Summer Training Project Report On Brand Image of ACC Cement in Cement Industry Submitted to Kurukshetra University – Kurukshetra M.B.A. Session 2010-2012 Under the Guidance of Submitted By: Ms./Mr. Sunny Sharma Faculty M.B.A. – II M.B.A. (Dept.) Roll No. 293558 1
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Summer Training Project Report
On
Brand Image of ACC Cement in Cement Industry
Submitted to
Kurukshetra University – Kurukshetra
M.B.A.Session 2010-2012
Under the Guidance of Submitted By:
Ms./Mr. Sunny Sharma
Faculty M.B.A. – II
M.B.A. (Dept.) Roll No. 293558
Swami Devi Dayal Institute of Engineering & Technology
Barwala , Panchkulla (Haryana)
1
ACKNOWLEDGEMENT
First of all I would like to thank my college lecturer for her whole hearted co-
operation during my summer training in ACC Barmana, which gave me a good exposure and a
hand-on experience of the modern office practices.
I would like to thanks Mr. Ravi Srivastava – Asstt. Manager Sales, for giving me an
opportunity to be associated with his esteemed team for gaining such practical knowledge &
providing me necessary inspiration as well as encouragement during the course of this training.
I wish to express a deep sense of gratitude & sincere thanks to my project guides
Mr. Ravi Srivastava (Asstt. Manager Sales ) and other staff, for giving me time, out of their
busy schedule, for imparting me with such great knowledge and making my training successful. I
also want to wish my gratitude to the following for providing me the necessary information:
Mr. Kaushal Kishore Distt. Officer
Mr. Anish kaundal Chief Manager
In the end I would like to thanks all those persons who have helped me directly or
indirectly in completing my industrial training and also this project report.
SUNNY SHARMA
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Chapter 1
Introduction
(A) JUSTIFICATION OF STUDY
The study in itself is a problem of how best to manage market of a company i.e. ACC Ltd.
Therefore, needs for conducting the study are as follows:-
After production, every company has to maintain and achieve its required sales targets from the
market to run its operation smoothly.
In case of manufacturing companies it is required to maintain about 40% - 50% of their capital as
current and remaining in the form of fixed assets for the large scale production of product. So,
every manufacturing company needs to arrange required working capital.
The production in a industry is constant process and if the sales does not match the level of
expectations then long term business interest of company suffers.
It’s necessary to know the short and long term Sales position of the firm. To know that Market
surveys and customer behavior analyses are done for the current year i.e. for the year 2011.
OBJECTIVE OF THE STUDY
The objectives aim to highlight the reasons how to improve the branch image of ACC cements
by market survey of various cements stores dealing all brands in the area of Palampur, Distt.
Kangra, H.P. There are various objectives of the study are as follows:
To find position of the firm.
To study short term sales position.
To study long term sales position.
To study brand image of the firm.
To find correlation between company and the firm.
To study the trend of the market and use it for the profits of the firm.
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B) Introduction to the Company :
HISTORY OF CEMENT INDUSTRY
F. E. Dinshaw – the founder of ACC
Associated cement companies was constituted in year 1936 under
Indian govt. act 1936.
The history of the cement industry is the story of civilization from primitive caves of prehistoric
times to the skyscrapers of the modern age. It is said that the use of cement is from period use of
fire Egyptians utilize gypsum plaster as cementing material as early as 3000 BC in building their
monuments.
Material cement has existed the roman empire Joseph Arpdin invited Portland cement in 1824
after the discovery of hydraulic properties of time, patented his product which was call
Portland cement. Portland stone which is lime stone quarried on Portland bill indorsed, England.
Modern cement is outcome of effort of chemist’s technologist & architects.
Cement is binding agent having hydraulic properties, which after hydration gives the setting
properties strengthening concrete. Intergrading, Clinker, Gypsum, & Pozzolanic material in a
proper ratio to get Portland Pozzolane Cement manufacture cement.
Cement essentially made up of material containing calcium silicon, aluminum and iron.
Limestone, marl and chalk are major source of clay shale, quartzite, bauxite iron ore provide
silicon, aluminum & iron components.
Many men of outstanding initiative and foresight contributed to the development of
the cement industry in India. Fore most them was the great industrial and patriot Mr. F.E.
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Dinshaw, who was mainly responsible for the merger of the ten existing companies into a single
organization in 1936.
This was christened the Associated Cement Companies. In defining the objectives of
the late Mr. Dinshaw had stressed that it was not to attain a monopolistic position. But that its
primary objectives will be to make and deliver cement as cheaply as possible.
Mr. Dinshaw’s confined was abundantly justified, and between 1936 and 1939 four
new factories were add to the ACC group. With the outbreak of the leadership of ACC
responded to war needs.
In the post war years Govt. set up a planning and development the industry
responded and ACC planned substantial increase in its production capacities to need national
need inspire of hurdles, ACC succeeded in achieving in its expansion program.
Today ACC is the leader in the cement industry, production 12% to 14% of India’s
total cement production. It is one of the most respected blue chip conglomerate in India and is
one of the largest integrated producer among the developing companies its annual turnover
exceed Rs. 5900 crores and its assets base exceed 3000 crores.
The company employees 12000 people at its corporate office research and constancy
directorate, 13 cement plants, 3 refractory plants, 11 regional offices and various other new
businesses. Cement continues to be core business activity, but ACC moving into Greenfield
areas, advanced materials, hi-tech refractories and refactory intermediates a broad spectrum of
constancy packages and engineering products and services, enroot, the company has acquired
and signed moue’s to facilitate transfer of technologies and Access to export and market.
ACC stands out as the most unique and successful merger in Indian business history, in which
the distinct identities of the constituent companies were melded into a new cohesive organization
- one that has survived and retained its position of leadership in industry. In a sense, the
formation of ACC represents a quest for the synergy of good business practices, values and
shared objectives. The use of the plural in ACC's original name, The Associated Cement
Companies Limited, itself indicated the company's origins from a merger. Many years later,
5
some stockbrokers in the country's leading stock exchanges continued to refer to this company
simply as 'The Merger'.
ACC's First Board Meeting in 1936 at The Esplanade
Sir Nowroji B Saklatvala was the first chairman of ACC. The first Board included distinguished
luminaries of the Indian business world of the time - names like J R D Tata, Ambalal Sarabhai,
Walchand Hirachand, Dharamsey Khatau, Sir Akbar Hydari, Nawab Salar Jung Beadier and Sir
Holy Mody among others.
MAJOR COMPANIES IN THE CEMENT INDUSTRY ARE:-
The Associated Cement Companies Ltd.
Birla Group.
Larsen & Turbo.
J.K. Group.
Jaypee cement.
Guraj Ambuja.
6
INTRODUCTION OF ACC
HISTORY OF ACC
Many men of outstanding initiative and foresight contributed to the development of the cement
industry in India. Fore most them was the great industrial and patriot Mr. F.E. Dinshaw, who was
mainly responsible for the merger of the ten existing companies into a single organization in
1936.
This was christened the Associated Cement Companies. In defining the objectives of the late Mr.
Dinshaw had stressed that it was not to attain a monopolistic position. But that its primary
objectives will be to make and deliver cement as cheaply as possible.
