW have sufficed 100 % of our power
requirement.

Dust Suppression System

M/s NIVIS, ITALY Dust Suppression System based on Water Mist Technology is used to control fugitive
emission away from 25 to 50 meters during loading and unloading of raw materials like Coal and
Limestone.

Dust Suppression System

NIVIS dust suppression with remote control system is used for spraying water on blasted limestone
before commencement of loading operations.

Rain water harvesting at mines & power plant

Rainwater harvesting pit capacity: 3.5 Lakh Cubic Meters.

Mines pits /water reservoir capacity: 40 Lakh Cubic Meters.

This reservoir supplies water during lean period.

Presence (across India)

Kesoram Industries boasts of a vast dealer & retailer, network and offices to ensure prompt supply
and excellent post-sales service. BSC is highly sought after, due to a wide market presence in
Karnataka, Telangana, Maharashtra, Madhya Pradesh, Chhattisgarh, Goa, Tamil Nadu & Kerala.
Strategic positioning in these states has resulted in a vast network of dealers and retailers. Our
premium brands offer genuine value-for-money, rising high above standard BIS specifications with
super relative quality.
Our Ready Mix Concrete Business (RMC) with state of the art plant is running successfully and
producing Birla Shakti Concrete to cater to the needs of construction industry in Pune, with the sole
objective of On time...Every time delivery. We plan to increase our presence in all major markets soon.

M a rke t s M a nuf a c t uring Unit s

M a d h ya Pra d e sh Ba sa n t Na g a r
Karim Nagar (Dist)
Ma ha ra shtra Telangana
Tela ng a na Se d a m
Gulbarga (Dist)
Ka rn a ta ka Karnatka

Goa

Ke ra la

Ta m il Na d u

C h h a ttisg a rh

A n d h ra Pra d e sh
Some of our prestigious clients & projects across India:

ENTERPRISES
Awards & Certifications
We have won several accolades, the most significant ones enlisted below-

• Green-Co Gold rating for VasavadattaCement Unit, Sedam by CII in 2013. (1st in the Indian
Cement industry)

• CII-National Energy Management Award, Excellent Energy Efficient Unit in 2012.

• Safe Power Boiler Appreciation Certificate issued by Karnataka State Safety Institute and
Dept. of Factories, Boilers, Industrial Safety and Health, Bengaluru in 2012.

• Safe Industrial Boiler- 2nd prize by Karnataka State Safety Institute & Department of
Factories & Boilers, Government of Karnataka in 2011.

• Injepalli Limestone Mines bagged 1st prize in Drilling & Blasting, Environment & Health
Management from Dy. Director General of Mines Safety in 2011.

• Environment Excellence Award Karnataka State Pollution Control Board, Government of

Karnataka in 2011.

• CII-“Excellent Water Efficient Unit- Within the fence” Award in 2010.

• National Award by President of India –Lowest frequency Rate in Category large Mechanized
Mines for the year 2009 (Runner Up) in 2010.

• Three Leaves (Rank 10) in the Green Rating Project of the Indian Cement Industry by Center
for Science and Environment in 2005.

• CII-National Energy Management Award, Excellent Energy Efficient Unit in 2004-05, 2006-08
& 2010-11

• Best Improvement in Thermal Energy Performance Award from NCBM in 2003-04.

• Environmental Award from Dept. of Ecology & Environment from Government of Karnataka
in 1996.

• National Productivity Award from Hon’ble Prime Minister in 1994-2005.

• National Award for Second Best Improvement in Energy Performer from NCCBM & Ministry
of power in 1990 -91 & 1991-92.

Head Office:
Kesoram Industries Ltd

Office No: 613 to 616, Block - 3, White House: 6-3-1192/1/1,

Kundanbagh, Begumpet, Hyderabad-500016, Telangana, India.

www.kesocorp.com