Total Cement Plant Solutions
Engineering Expertise of 200+ Years Across 500+ plants
Total Cement Plant Solutions
Engineering Expertise of 200+ Years Across 500+ plants
WHO WE ARE
Nextcem Consulting embodies a forward-thinking ethos with a team of dynamic professionals who deliver comprehensive plant strategies. Our commitment is to sculpt the future of the Cement Industry with a suite of unparalleled innovative solutions. We specialize in designing and delivering solutions that optimise design, technology, operations, digitisation, and sustainability.
Our approach is anchored in:
Value Engineering & Projects : where we drive cost-effectiveness without compromising on quality.
Operations Excellence: is our cornerstone, ensuring seamless, efficient processes that underpin the operational success of cement plants.
Innovation & Green Tech: we pledge to pioneer eco-friendly technologies, steering the industry toward a sustainable future
Business Digital Transformation: we embrace the digital revolution, leveraging cutting-edge tools to revolutionize traditional practices
In essence, Nextcem Consulting is at the vanguard of transforming the Cement Industry, integrating ingenuity and sustainability with our total plant solutions.
WHO WE ARE
Nextcem Consulting embodies a forward-thinking ethos with a team of dynamic professionals who deliver comprehensive plant strategies. Our commitment is to sculpt the future of the Cement Industry with a suite of unparalleled innovative solutions. We specialise in designing and delivering solutions that optimise design, technology, operations, digitisation, and sustainability.
Our approach is anchored in:
Value Engineering & Projects : where we drive cost-effectiveness without compromising on quality.
Operations Excellence: is our cornerstone, ensuring seamless, efficient processes that underpin the operational success of cement plants.
Innovation & Green Tech: we pledge to pioneer eco-friendly technologies, steering the industry toward a sustainable future
Business Digital Transformation: we embrace the digital revolution, leveraging cutting-edge tools to revolutionize traditional practices
In essence, Nextcem Consulting is at the vanguard of transforming the Cement Industry, integrating ingenuity and sustainability with our total plant solutions.
WHAT WE OFFER
Explore our Solutions
WHAT WE OFFER
Explore our Solutions
Value Engineering
& Technology
Nextcem Consulting provides Value Engineering & Technology by integrating advanced methodologies to maximize the utility and cost-effectiveness of cement manufacturing operations. Leveraging state-of-the-art technological innovations, our engineering protocols are designed to optimize process flow and plant infrastructure.
We focus on critical aspects such as thermodynamic efficiency, process automation, and material sciences to drive down costs and enhance the structural integrity of cementitious compositions. Our team employs robust analytical techniques and lean principles to identify and implement value-additive measures, ensuring that our clients' facilities operate at the pinnacle of industrial efficiency and technological sophistication.
Value Engineering
& Technology
Nextcem Consulting provides Value Engineering & Technology by integrating advanced methodologies to maximize the utility and cost-effectiveness of cement manufacturing operations. Leveraging state-of-the-art technological innovations, our engineering protocols are designed to optimize process flow and plant infrastructure.
We focus on critical aspects such as thermodynamic efficiency, process automation, and material sciences to drive down costs and enhance the structural integrity of cementitious compositions. Our team employs robust analytical techniques and lean principles to identify and implement value-additive measures, ensuring that our clients' facilities operate at the pinnacle of industrial efficiency and technological sophistication.
Nextcem Consulting excels in Plant Operations and Maintenance by implementing sophisticated asset management frameworks and cutting-edge operational technologies. We deploy predictive analytics and condition-based monitoring systems, aligning with industry 4.0 practices to preemptively address equipment needs and system inefficiencies.
the cement industry.
Our focus on Total Productive Maintenance (TPM) and reliability-centered maintenance (RCM) principles minimizes unplanned downtime and maximizes asset reliability and availability. We integrate advanced process control (APC) systems to optimize plant performance, ensuring operations are within critical control parameters for enhanced productivity. Our commitment to technical excellence ensures that plant operations are not only sustained at peak efficiency but also aligned with evolving technological advancements and best practices in the cement industry.