Mr. Dinshaw’s confined was abundantly justified, and between 1936 and 1939 four new
factories were add to the ACC group. With the outbreak of the leadership of ACC responded to
war needs.
In the post war years Govt. set up a planning and development the industry responded and ACC
planned substantial increase in its production capacities to need national need inspire of hurdles,
ACC succeeded in achieving in its expansion program.
Today ACC is the leader in the cement industry, production 12% to 14% of India’s total cement
production. It is one of the most respected blue chip conglomerate in India and is one of the
largest integrated producer among the developing companies its annual turnover exceed Rs. 5900
crores and its assets base exceed 3000 crores.
The company employees 12000 people at its corporate office research and constancy directorate,
13 cement plants, 3 refractory plants, 11 regional offices and various other new businesses.
Cement continues to be core business activity, but ACC moving into Greenfield areas, advanced
materials, hi-tech refractories and refactory intermediates a broad spectrum of constancy
packages and engineering products and services, enroot, the company has acquired and signed
moue’s to facilitate transfer of technologies and Access to export and market.
Associated cement companies was constituted in year 1936 under Indian govt. act 1936.
7
ACC has distributed its operation in following three regions:
NORTH REGION (CAPACITY 6.3 MTPA)
(Regional office: Delhi)
Gagal I & II
Tikaria
Lakheri
Kymore
SOUTH-WEST REGION (CAPACITY: 6.1 MTPA)
(Regional office: Pune)
Wadi
Chanda
Madukarrai
EAST REGION (CAPACITY: 3.5 MTPA)
(Regional office: Kolkatta)
Chaibasa
Sindri
Bargarh
Jamul
Damodar Cement Works
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MISSION, VISION AND STRATEGY OF ACC LTD:-
QUALITY:- To make continuous improvement in the quality of our product
and services and add some essential features for customer satisfaction and
ensure their supply at fair prices.
PROFITABILITY: - To achieve fair and reasonable return on capital
employed by making optimum utilization of available resources and
increasing productivity & effectiveness throughout the company.
RESPONSIBILITY: - To fulfill our obligation to society, specifically in the
area of rural development and in safeguarding.
LEADERSHIP: - Maintain our leadership of the Indian cement industry
through the country modernization and expansion of our manufacturing
Region (South West)Region (South West)
Region (East)Region (East)Region (North)Region (North)GAGALGAGAL
TIKARIATIKARIA
LAKHERILAKHERI
KYMOREKYMORE
JAMULJAMUL
CHAIBASA
CHAIBASA
SINDRI
SINDRI
DCWDCW
BARGARHBARGARH
CHANDACHANDA
WADIWADI
MADUKKARAIMADUKKARAI
9
facilities and activities and through the establishment of a wide and efficient
marketing network.
GROWTH: - Ensure a steady growth of business by strengthening our
position in the cement sector.
EQUITY: - Promote and maintain fair industrial relation and environment for
the effective involvement, welfare and development of staff at all levels.
VISION:- Vision of ACC is to be a world class corporation with diverse
business built around ACC’sunita core competencies and knowledge base in
cement refectories advanced material engineering geology mining and
research.
ACC’s Vision vividly declares the company’s
commitment to community and sustainable development issues making this
an essential part of the five interdependent and intertwined business goals
for the company. The essence of this resolve is contained in the fifth goal or
“diamond” which envisages that ACC inspires trust and respect.
The Vision statement narrates these areas as:-
ACC is a trusted and ethical organization
ACC delivers enduring value to investors and other stakeholders
ACC is committed to environment protection and the well being of the commu-
nity.
This statement is synonymous with balancing the Triple Bottom Line –
defined as the achievement of three interdependent and mutually reinforcing
goals of economic development, social development and environmental
protection.
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ACC SHARED VISION
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ACC is a customer driven
org.
ACC has employees who are committed to delivering ultimate customer satisfaction.
ACC is the most preferred brand in India.
ACC is a customer driven
org.
ACC has employees who are committed to delivering ultimate customer satisfaction.
ACC is the most preferred brand in India.
ACC is a learning org.
ACC is alert to the changes in business environment and respond effectively.
ACC adopts world class business practices to surpass global benchmarks.
ACC develops employees through need based learning.
ACC is a learning org.
ACC is alert to the changes in business environment and respond effectively.
ACC adopts world class business practices to surpass global benchmarks.
ACC develops employees through need based learning.
ACC inspires trust and respect.
ACC is a trusted and ethical org.
ACC is committed to environment protection and well being of the community.
ACC inspires trust and respect.
ACC is a trusted and ethical org.
ACC is committed to environment protection and well being of the community.
ACC is a great place to work.
ACC has HR policies which promote a healthy work place.
ACC rewards employees well based on profitability and performance.
ACC cares for its employees welfare.
ACC is a great place to work.
ACC has HR policies which promote a healthy work place.
ACC rewards employees well based on profitability and performance.
ACC cares for its employees welfare.
ACC is a customer driven
org.
ACC has employees who are committed to delivering ultimate customer satisfaction.
ACC is the most preferred brand in India.
ACC is a customer driven
org.
ACC has employees who are committed to delivering ultimate customer satisfaction.
ACC is the most preferred brand in India.
Value Creation
ACC delivers long term values to i nvestors and to other shareholders
BUSSINESS STRATEGY
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20072007 20082008 20092009 20102010 20112011
Market Share Maintain leadership position in the industry.Maintain leadership position in the industry.
Competitiveness Leadership in quality, services and cost efficiency.Leadership in quality, services and cost efficiency.
Organization Accountable, Motivated and responsive.Accountable, Motivated and responsive.
Corporate Citizenship
Create safe place to work
Become employer of choice.
Reputed corporate entity.
Leadership in sustainable development.
Enhance community living standards.
Create safe place to work
Become employer of choice.
Reputed corporate entity.
Leadership in sustainable development.
Enhance community living standards.
Bottom LineAchieve internal target for growth in EBITDA over 2007.Achieve internal target for growth in EBITDA over 2007.
VARIOUS DIVISIONS OF ACC
1) OPERATIONS DIVISIONS
This division is responsible for the operation of all the Company’s Cement Works & its slag
granulation plant. The Cement plants are
a) Bhupendra Works b) Chaibasa Works c) Chanda Works
d) Gagal Works e) Jamul Works f) Kymore Works
g) Lakheri Works h) Madukkarai Works i) Mancherial Works
j) Sindri Works k) Wadi Works
The division consists of the following departments sections:
a) Factory Operations b) Major Repairs
c) Mining Machinery d) Audit & Administration
e) Railway Liaison f) Safety
g) Environment & Pollution Control
2) FINANCIAL DIVISIONS
The division is responsible for all accounting & financial functions. This is addition, takes care
of the taxation function, the Company’s Provident Fund & Insurance. All receipts, development
& monitoring of funds is done by this division. This comprises of following sections:
a) Corporate Tax and Insurance
b) Payrolls, Provident Funds & Officers Superannuation Funds.
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c) Company Accounts
d) Treasury
f) Project Finance
g) Sales Accounting & Pricing Section
h) Management Accounting Sections
3) MATERIALS MANAGEMENT DIVISIONS
This division deal with materials management policy as also requirement of major raw material,
packaging materials, purchasing of capital equipment, high value & consumption stores & spares
& projects requirements.
