Maihar Cement By Sunny

Submitted by:Iqbal Ahmed Siddique

Chairman's Message "I believe that the Fortunes of Century Textiles & Industries Limited rest solely on its continuing ability to evolve and successfully implement new techniques and systems to anticipate future trends and zero in on to them, to be in short, a company that is plugged into tomorrow.."

"Complete Customer Satisfaction and fulfilling the expectations of society is the key to success of any business enterprise in Global Economy".

B.K. Birla Chairman Century Textiles & Ind. Ltd.

Apart from Maihar Cement, company has two more cement plants namely Century Cement at Baikunth, Dist. Raipur in the State of Chhattisgarh with an installed capacity of 1.80 Million TPA and Manikgarh Cement at Gadchandur, Dist. Chandrapur, Maharashtra with an installed capacity of 1.50 Million TPA. The combined Capacity of all cement plants taken altogether is 7.80 Million TPA. More emphasis is given for production of blended cement which constitutes about 95% of the total cement produced by the company. Plants of Century Textiles & Industries Limited:

Century Cement - Chhattisgarh

Maihar Cement – Madhya Pradesh Manikgarh Cement – Maharashtra

Units

Figures in Million TPA 2008-09

Century Cement

2.1

Maihar Cement

3.8

Manikgarh Cement

1.9

Total

7.8

Tradition:

Maihar Cement is a division of Century Textiles & Industries Ltd., belonging to the BK Birla Group of Companies, a leading Business House with its presence in Core Industries like Textiles, Rayons, Chemicals, Paper & Pulp and Cement, which has been at the vanguard in generating wealth for the Nation. Our heritage of being a part of this group carries with it a commitment to quality. All our Products meet the most stringent and exacting standards of our growing list of loyal customers who are engaged in building Modern India. Technology: Our Group's Core Value of Quality has built for us an invincible reputation and for this, the finest technology was sourced from world renowned manufacturers and state-of-the art equipment installed for energy efficient and pollution free large scale cement production. The presence of superior technology is also evinced in our various quality initiatives which have fetched for us the coveted ISO-9001, an International Certification for "Quality Management System". We have also got the ISO-140001 Certification for "Environmental Management System" which amply reflects our commitment to the environment. Trust: Our Customer is the focal point for all our endeavours and what we value most is their trust in us, whether that be in the aspect of reliability of supply or in the aspect of quality assurance. An extensive distribution network and a retail chain of thousands of outlets stretching across the length and breadth of regions, play a vital role in taking our cement units closer to the customer's doorsteps. Further, our efficient and responsive technical staff excel in providing quick and expert care so as to enable thousands of users to keep smiling and ever wanting our products.

Maihar Cement is a division of Century Textiles and Industries Ltd, a flagship company of BK Birla Group. The company is well diversified having interest in cement, textiles, rayon, chemicals, pulp and paper. Maihar Cement is situated at Sarlanagar (Maihar) Dist. Satna in the State of Madhya Pradesh with an installed capacity of 3.80 Million TPA. Maihar is 45 Kms South - East of Satna on Howrah Mumbai Central Railway Main Line. Maihar is well known for Sharda Devi Temple and Maihar Gharana Music whose proponent was renowned Musician padma Vibhushan Baba Allaudin Khan. Apart from this, company has two more cement plants namely Century Cement at Baikunth, Dist. Raipur in the State of Chhattisgarh with an installed capacity of 1.80 Million TPA and Manikgarh Cement at Gadchandur, Dist. Chandrapur, Maharashtra with an installed capacity of 1.50 Million TPA. The combined Capacity of all cement plants taken altogether is 7.80 Million TPA. More emphasis is given for production of blended cement which constitutes about 95% of the total cement produced by the company. . The capacity enhancement to 7.80 Million TPA is under implementation by carrying out modification, upgradation and debottlenecking of existing plant & machinery and equipments, which is likely to be completed by Oct-Dec 2007 Quarter. All cement plants are equipped with captive power plants, which not only ensure an uninterrupted power supply, but also help company substantially on power cost, as the own generated power is quite economical as compared to grid power. The company sells its cement under its premium brand name BIRLA GOLD.