O&M: Plant Operations and Maintenance
O&M: Plant Operations and Maintenance
Nextcem Consulting excels in Plant Operations and Maintenance by implementing sophisticated asset management frameworks and cutting-edge operational technologies. We deploy predictive analytics and condition-based monitoring systems, aligning with industry 4.0 practices to preemptively address equipment needs and system inefficiencies.
the cement industry.
Our focus on Total Productive Maintenance (TPM) and reliability-centered maintenance (RCM) principles minimizes unplanned downtime and maximizes asset reliability and availability. We integrate advanced process control (APC) systems to optimize plant performance, ensuring operations are within critical control parameters for enhanced productivity. Our commitment to technical excellence ensures that plant operations are not only sustained at peak efficiency but also aligned with evolving technological advancements and best practices in the cement industry.
Energy, Efficiency & Environment
Nextcem Consulting's Energy, Efficiency & Environment is underpinned by a rigorous application of thermal analysis, energy auditing, and emissions control strategies within the cement sector. We leverage high-precision computational fluid dynamics (CFD) models and energy simulation software to optimize fuel consumption and enhance the thermal efficiency of clinker production processes.
Our integrated approach involves the deployment of advanced waste heat recovery systems (WHRS) and the utilization of alternative fuels and renewable energy sources to lower carbon footprints. We also apply Six Sigma methodologies to refine operational processes, thereby reducing energy variance and ensuring compliance with stringent environmental regulations. By focusing on energy conservation measures (ECMs) and incorporating sustainable practices, Nextcem Consulting aids cement plants in achieving significant energy savings while maintaining a steadfast commitment to environmental stewardship.
Energy, Efficiency & Environment
Nextcem Consulting's Energy, Efficiency & Environment is underpinned by a rigorous application of thermal analysis, energy auditing, and emissions control strategies within the cement sector. We leverage high-precision computational fluid dynamics (CFD) models and energy simulation software to optimize fuel consumption and enhance the thermal efficiency of clinker production processes.
Our integrated approach involves the deployment of advanced waste heat recovery systems (WHRS) and the utilization of alternative fuels and renewable energy sources to lower carbon footprints. We also apply Six Sigma methodologies to refine operational processes, thereby reducing energy variance and ensuring compliance with stringent environmental regulations. By focusing on energy conservation measures (ECMs) and incorporating sustainable practices, Nextcem Consulting aids cement plants in achieving significant energy savings while maintaining a steadfast commitment to environmental stewardship.
Nextcem Consulting champions 'Green Technologies & Sustainability' in the cement industry through the adoption of advanced eco-efficient solutions and sustainable development practices. We implement state-of-the-art green chemistry applications and carbon capture, utilization, and storage (CCUS) technologies to significantly reduce greenhouse gas emissions and environmental impact.
Our approach incorporates life cycle assessment (LCA) methodologies to evaluate and optimize the environmental footprint of cement production processes. We promote the use of supplementary cementitious materials (SCMs) like fly ash, slag, and natural pozzolans, which not only conserve natural resources but also enhance the performance properties of concrete.
Furthermore, Nextcem leverages renewable energy systems and optimizes raw material sourcing to ensure sustainable operations. By integrating these innovative technologies and sustainable practices, we enable our clients to meet rigorous international sustainability standards while advancing toward a greener future.
Green Technologies
& Sustainability
Green Technologies
& Sustainability
Nextcem Consulting champions 'Green Technologies & Sustainability' in the cement industry through the adoption of advanced eco-efficient solutions and sustainable development practices. We implement state-of-the-art green chemistry applications and carbon capture, utilization, and storage (CCUS) technologies to significantly reduce greenhouse gas emissions and environmental impact.
Our approach incorporates life cycle assessment (LCA) methodologies to evaluate and optimize the environmental footprint of cement production processes. We promote the use of supplementary cementitious materials (SCMs) like fly ash, slag, and natural pozzolans, which not only conserve natural resources but also enhance the performance properties of concrete.
Furthermore, Nextcem leverages renewable energy systems and optimizes raw material sourcing to ensure sustainable operations. By integrating these innovative technologies and sustainable practices, we enable our clients to meet rigorous international sustainability standards while advancing toward a greener future.