This division is professionally manned to procure all stores & spares at economical prices & to
study the markets trends as well. Vendor development, supply diversification & import
substitution form an important part of this division.
4) CEMENT MARKETING DIVISION
With liberalization there is an increase in completion from more manufactures, more brands,
higher grade products, increased production & free availability of Cement in the country.
In the buyer’s market & in order to meet the competition the Cement Marketing Division has
taken the following steps to retain the company’s share as a market leader:-
i) The company has appointed a network of 10,000 stockiest in all rural urban markets
ii) Opening of warehouses: The Company has organized warehousing facilities at almost all
important urban consumption centers in the country so that ACC Cement is freely
available to the consumers in proximity to the point of consumption.
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iii) The company has customer service cells in the North, South, East & West regions to
attend all kind of customer’s complaints to provide promp ans satisfactory customers
servicing.
The Cement marketing to the above, CMD has eleven regional Marketing Officers situated at
Leading exporter world wide, of top quality high alumina products.
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7) DOMESTIC AND INTERNATIONAL TRADING DIVISION
This division is the marketing trust for the company’s non cement business. The scope of the
division includes explores, marketing of franchised & allied products manufactured by ACC’s
subsidiaries & associate companies. It also include marketing agency in India for our joint
venture products like Alcoa, Asahi Glass etc.
8) PROJECTS DIVISION
The projects division is responsible or the design & construction of the company’s new projects.
The division formulates implements, monitors & control annual capital expenditure budget for
the new projects.
The various functions under the division are listed below:
a) Process Engg. & Design
b) Civil Engineering
c) Electrical & Instrumentation Engineering
d) Projects Execution Group
e) Project Services
9) INFORMATION SYSTEMS DEPARTMENT
The IS department’s basic function are to provide adequate & efficient computer services at the
Corporate Office Works & RMO’s for routine data processing as well as management
information for planning & control of various functions of the company. It handles all maters
connected with installation of the computer hardware & its subsequent operations at various
locations wherever it is installed. The deptt. Deals with all computerized systems designs,
development & modifications as well as operation research work for the entire company.
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10) SECRETARIAL DIVISION
The division ensures compliance with the statutory enactment applicable company & in
particular the comparises act & other important legal matters. The share deptt. Comes under the
preview of the secretarial division.
11) OVERSEAS PROJECT CELL
This department is primarily responsible for the development of overseas business opportunities
for the company & for monitoring the performance of contracts awarded. It is responsible for
putting together a package of services, as required by the prospective client &
tendering/negotiating with prospective clients to secure business.
12) CORPORATE PLANNING DEPARTMENT
The department assists the top management in developing long term/short term objectives,
strategies in existing new business lines. It undertakes studies & explores new business
opportunities for divaricating.
13) ADMINISTRATIVE SERVICES DIVISION (A.S.)
This division renders various services & assistance to the different division/deptt. at the head
office & the subsidiaries of the company.
It provides its services in the following areas:
a) Property matters
b) Building Maintenance Services
c) Maintaining Inventory of furniture & furniture etc.
d) Communication Services
e) Vehicle Procurement & maintenance
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14) HUMAN RESOURCES DIVISION
The human Resources Division covers the entire human resources management activity in the
company. It guides the unit in formulation & implementation pf personnel policies in the area of
Human Resources Development, Industrial Relations, Personnel Administration, Welfare &
Training.
15) RESEARCH & CONSULTANCY DIRECTORATE
This fully autonomous division is the brain of the company & serves as the prime origin to meet
all the technological & innovative needs of the organization. It is a project engg. & technical
consultancy organizations. RCD’s expertise covers the following areas of specialization:
a) Cement & Mineral Projects
b) Geology, Environment & Mining
c) Erection & Construction
d) Refractories & Development
e) Agri-horticultural & Rural Development
f) Management Training
g) Environment Management
h) Advanced Management
i) Advanced Materials
Today, RCD’s services offered are even more broad based, catering to industries like cement,
refractory, ceramics, chemical, minerals processing, petrochemical, fertilizers, ferrous & non
ferrous among others.
ACC LTD. PROGRAMS
Company is running various system programs which provide the valuable system to the workers
to show their job efficiently.
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QUALITY POLICY AT ACC LTD
Build quality in, Do not sort bad quality out
Quality improvement is limitless & therefore continuous
Concern for quality is for the entire organization & not for the product
Satisfy customer fully & continuously
CORPORATE PROFILE OF ACC LTD.
ACC (ACC Limited) is India's foremost manufacturer of cement and concrete. ACC's operations are spread throughout the country with 14 modern cement factories, more than 30 Ready mix concrete plants, 20 sales offices, and several zonal offices. It has a workforce of about 10,000 persons and a countrywide distribution network of over 9,000 dealers. ACC's research and development facility has a unique track record of innovative research, product development and specialized consultancy services. Since its inception in 1936, the company has been a trendsetter and important benchmark for the cement industry in respect of its production, marketing and personnel management processes. Its commitment to environment-friendliness, its high ethical standards in business dealings and its on-going efforts in community welfare programmes have won it acclaim as a responsible corporate citizen. ACC has made significant contributions to the nation building process by way of quality products, services and sharing its expertise.
In the 70 years of its existence, ACC has been a pioneer in the manufacture of cement and concrete and a trendsetter in many areas of cement and concrete technology including improvements in raw material utilisation, process improvement, energy conservation and development of high performance concretes.
ACC’s brand name is synonymous with cement and enjoys a high level of equity in the Indian market. It is the only cement company that figures in the list of Consumer SuperBrands of India.
The company's various businesses are supported by a powerful, in-house research and technology backup facility - the only one of its kind in the Indian cement industry. This ensures not just consistency in product quality but also continuous improvements in products, processes, and application areas.
ACC has rich experience in mining, being the largest user of limestone, and it is also one of the principal users of coal. As the largest cement producer in India, it is one of the biggest customers of the Indian Railways, and the foremost user of the road transport network services for inward and outward movement of materials and products.
ACC has also extended its services overseas to the Middle East, Africa, and South America, where it has provided technical and managerial consultancy to a variety of consumers, and also helps in the operation and maintenance of cement plants abroad.
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ACC is among the first companies in India to include commitment to environmental protection as one of its corporate objectives, long before pollution control laws came into existence. The company installed pollution control equipment and high efficiency sophisticated electrostatic precipitators for cement kilns, raw mills, coal mills, power plants and coolers as far back as 1966. Every factory has state-of-the art pollution control equipment and devices. ACC demonstrates the practices of being a good corporate citizen undertaking a wide range of activities to improve the living conditions of the under-privileged classes living near its factories.
A GLIMPS ON THE HISTORY OF SUCCESS
The Associated Cement Companies Limited is a multi business enterprise with operation in
cement manufacturing. It is one of leading companies in India, producing more than one-
fourth of national output. ACC. Ltd as company duly registered under Indian Companies
Act 1956, having its registered office at Cement House, 121 Maharishi Karv Road, Mumbai-
400020.It has 14 cement plants spread all over the country and has major force of its industry
through customer satisfaction & through continuous innovation in quality of the product. As
company ACC Ltd. is committed to make and deliver as cheaply as possible.
Initially, when cement was introduced in 1914, South India Industry Ltd.started first cements
plant near Madras. But due to lack of labors and knowledge in manufacturing of cement, this
plant after a few months working closed down. After ward in 1912-1919 two more plants
wee started in Katni situated in Madhya Pradesh and in,Lakhri in Rajasthan, before 1924 six
more plants were started at various other places but they did not led any good start.
In 1936 with the effort of Mr.Dinshaw a group of companies and formed Associated Companies
Ltd.
Many men of outstand initiative and foresight contributed towards the development of cement
industry in India. About 62 years ago in 1936 a number of companies belonging to the house of
Tata Khatias and Kellick, Nixon combined to from “The associated Cement Companies
Ltd”.Great industrialist and patriot Mr.F.E.Dinshaw was mainly responsible into a single
organization.
The objectives of this merger were not to attain monopolistic position but to make and deliver
cement as cheaply as possible. Mr. Dinshaw added for new factories in ACC group from 1929
20
to 1936. During Second World War, the cement was deliver as essential commodities under
the defences of Indian rule and through under price and distribution control. The cement
industry gets further impetus under the leadership of ACC.
ACC MILESTONES.
1936 Incorporation of The Associated Cement Companies Limited on August 1, 1936.
1936 First Board Meeting of The Associated Cement Companies Limited held at
Esplanade House, Mumbai on November 10, 1936.
1937 With the transfer of the 10th company to ACC, viz. Dewarkhand Cement
Company, the formation of ACC is complete on October 23, 1937.
1944 ACC’s first community development venture near Bombay
1947 India’s first entirely indigenous cement plant established at Chaibasa in Bihar
1952 Village Welfare Scheme launched
1955 Sindri cement works used the waste product calcium carbonate sludge from
fertilizer factory at Sindri.
1956 Bulk Cement Depot established at Okhla, Delhi
1957 Technical training institute established at Kymore, Madhya Pradesh.
1957 Katni Refractories
1961 Blast furnace slag from TISCO used at the Chaibasa Unit to manufacture Portland
Slag Cement for the first time in India.
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1961 Manufacture of Accocid Cement, which resists the corrosive action of acids and
chemicals.
1961 Oil well Cement manufactured at ACC Shahabad Cement Works in Karnataka for
cementation of oilwells up to a depth of 6,000 feet.
1961 Manufacture of Hydrophobic (waterproof) cement at ACC Khalari Cement Works
in Bihar.
1962 Manufacture of Accoproof, a waterproofing additive.
1965 ACC’s Central Research Station (CRS) established at Thane
1965 Manufacture of Portland Pozzolana Cement.
1965 Manufacture of Calundum, a High Alumina Binder; Firecrete, Low Density
Alumina Castables and High Alumina Refractory Cement.
1968 Advent of computers in ACC for data processing and designing management
information and control systems.
1968 ACC supplied and commissioned one-million-toner iron ore pelletising plant
ordered by TISCO
1971 Manufacture of Whytheat Castables A, K, C and Cal-Al-75
1973 Take-over of The Cement Marketing Company of India (CMI)
1977 ACC receives ASSOCHAM first national award for the year 1976 instituted for
outstanding performance in promoting rural and agricultural development
activities.
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1978 Introduction of the energy efficient precalcinator technology for the first time in
India. Full scale commercial production based on MFC technology at Wadi in
1979.
1979 ACC wins international contract for operation and management of a new one
million tonne cement plant at Yanbu-Ras Biridi in Saudi Arabia.
1982 Commissioning of the first 1 MTPA plant in the country at Wadi, Karnataka.
1984 ACC achieves a breakthrough in import substitution by developing and supplying a
special G type of oil well cement to ONGC.
1987 ACC develops a new binder for use at sub-zero temperatures, which is successfully
used in the Indian expedition to Antarctica.
1992 Incorporation of Bulk Cement Corporation of India, a joint venture with the
Government of India.
1993 ACC starts the commercial manufacture of Ready Mixed Concrete at Mumbai.
1998 Commissioning of the 0.6 MTPA cement grinding unit at Tikaria, Uttar Pradesh.
1999 Commissioning of captive power plants at the Jamul and Kymore plants in Madhya
Pradesh.
1999 Tata group sells 7.2% of its stake in ACC to Ambuja Cement Holdings Ltd, a
subsidiary of Gujarat Ambuja Cements Ltd. (GACL)
2000 Tata Group sells their remaining stake in ACC to the GACL group, who with
14.45% now emerge as the single largest shareholder of ACC.
2001 Commissioning of the new plant of 2.6 MTPA capacity at Wadi, Karnataka plant,
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the largest in the country, and among the largest sized kilns in the world.
2002 ACC wins PHDCCI Good Corporate Citizen Award
2003 IDCOL Cement Ltd becomes a subsidiary of ACC
2004 IDCOL Cement Limited is renamed as Bargarh Cement Limited (BCL).
2004 ACC raises US $ 100 million abroad through Foreign Currency Convertible Bonds
(FCCB’s) for US$ 60 million and Global Depository Shares (GDS’s) for US $ 40
million. Both offerings are listed on the London Stock Exchange.
2004 ACC named as a Consumer Superbrand by the Superbrands Council of India,
becoming the only cement company to get this status.
2004 GreenTech Safety Gold and Silver Awards awarded to Madukkarai Cement Works
and Katni Refractory Works by Greentech Foundation for outstanding performance
in Safety Management System.
2005 ACC receives the CFBP Jamnalal Bajaj Uchit Vyavahar Puraskar Certificate of
Merit – 2004 from Council For Fair Business Practices.
2005 Holcim group of Switzerland enters strategic alliance with Ambuja Group by
acquiring a majority stake in Ambuja Cements India Ltd. (ACIL) which at the time
held 13.8 % of the total equity shares in ACC. Holcim simultaneously makes an
open offer to ACC shareholders, through Holdcem Cement Pvt. Limited and ACIL,
to acquire a majority shareholding in ACC. Pursuant to the open offer, ACIL’s
shareholding in ACC increases to 34.69 % of the Equity share capital of ACC.
2005 Commissioning of Modernisation and Expansion project at Chaibasa in Jharkhand,
replacing old wet process technology with a new 1.2 MTPA clinkering unit,
together with a captive power plant of 15 MW.
24
2005 Financial accounting year of the company changed to calendar year January-
1956 Bulk Cement Depot established at Okhla, Delhi
1961Blast furnace slag, (a waste by-product from steel) from TISCO used at ACC
Chaibasa to manufacture Portland Slag Cement.
1961Oilwell Cement manufactured at ACC Shahabad for cementation of oilwells upto a
depth of 6,000 feet.
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1961 Manufacture of Hydrophobic (waterproof) cement at ACC Khalari.
1965Manufacture of Portland Pozzolana Cement using naturally available materials. An
eco-friendly cements using an eco-friendly process.
1966
ACC inducts use of pollution control equipment and high efficiency sophisticated
electrostatic precipitators for its cement plants and captive power plants decades
before it becomes mandatory to do so.
1978Introduction of the energy efficient pre-calcination technology for the first time in
India.
1982Commissioning of the first 1 MTPA (million tonne per annum) plant in the country
at Wadi, Karnataka.