Business & Digital Transformation
Nextcem Consulting leads the charge in 'Business & Digital Transformation' within the cement industry by integrating sophisticated digital infrastructures and data-driven decision-making frameworks. Our approach leverages Enterprise Resource Planning (ERP) systems and Advanced Planning and Scheduling (APS) software to streamline operations and enhance logistical efficiencies.
We deploy Industrial Internet of Things (IIoT) solutions and leverage artificial intelligence (AI) and machine learning (ML) algorithms to optimize process controls and predictive maintenance strategies. These digital tools provide deep analytical insights, enabling real-time monitoring and management of plant operations, which significantly enhances operational agility and responsiveness.
Our digital transformation initiatives also include implementing blockchain for secure, transparent supply chain interactions and smart contracts. By adopting these high-level digital strategies, Nextcem Consulting empowers cement manufacturers to innovate their business models, achieve substantial operational improvements, and maintain competitiveness in an increasingly digital world.
Business & Digital Transformation
Nextcem Consulting leads the charge in 'Business & Digital Transformation' within the cement industry by integrating sophisticated digital infrastructures and data-driven decision-making frameworks. Our approach leverages Enterprise Resource Planning (ERP) systems and Advanced Planning and Scheduling (APS) software to streamline operations and enhance logistical efficiencies.
We deploy Industrial Internet of Things (IIoT) solutions and leverage artificial intelligence (AI) and machine learning (ML) algorithms to optimize process controls and predictive maintenance strategies. These digital tools provide deep analytical insights, enabling real-time monitoring and management of plant operations, which significantly enhances operational agility and responsiveness.
Our digital transformation initiatives also include implementing blockchain for secure, transparent supply chain interactions and smart contracts. By adopting these high-level digital strategies, Nextcem Consulting empowers cement manufacturers to innovate their business models, achieve substantial operational improvements, and maintain competitiveness in an increasingly digital world.
OUR TEAM
Ashwani Pahuja
Chairman & Managing Director
Cement Industry stalwart, a seasoned Chemical Engineer with 43 years of rich experience. Ex Director General NCBM and Executive Director Manufacturing and Chief Sustainability Officer at Dalmia Cement.
Expert in Project/Plant Management, Process Optimization, Productivity Enhancement, Energy Conservation and Management, Cost Reduction, Sustainability, Climate Change Mitigation, Quality Control, and more.
A trailblazer in Carbon Neutrality, Innovation and Strategic Planning. Adept at driving excellence in Product/Designs development and fostering Team Management. He is known for nurturing and developing leaders.
PVR Murthy
Chief Executive Officer
A seasoned Chemical Engineering professional with 37+ years in the Cement Industry. Ex Research Scientist at NCBM, Senior Technical Leader with CIMMCO Birla, KHD, HOLCIM, Adani, Ambuja, ACC.
Expertise in emerging Technologies Promotion, Process Engineering and Business Development.
Proficient in designing and managing projects from concept to commissioning.
Mastermind in improving Engineering and Operational Efficiencies. Passionate for Energy Efficiency, Environment & New Technologies
VVGK Gokhale
Chief Technology Officer
A Mechanical Engineer with 45+ years in the Cement Industry. Associated with KCP, FL Smidth, LNV Technology, President Witt and Sohn.
Experience in Design Engineering, Proposals, Estimation, and Business Development.
Proficient in project execution, procurement, vendor development, and overseeing various Cement plant projects globally.
Renowned for his expertise in sizing and selecting equipment, managing EPC/EP projects, and excelling in Construction Management,
Managed large complex global bids.
Sharad Nema
Chief Engg & Project officer
A Mechanical Engineer with 33+ years of Cement Industry experience. Associated with Century & Maihar Cement, HOLTEC, KHD Humboldt Wedag. PEG India.
Specializes in Project Design Engineering, Maintenance, Feasibility Studies, and Project Coordination for Greenfield and Brownfield Projects.
Proficient in Layout and System Design Engineering, Maintenance Planning, Troubleshooting, and Technical Audits. Experienced in Civil Structural and E&I Assessments, Construction Management.