1984ACC achieves a breakthrough in import substitution by developing and supplying a
special G type of oil well cement to ONGC.
1987ACC develops a new binder, working at sub-zero temperature, which is
successfully used in the Indian expedition to Antarctica.
1992Incorporation of Bulk Cement Corporation of India, a JV with the Government of
India.
1993 Commercial manufacture of ready-mixed concrete at Mumbai.
2001Commissioning of the new Wadi plant of 2.6 MTPA capacity in Karnataka, the
largest in India, and among the largest sized kilns in the world.
2002 Supply of High Performance Concrete of M -75 grades to JJ Flyover in Mumbai
becoming first time in India to supply concrete of such high strength level for use in
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a mega construction project.
2005
Commissioned Asia’s largest Tube Conveyor of 2.5 kms for transportation of
Limestone from mines to plant at the newly modernized Chaibasa Works in
Jharkhand.
CORPORATE GOVERNANCE
The importance of Corporate Governance has always been recognised in ACC. Much before
Corporate Governance guidelines became applicable and mandatory for listed companies; ACC
had systems in place for effective strategic planning and processes, risk management, human
resources development and succession planning. The Audit Committee in ACC was constituted
as far back as in 1986. The Shareholders-Investors Grievance Committee was formed way back
in 1962 and the Compensation Committee was convened since 1993. The Company’s core
values are based on integrity, respect for the law and strict compliance thereof, emphasis on
product quality and a caring spirit. Corporate Governance therefore in ACC is a way of life.
ACC is a professionally managed Company with a majority of its Directors being Independent
Directors. The Board of Directors has always consisted of persons who are professionals in their
respective fields and with unquestionable integrity and reputation. The role, responsibility and
accountability of the Board of Directors is clearly defined. Members of the Board have full
freedom to express their views on matters placed before them for deliberation and consideration.
It is the continuous endeavor of the Board of Directors to achieve the highest standards of
Corporate Governance through the adoption of a strategic planning process, succession planning
for attracting, motivating and energizing human resources, identification of major risks and the
way and means to manage such risks, an effective communication policy and integrity of
Company’s internal control systems. The Board of Directors are also constantly looking at ways
and means to ensure that the most effective use is made of the scarce resources at its disposal and
31
that the management and employees have the freedom to take the Company forward within the
framework of effective accountability.
The Annual Reports, press releases and other communication have always made full
disclosures on various facets of importance to the stakeholders, particularly with regard
to information relating to financial matters, company’s operations/performance, stock
movements etc.
CORPORATE SOCIAL RESPONSIBILITY:
Today we define Corporate Social Responsibility as the way a company balances its economic, social and environmental objectives while addressing stakeholder expectations and enhancing shareholder value.
But ACC has undertaken social volunteering practices almost from its inception, – long before the term corporate social responsibility was coined. The company’s earliest initiatives in community development date back to the 1940's in a village on the outskirts of Mumbai while the first formal Village Welfare Scheme was launched in 1952. The community living around many of our factories comprises the weakest sections of rural and tribal India with no access to basic amenities.
Corporate Social Responsibility Policy:
“The Company shall continue to have among its objectives the promotion and growth of the national economy through increased productivity, effective utilization of material and manpower resources and continued application of modern scientific and managerial techniques, in keeping with the national aspiration; and the Company shall continue to be mindful of its social and moral responsibilities to consumers, employees, shareholders, society and the local community.In pursuance of the above objective, ACC acknowledges the importance of the concept of inter-dependence of all sections of society. In particular, its focus revolves around the community residing in the immediate vicinity of its Cement Plants and Mines where it seeks to actively assist in improving the quality of life and making this community self-reliant. In line with its abiding concern for preservation of the ecological balance and safeguarding the health of the community, ACC has always actively demonstrated its firm resolves to protect the environment
Mindful of its great tradition, ACC is deeply committed to enhancing its reputation and respect built over the years in industry and society for its professional style of management based on philosophy of the best in business ethics.”
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PERFORMANCE MANAGEMENT:-
The Company’s performance management
system is in itself a benchmark that provides ample opportunities and
motivational incentives to employees to reward and retain good talent. There
are Performance Linked Incentives, Good Work Awards, Letters of
Appreciation, Special Increments, Promotions, Nomination to external
training programmes in India and abroad, public felicitation and appreciation
Awards. Some plants felicitate and reward Best Employee and Employee of
the Month. Employees who display aptitude are invited to become Trainers
themselves and receive Train the Trainer facilitation. ACC’s new Performance
Management System incorporates a linkage between an individual
employee’s performance indicators with the organizational goals which
allows the employee to see his or her role in contributing to achieve the
organization’s objectives. Training is imparted to take care of an individual’s
career development as well as functional and skills enhancement.
Competency and Development training inputs include Skill and general
performance enhancement, communication skills and career development.
EMPLOYEE SATISFACTION:-
In addition to periodic internal Employee
Satisfaction Surveys, ACC participates in Employee Satisfaction and Work
Place Surveys conducted by reputed external agencies like Hewitt Associates
and Grow Talent. ACC has also retained reputed firms like Mercer and Boston
Consulting Group to study the internal work environment and employee
policies to suggest areas of improvement. We share below salient points of
the latest survey of employees:-
People are treated fairly regardless of religion and gender
ACC is a safe place to work
Management is competent in running business
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Employees feel good about what we do for society
Proud to tell others I work here
Management thinks positively
The overall findings show significant job satisfaction at all levels as also deep
respect for the Company, its performance management system and its
overall business performance. The company has just concluded a survey to
assess employee perceptions of the quality of life of its employees,
particularly those posted at our cement plants.
ARCHITECTS OF SUCCESS.
NO NAME OF DIRECTOR NATIONALITY
1. MR.N.S.SEKHARIA
(CHAIRMAN)
INDIAN
2. MR.PAUL HUGENTOBLER (DEPUTY
CHAIRMAN)
SWISS
3. MR.SUMIT BANERJEE (MANAGING DIRECTOR) INDIAN
4.MR.A.L.KAPUR
INDIAN
5.MR.S.M.PALIA
INDIAN
6. MR.NARESH CHANDRA INDIAN
7. MR.MARKUS AKERMAN SWISS
8. MR.D.K.MEHTROTRA INDIAN
9. MR.R.A.SHAH INDIAN
10. Dr.NIRMALYA KUMAR INDIAN
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11. MR.SHAILESH HARIBHAKTI INDIAN
12. MR.ANIL SINGHVI INDIAN
13. MR.A.K.JAIN (WHOLETIME
DIRECTOR)
INDIAN
ENVIRONMENTAL POLICY OF ACC LTD.
Ensure continual improvement in environmental performance by
carrying out periodic review of action plan.
Prevent pollution and minimize fugitive emissions.
Comply with all applicable legal and regulatory requirements.
Create environment awareness among employee and community at large.
Minimize the waste generation at source reutilize the work if generated.
Conserve energy and mineral resource.
BUSINESS RELATION BETWEEN ACC & HOLCIM
A new association was forged between ACC and the Holcim group of Switzerland in 2005. In
January 2005, Holcim announced its plans to enter into a long-term strategic alliance with the
Ambuja Group by acquiring a majority stake in Ambuja Cements India Ltd. (ACIL), which at
the time held 13.8 per cent of the total equity shares in ACC. Holcim simultaneously announced
its bid to make an open offer to ACC shareholders, through Holdcem Cement Pvt Limited and
ACIL, to acquire a majority shareholding in ACC. An open offer was made by Holdcem Cement
Pvt. Limited along with Ambuja Cements India Ltd. (ACIL), following which the shareholding
of ACIL increased to 34.69 per cent of the Equity share capital of ACC. Consequently, ACIL has
filed declarations indicating their shareholding and declaring itself as a Promoter of ACC.
35
Holcim is the world leader in cement as well as being large suppliers of concrete, aggregates and
certain construction-related services. Holcim is also a respected name in information technology
and research and development. The group has its headquarters in Switzerland with worldwide
operations spread across more than 70 countries. Considering the formidable global presence of
Holcim and its excellent reputation, the Board of ACC has welcomed this new association.
The company implemented an ERP system that has standardized business process to run SAP
software called “CONNECT INDIA” system is based on a template that caters to ready-mix
concrete business, cement and AFR process of the company with the assistance of Holcim
Group. All operations, locations and transaction become fully integrated in a manner i.e. on line
with updated data and information. The new system will greatly enhance the company’s
capability to capture and process a comprehensive range of data to be used for decision making
and day to operation while automating some processes which were not part of earlier IT system.
Project connect India integrates tighter control through well defined authorization profiles and
rigid system. The new features serves as triggers to usher in better work habits and practices.
ACC’s registered office was first located at Esplanade House in South Mumbai, a graceful edifice that still stands out in its neighborhood. The head office then shifted to its own premises in Cement House shown here. The address of this stately building was then Number 1, Queen’s Road, and
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Churchgate. An all-India competition in 1938 had invited leading architects of the time to send in their designs of which this elegant design made by Ballardie Thompson & Mathews was chosen as the winning entry. Work on its construction began in 1939 and was completed during the War period. The building was occupied by the Royal Air Force and vacated only in 1946.
In 2009, a unique project, has transformed Cement House into an energy efficient environment-friendly building. Its attractive refurbished façade now houses an ultramodern office equipped with space-saving modular workstations, access control and intelligent lighting with motion and light sensors, waste management systems and water saving devices set amid greenery and a central atrium that further expands the sense of light and space.
SUBSIDIARIES AND ASSOCIATES
Bulk Cement Corporation (India) Limited (BCCI)
Situated at Kalamboli, in Navi Mumbai (formerly New Bombay), this company caters to bulk
cement requirements of the city of Mumbai and its environs. It has two cement storage silos with
a capacity of 5,000 tons each. The plant receives cement in bulk from ACC plants at Wadi. The
plant has its own special purpose railway wagons and rakes and its own railway siding. The first
of its kind in India, BCCI is equipped with all the facilities required by increasingly sophisticated
construction sites in a bustling metropolis, including a laboratory, a fleet of specialized trucks
and site silos for the convenience of customers and is capable of offering loose cement in bulk-
tanker vehicles as well as packed cement in bags of varying sizes from 1 tonne down to 25 kg
bags. BCCI is situated strategically on the outskirts of Mumbai, just off the new Mumbai-Pune
Expressway. It is a landmark structure spread over 30 acres of land.
ACC Concrete Limited
ACC set up India's first commercial Ready Mix Concrete (RMX) plant in
Mumbai in 1994 which together with the promotion of bulk cement has
played a key role in redefining the pace and quality of construction activity in
our large cities and mega infrastructure projects.
The Ready Mix Concrete business of ACC was reorganized
as a separate wholly owned subsidiary which was
incorporated as ACC Concrete Limited with headquarters in
37
Mumbai. Today this company is one of the largest manufacturers of Ready Mix Concrete in
India with a countrywide network of over 30 plants, with modern equipment and a large fleet of
transit mixers.
Lucky Minmat
ACC acquired 100 per cent of the equity of Lucky Minmat Private Limited.
This company holds limestone mines in the Sikar district of Rajasthan, and
helps supplement limestone supply to the Lakheri Plant.
ACC's brand name is synonymous with cement and enjoys a high level of
equity in the Indian market. Our range of cements and blended cements is
marketed through a network of 19 Sales Units, 54 Area Offices, and 194
warehouses. This is backed by a countrywide network of over 9,000 dealer
who, in turn, are assisted by their sub-dealers.
ACC’s marketing, sales and distribution processes are industry standards. Although we take
immense pride in having supplied some of India’s most admired projects, ACC is essentially a
people’s brand of cement with more than 80 per cent of sales made through an extensive dealer
network that covers every state in India. Its customer base represents the masses of India -
individual homebuilders in small towns, rural and semi-urban India. ACC cement enjoys an
image of assuring consistency and of high quality backed by in-house research and expertise.
Complementing this is a unique customer services cell comprising qualified civil engineers, who
assist and advise customers with prior and post sales service. This service begins with selection
of type and grade of cement (where applicable) to troubleshooting and on-site assistance.
GAGAL CEMENT WORKS
INTRODUCTION TO GAGAL CEMENT WORKS
38
The Gagal Cement Project was initiated in October 1978. Construction work started in august
1980 and erection of machinery in October, 1981, on 12th March 1984 Gagal Plant-1 was
successfully commissioned and commercial production commenced with initial capacity of 5.6
lakh tones per annum, Gagal Plant-II was commissioned in 1994 and present capacity of the
plant is 4.4 MTPA of cement.
The plant is based on the most modern process of cement manufacture; namely a dry process
suspension preheated kiln with proclaimed. The limestone is crushed in the crusher; it is then
ground in the raw mill along with shale and iron ore to fine powder. The ground material is
blended to a uniform consistency and fed to the kiln system pulverized coal is fired in the kiln
system to heat the material to a temperature of 1450 Deg.celcius. The material undergoes a series
of chemical reactions to form a clinker. The clinker is cooled in the clinker cooler and stored in
clinker silos. It is extracted from the silos and inter ground along with Gypsum and Pozzolananic
material to form Portland Pozzoiana cement. The cement is stored in cement silos. It is packed in
50-kg bags by automatic packing machines, loaded in trucks by auto-loaders and various
consumption centres in Himachal Pradesh as well as the neighbouring states of Punjab and
Haryana.
POWER:
The co. met 54% power requirement through captive generation. Cost of captive power
generation was 34% lower as compare to grid power. In keeping with its policy of maximizing
its captive power capability. It is also in the process of increasing its thermal captive power
generation capacity by another 45 MW. The company has already achieved significant reduction
in cost in specific area like fuel, power and manpower. The drives for cost reduction will be
further unified all area of operations.
MAIN RAW MATERIALS:
Limestone
Quartzite
Iron ore
39
Shale
Gypsum
Fly ash
EMPLOYEES IN GAGAL CEMENT WORKS:
The company is having the strength of manpower approximately nine hundred, out of which 90
are from management staff. Company needs low employees because of automation.
CERTIFICATION:
Certification from IS/ISO 9002, ISO 14001 for environmental management system and OHSAS
18001 for adopting high class measure in the sphere of occupational health and workers safety in
the manufacturing of cement.