Shyam S Chaurasia
Chief Operating Officer
A Chemical Engineer with 40+ years in the Cement Industry. Associated with JK Cem, Rajashree, Dangote Industries – Nigeria, Andhra Cem, National Cement – Yemen.
Specializes in Plant Operations, Process Optimization, Quality Improvement. Greenfield and Brownfield Project commissioning, Refractory Management. Raw Mix Design and reducing production costs. Solutions to Chronic problems and Downtime reduction.
Skilled in Alternate Fuels and RDF, Environmental compliance. Adept optimizing Cement Plant operations,
Raj Janapareddy
Chief Innovation Officer
A seasoned Technologist and Management professional with 36+ years of experience in Cement & IT Industries. Business Leader with L&T, Enexco, Deloitte, PWC, GE/Genpact, Satyam, and Utopia Inc. helping Fortune 100 firms with Business and Digital Transformation,
Specializes in Cement Process Automation, Expert systems , Fuzzy Logic, Scanners, PGNAA Gamma Metrics, Lab automation, and new technologies: (BoTs, IoT, AI, ML, Analytics, Big Data),
Established SAP, EDLM, Big Data, Analytics, AIML RPA, practices.
OUR TEAM
Ashwani Pahuja
Chairman & Managing Director
Cement Industry stalwart, a seasoned Chemical Engineer with 43 years of rich experience. Ex Director General NCBM and Executive Director Manufacturing and Chief Sustainability Officer at Dalmia Cement.
Expert in Project/Plant Management, Process Optimization, Productivity Enhancement, Energy Conservation and Management, Cost Reduction, Sustainability, Climate Change Mitigation, Quality Control, and more.
A trailblazer in Carbon Neutrality, Innovation and Strategic Planning. Adept at driving excellence in Product/Desgess development and fostering Team Management. He is known for nurturing and developing leaders.
PVR Murthy
Chief Executive Officer
A seasoned Chemical Engineering professional with 37+ years in the Cement Industry. Ex Research Scientist at NCBM, Senior Technical Leader with CIMMCO Birla, KHD, HOLCIM, Adani, Ambuja, ACC.
Expertise in emerging Technologies Promotion, Process Engineering and Business Development.
Proficient in designing and managing projects from concept to commissioning.
Mastermind in improving Engineering and Operational Efficiencies. Passionate for Energy Efficiency, Environment & New Technologies
VVGK Gokhale
Chief Technology Officer
A Mechanical Engineer with 45+ years in the Cement Industry. Associated with KCP, FL Smidth, LNV Technology, President Witt and Sohn.
Experience in Design Engineering, Proposals, Estimation, and Business Development.
Proficient in project execution, procurement, vendor development, and overseeing various Cement plant projects globally.
Renowned for his expertise in sizing and selecting equipment, managing EPC/EP projects, and excelling in Construction Management,
Managed large complex global bids.
Sharad Nema
Chief Engg & Project officer
A Mechanical Engineer with 33+ years of Cement Industry experience. Associated with Century & Maihar Cement, HOLTEC, KHD Humboldt Wedag. PEG India.
Specializes in Project Design Engineering, Maintenance, Feasibility Studies, and Project Coordination for Greenfield and Brownfield Projects.
Proficient in Layout and System Design Engineering, Maintenance Planning, Troubleshooting, and Technical Audits. Experienced in Civil Structural and E&I Assessments, Construction Management.
Shyam S Chaurasia
Chief Operating Officer
A Chemical Engineer with 40+ years in the Cement Industry. Associated with JK Cem, Rajashree, Dangote Industries – Nigeria, Andhra Cem, National Cement – Yemen.
Specializes in Plant Operations, Process Optimization, Quality Improvement. Greenfield and Brownfield Project commissioning, Refractory Management. Raw Mix Design and reducing production costs. Solutions to Chronic problems and Downtime reduction.