TOTAL PRODUCTIVE MAINTENANCE
ACC Gagal Cement Works has continuously tried to improve upon its operational productivity
through world class plant management practices known as Total Productive Maintenance (TPM).
TPM is the integration of the basic functions of Production and Maintenance allowing the
employees to jointly take the responsibility for, and ownership of their work processes and
equipment. It aims to maximize Overall Equipment Effectiveness (OEE). It establishes and
promotes a systematic approach to achieve operational excellence through autonomous working.
TPM involves all employees at all levels in every function of its implementation. The most
important point about TPM is that it continuously encourages all the employees to undertake
continuous improvement of all work-related processes and systems by adopting a proactive
problem solving approach. 15th of every month is the day for TPM gate Meeting.
We are striving towards following goals using TPM:
Zero Breakdown
Zero Accident
Zero Defect
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Zero Waste
Zero Inventory
SAFETY
Gagal Cement Work constantly keeps a vigil on the safe practices of doing work and in this
regard expects the same from all its employees. The following table presents the expectations
from both the participants in this regard.
Deputy Manager-Safety coordinates all activities related to safety at works. Besides day to day
safety functioning, safety committee meets once in every month. The committee consists of
equal number of representatives form management and wage board employees.
All employees working inside the factory are required to wear helmets, safety shoes and
other safety gadgets. Other regular safety activities include monthly Gate Meeting, on first of
every month, Nukkad Drama, Quiz & Slogan Competition celebration of National Safety Day
etc.
OUR SAFETY COMMITMENT
MANAGEMENT EMPLOYEES
1. Provide Safe working
Condition
1.The care of oneself and colleague
2.Provide system for the safe control of work 2. Immediately report any unsafe
condition/hazard
3. Supply information on work h 3. Look out for hazards and potential
41
Azard dangers to self and others
4. Arrange adequate training and instrucyion in
safe working practices
4. Do not take any short – cuts
5. Make appropriate protective clothing and
equipment available
5. Know the safety guidelines and follow
working instructions
6. Punish people violating instructions on safety
and health
6. Always use safety equipment indicated
and provided
GEOGRAPHICAL DETAILS
Among the largest private sector companies, ACC is the only company to set up a cement plant
in 1982 in backward designated area at Barmana, Distt. Bilaspur (HP) and started production
with effect from 12th March 1984.
Barmana is 18 kms north to Bilaspur. The National Highway No.21 connecting Impala in
Haryana and Manual in H.P. passes through Gagal Cement Works and its colony.
The colony is at latitude 31.5-degree north and 77degree East Longitude. The total land acquired
for the factory, colony and mining area is 2319.10 bighas. Factory covers 365 bighas, the colony
covers 345 bighas and the mining area is about1633 bighas. The topography of the area around
the worksis mount-rainouts.Mean maximum temperature of the area goes upto 45 degree Celsius
in the month of June and the minimum temper- ature upto 3-degree in the month of December.
The work has generated direct and indirect employment to the scale of nearly 12000. Nearby
Towns: Bilaspur, Sunder Nagar, Mandi.
MANPOWER ARRANGEMENT
The total manpower employed at ACC, Gagal Cement works are divided into 2 categories.
Management Staff is governed by Conduct Rules framed by the company whereas Non-
Management Staff is governed by Standing Orders certified under the Industrial Employment
(Standing Orders) Act, 1946
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Management
Staff
TM - Top Management
WM -Works Manager
E4 - Sr. Manager
E3 - Manager
E2 – Deputy Manager
E1 – Assistant Manager
M3 – Senior Officer/Engg.
M2 - Officer/ Engineer
M1 – Junior Officer/Engineer
M - Asst. Officer/Engineer
Non-Mgmt.
Staff
DAILY PAID
Grades
A
B
C
D
E
MONTHLY PAID
Grades
TC
I
II
III
IV
V
VI
VII
MANPOWER
ORGANIZATIONAL STRUCTURE
ACC’s organization structure was revised in 2006. Added thrust was given to
sustainable development with the creation of separate cells at the corporate
office and plants to coordinate activities relating to waste management,
alternate fuels and raw materials, corporate social responsibility and
occupational health and safety. All these were placed under the supervision
of the Managing Director.
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BOARD OF DIRECTORS
Business Head North
MANAGING
DIRECTOR
ACC Concrete Ltd.
Business Head East Region
Business Head South & West Region
Central
Procure
Tech. Support
Operation
Commercial
Corporate
Chief Fin.
Managing
Committee
Managing
Committee
To enable better coordination of the organization’s
triple bottom line performance, it is proposed to constitute a high level team
with representatives from functions relating to the main pillars of sustainable
development to coordinate reporting and align operations in line with the
overall corporate objectives. The committee will include the heads of
Environment & Energy Conservation, Alternate Fuels and Raw Materials
Business Development, Occupational Health & Safety, Corporate
Communications & Social Responsibility, Corporate Human Resources,
Commercial Services, Central Procurement and Secretarial & Compliance.
CONTRIBUTION TO GOVERNMENT
44
Legal Secretarial &
Chief Knowled
Alternate Fuels &
Raw Material &
OH & S
Internal Audit
Business Development & Planning
Communication & CSR
Overseas Project & Consultancy
Annual contribution to center government by way of taxes, duties is 155 crore out of which for
Himachal Government is 100 crore. And along with this it is also helping Govt. as its social
responsibility. The company has constructed a Govt. Degree college; it is spending money on
schools, hospital and on other works of public welfare.
GAGAL CEMENT WORKS-AN UNRELENTLESS PURSUIT TOWARDS EXCELLENCE
Gagal Cement Works is committed to deliver quality products to the customers. Gagal Cement
Works has to its credit many a prestigious certifications like IS/ISO 9002, ISO 14001 for
environmental management system and OHSAS 18001 for adopting high class measures
in the sphere of Occupational Health and Workers Safety in the manufacturing of cement.
QUALITY POLICY
Build Quality In
Do not Sort Bad Quality Out
Quality Improvement is Limitless and therefore Continuous
Concern for Quality is for Entire Organization and Not Just for Product
Satisfy Customer Fully and Continuously
GAGAL CEMENT WORKS- A SYSTEMATIC APPROACH FOR CLEANER WORLD
ACC GAGAL Cement Works is the first point in Himachal Pradesh to have EMS certificate.
The Bureau of Indian standards awarded this certificate to the works in March 1999. The
certificate has resulted in batter understanding among all the employees, of overall
environmental issues related to the plant. The main feature of EMS at Gagal is total involvement
of employees.
EMS is a program of continuous environmental improvement following a well-defined
sequence of steps drawn from the established project management practice and routinely
applied in business environment.
ENVIRONMENTAL POLICY
45
Prevent pollution and minimize fugitive emissions
Comply with all applicable legal and regulatory requirements
Conserve water, energy and natural resources
Minimize waste generation and utilize the same
Create environmental awareness and provide clean and safe environment to
employees and community at large
PRODUCTION SYSTEM IN GAGAL UNIT
Main Raw Material
Limestone
Quartzite
Iron Ore
Shale
Gypsum
Fly Ash
MANUFACTURING PROCESS
The Gagal Cement Works is based on the most modern process of cement manufacturing namely
a dry process suspension preheated kiln with precalcener. The limestone is crushed in the
crusher. It is than grinding in Raw Mill along with Shale and Iron Ore to fine power. The
grinding material is blended to a uniform consistency and fed to the kiln system pulverized Coal
in the kiln system to heat the material to a temperature of 1500 degree Celsius. The material
undergoes a series of chemical reaction to form a Clinker. The clinker is cooled in the Clinker
Cooler and stored in the Clinker silos. It is extracted from the Silos and integrated along with
Gypsum and Pozzolanaic material to form Portland Pozzoiana cement. The cement is stored in
cement silos. It is packed in 50-kg bags by automatic packing machine, loaded in trucks by auto
46
loaders and various consumption centers in Himachal Pradesh as well as the neighbouring states
of Punjab, Haryana and J&K.
POWER
The co. met 54% power requirement through captive generation. Cost of captive power
generation was 34% lower as compare to grid power. In keeping with its policy of maximizing
its captive power capability. It is also the process of increasing its thermal captive power
generation capacity by another 45 MW. The company has already achieved significant reduction
in cost in specific area like fuel, power and manpower. The drives for cost reduction will be
further insified all area of operations.
MAP KEY
00 – Limestone quarry and crushing plant.
01 – Lime Stone Stock Pile.
02 – Additive Hooper.
03 – Additive Storage.
04 – Raw Mill Building.
05 – Blending & Storage Silo.
06 – Preheater.
07 – Gas Conditioning Tower and ESP.
08 – Kiln.
09 – Cooler.
10 – Deep Bucket Conveyor.
11/12 – Clinker/Gypsum Storage.
13 – Coal Mill Building.
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14 – Coal Mill and Bag Storage.
15 – Cement Storage Silo.
16 – Packing & Dispatch.
17 – Cement Control Room.
DEPARTMENTATION:
QUARRY DEPARTMENT
The Quarry Department is mainly concerned with the maintenance of Mines at ACC Barmana.
The sub-departments namely MINE; ELECTRICAL, GARAGE, CRUSHER, STACKER &
RECLAIMER support the Quarry department.
MINES
Gagal lime Stone Mine is captive mine of M/S ACC Ltd., Gagal Cement Works. The mining
lease covers an area of 265.97 hectares. Presently the mine is one of the largest mine of northern
India and is fully mechanized by Heavy Earth Moving Equipment's.
LIME STONE AND COAL HANDLING SECTION
LIMESTONE
The crushed limestone is received from Gagal Quarry with the help of a series of belt conveyer
and stacked in stockpile with the help of stackers.
COAL
Coal is used as a fuel for firing in the Kiln. Gagal Cement Works receives coal from different
collieries of CCC, ECL and NEC by rail upto Kiratpur Sahib.
LABORATORY DEPARTMENT
Laboratory department in coordination with other departments carries our regular quality control
functions. Quality and process control measures are exercised at each and every stage of process.
48
Inspection and procurement of raw materials, its testing, quality control of input materials,
intermediate products at different level of process and final product that is cement are done as
per procedures. Inspections and Test Records are maintained in the Laboratory as per the scheme
of testing and inspection. The departmental activities are coordinated by Deputy Manager-QPC
who reports to Manager- Production.
Gagal Works laboratory has three sections:
1. Chemical & Instrumentation laboratory
2. Physical Laboratory
3. Site Laboratory
PROCESS DEPARTMENT
The Process department guides the operations in maintaining process parameters so that
production is within the desired range of quality parameters. The process parameters are arrived
at after discussions with the Departmental Heads of various sections (Raw Mill, Cement Mills &
Laboratory)
Manager – Production coordinates the departmental activities.
RAW MILL
Activity of Raw Mill starts from feeding Raw Material (limestone, Quartzite and Iron Ore) to the
Mills and ends at filling the Raw Meal to Silos.
RAW MATERIAL FEEDING
Lime stone feeding to Raw Mills/Roller Mills is through the sequence of belt conveyors to
different Hoppers. Feed size of limestone is 90 mm and Mills Scale; Shale feeding is from the
Gantry to the respective Hoppers through sequence of belt conveyors. Shale feeding is through
Reclaimed or Pay Loader.
RAW MILL
Two close circuits two chamber Ball Mills are performing the grinding of limestone and
Additive mix. Raw Mill is a tube construction of thick MS plate with steel lines and
49
compartments are separated by diaphragm for improving the retention time and transfer of
materials in second for further grinding. Mill is charged with hyper steel balls. Raw material is
first fed to Tertiary Crusher (Single Rotor Reversible Impact Crusher) which reduces the size of
Mix. After crushing the mix the material is fed to Ball Mill where fine grinding takes place. The
finer product is separated by Air Separator and is fed to the blending silos and the coarse
material is fed back to the Mill Inlet.
VERTICAL ROLLER MILL (VRM)
In VRM Section the material is directly fed into Mill through the feed belt for grinding. The
ground material is stored in continuous flow silos from where it is fed to the Kiln. VRM utilizes
hot air from the kiln exhaust for drying the Raw Mix
Deputy Manager – VRM, who reports to Manager (Maintenance), coordinates the
departmental activities
KILN DEPARTMENT
Kiln Department functions are categorized under two heads, Manager (Maintenance) is
responsible for the maintenance of all equipment and Manager (Production) is responsible
for the Clinker Production and its quality parameters. Gagal Cement Work has two rotary kilns.
Kiln no 1 is having 3 streams coupled with 2 four stage and 1 five stage preheater with 2
precalciners, DDF and MFC. Kilns No 2 are having twin stream 5 stage preheater with
precalciners. Pulverized coal is used as a fuel for calcination. The Clinker is discharged to
horizontal grate cooler and is stored either in Silos or in stockpiles.
CEMENT MILLS DEPARTMENT
The basic function of the department is to grind the required ratio of clinker and gypsum in the
manufacture of OPC and clinker, Gypsum and CCP/fly ash for the manufacture of PPC with
the help of 4 ball Mills for cement grinding.
PRE GRINDING UNIT
Roller Press is the pre-grinding unit for Cement Mills 1 & 2. In Roller Press two rollers are
arranged in horizontal fashion. One is fixed and other has a hydraulic thrust arrangement for
horizontal movement. The clinker is fed vertically down ward between the rollers and gets
50
crushed by the hydraulic pressure arrangement The product, which is in flakes, is fed to the Ball
Mill with other additives for finished grinding.
FINISHED GRINDING
Finished grinding is performed in Ball Mills. Ball Mill is a rotating shell divided into two
chambers fitted with shell liners for shell protection and charged with grinding media to the
required volume. The impact and friction between the grinding media and material perform
grinding. Out put from the ball Mills is fed to the dynamic separator where the course and fines
of specific sizes are separated. The course is again conveyed to the Ball Mill for further grinding.
The fines are conveyed to cement silos through a series of elevators and air slides. In order to get
the desired specific surface for cement the RPM of separator is varied accordingly?
The departmental activities are coordinated by Dy. Manager-Plant who reports to
Manager (Maintenance).
ELCTRICAL AND INSTRUMENTATION (E & I) DEPARTMENT
The primary function of the E & I department is to maintain all E & I equipment in the plant to
provide the necessary service to ensure the smooth operation of all E 8 & I equipment.