Skilled in Alternate Fuels and RDF, Environmental compliance. Adept optimizing Cement Plant operations,
Raj Janapareddy
Chief Innovation Officer
A seasoned Technologist and Management professional with 36+ years of experience in Cement & IT Industries. Business Leader with L&T, Enexco, Deloitte, PWC, GE/Genpact, Satyam, and Utopia Inc. helping Fortune 100 firms with Business and Digital Transformation,
Specializes in Cement Process Automation, Expert systems , Fuzzy Logic, Scanners, PGNAA Gamma Metrics, Lab automation, and new technologies: (BoTs, IoT, AI, ML, Analytics, Big Data),
Established SAP, EDLM, Big Data, Analytics, AIML RPA, practices.
FAQS
What makes Nextcem's approach to Value Engineering unique in the cement industry?
Nextcem Consulting employs a combination of advanced analytical tools and extensive industry expertise to deliver cost-effective and innovative solutions. Our unique approach involves a detailed analysis of existing processes, implementation of lean manufacturing principles, and integration of state-of-the-art technologies, ensuring that every aspect of cement production is optimized for both performance and sustainability.
How does Nextcem ensure the reliability and efficiency of plant operations?
We utilise predictive maintenance techniques, real-time data monitoring, and advanced process control systems to enhance plant operations. Our methodologies are grounded in reliability-centered maintenance (RCM) and total productive maintenance (TPM) strategies, which not only predict and prevent failures but also promote operational excellence and energy efficiency.
Can Nextcem help in reducing our plant’s environmental impact while maintaining production efficiency?
Absolutely. Nextcem Consulting integrates green technologies such as waste heat recovery systems, emissions reduction technologies, and the utilization of alternative fuels and raw materials. We also conduct environmental impact assessments and employ continuous improvement strategies to ensure that your operations meet both production and environmental targets effectively.
What are the key components of Nextcem’s Business and Digital Transformation services?
Our services encompass the integration of ERP systems, deployment of IIoT and AI technologies for process optimization, and the adoption of digital twins to simulate and improve plant operations. We focus on enhancing data visibility across operations, which supports strategic decision-making and fosters a culture of innovation and continuous improvement.
How does Nextcem Consulting support the implementation of sustainable practices in cement production?
We support sustainable practices through the strategic use of SCMs to replace traditional raw materials, promote energy-efficient processes, and implement CCUS technologies to reduce carbon emissions. Our sustainability efforts are tailored to meet global standards and help clients achieve their CSR objectives while enhancing operational and cost efficiencies.
FAQS
What makes Nextcem's approach to Value Engineering unique in the cement industry?
Nextcem Consulting employs a combination of advanced analytical tools and extensive industry expertise to deliver cost-effective and innovative solutions. Our unique approach involves a detailed analysis of existing processes, implementation of lean manufacturing principles, and integration of state-of-the-art technologies, ensuring that every aspect of cement production is optimized for both performance and sustainability.
How does Nextcem ensure the reliability and efficiency of plant operations?
We utilise predictive maintenance techniques, real-time data monitoring, and advanced process control systems to enhance plant operations. Our methodologies are grounded in reliability-centered maintenance (RCM) and total productive maintenance (TPM) strategies, which not only predict and prevent failures but also promote operational excellence and energy efficiency.
Can Nextcem help in reducing our plant’s environmental impact while maintaining production efficiency?
Absolutely. Nextcem Consulting integrates green technologies such as waste heat recovery systems, emissions reduction technologies, and the utilization of alternative fuels and raw materials. We also conduct environmental impact assessments and employ continuous improvement strategies to ensure that your operations meet both production and environmental targets effectively.
What are the key components of Nextcem’s Business and Digital Transformation services?
Our services encompass the integration of ERP systems, deployment of IIoT and AI technologies for process optimization, and the adoption of digital twins to simulate and improve plant operations. We focus on enhancing data visibility across operations, which supports strategic decision-making and fosters a culture of innovation and continuous improvement.
How does Nextcem Consulting support the implementation of sustainable practices in cement production?
We support sustainable practices through the strategic use of SCMs to replace traditional raw materials, promote energy-efficient processes, and implement CCUS technologies to reduce carbon emissions. Our sustainability efforts are tailored to meet global standards and help clients achieve their CSR objectives while enhancing operational and cost efficiencies.
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