Cement Production at A Glance: Units

Figures in Million TPA

Century Cement Maihar Cement Manikgarh Cement Total

2008-09 2.1 3.8 1.9 7.8

Captive Mines: Maihar Cement has its own Captive Mines with rich limestone reserves at Bhadanpur just 7 Kms from the plant. mines' working is fully mechanized and an overland belt conveyor of 7 kms passing through hilly terrain transports limestone from mines to plant. The aesthetic view of the surrounding area has been maintained by afforestation of the mining area and also by creating water reservoir in the excavated area. Captive Power Plant: To meet the need of the hour and in order to reduce the cost of production, so as to be competitive, Maihar Cement has installed its own Captive Thermal Power Plant and the total installed capacity is 35 MW which is helpful in uninterrupted running of the plants on sustainable basis. Logistics: Strategic location of the plant, connected with NH-7 puts Maihar Cement in a very advantageous position so far as logistics is

concerned. The Plant is well connected by Road with all the major marketing centers. Being situated on Mumbai - Howrah (via Allahabad) main Railway Line, it is also well connected with all the States in East & North East. Products:

Maihar Cement is pioneer in producing Blended Cement i.e. Portland Pozzolana Cement . The motivation for the production of blended cement has been primarily with the aim of preserving limestone reserves and environment.

Advantages: •

Low Heat of hydration resulting in resistance to cracking.

• • • •

Resistance to corrosive water and chemical attacks and thereby longer life to steel/iron structure underneath. High degree of impermeability and workability for the concrete mix. Higher ultimate strength at longer duration Higher degree of fineness, resulting in - Complete chemical reaction - Easy workability - Increased plasticity

• •

Reduced Alkali aggregate reaction as also free lime expansion and thereby resistance to cracking. Lower drying shrinkage and low leaching value.

PPC can be used for any type of construction which earlier had been the forte of OPC. However due to it's special attributes, its use is rather imperative for the following construction works. Uses: • • • • •

Hydraulic Structures Mass Concreting Works Marine Structures Masonry Mortars and Plastering Under aggressive Conditions

Process:

The basic raw material in the production of cement is Limestone. The Limestone ore as obtained from the Mines is fed to the Raw Mills after first crushing it to acceptable size. Certain additives such as Laterite, Bauxite, High Grade Limestone (Sweetener) etc. are also introduced alongwith Limestone into the Raw Mills as applicable. In the Raw Mills, the above inputs are reduced to a particular fineness. The output of the Raw Mills, called 'Raw Meal' is then burnt in the Kiln and then cooled to produce Clinker. The fuel used for burning of limestone is powdered coal produced from the coal Mill. The Clinker is thereupon fed into Cement Mill & pulverized along with Gypsum to yield the basic cement. A certain proportion of Clinker in the production of cement is replaced by Flash to produce PPC. Process in Nutshell: Scenic View of Our Uniqueness 1. Limestone excavated from Mines is transported through Dumpers and fed to crushers wherein it is reduced from above 850 mm to 80 mm size. 2. Environmental friendly Conveyor belts transport the limestone from the Crusher to the Plant Site over a distance of 7 kms.

3. Scientifically designed Stackers provide for stacking of the limestone’s received from the mines in circular / longitudinal stock piles. Use of Reclaimers ensures consistency in quality. 4. State of the Art Vertical Roller Mill grinds Limestone feed to powdered form called Raw Meal.

5. Most advanced Coal Mill pulverizes the coal to be injected into Kiln for burning of Raw Meal. 6. Rotary Kiln provides for Clinkerisation where in Raw Meal fed from VRM is first burnt to melting (1400 C) & then cooled to 100 - 120 C by means of coolers immediately outside the Kiln to produce Clinker.

7. Close Circuit Cement Mill ensures high quality grinding of clinker, gypsum and Pozzolana to yield best possible uniformity of the cement particles. 8. Centralised Control Room monitoring the manufacturing process through computers.

Consistency and accuracy in the packing of bags by electronic packing machines. Packing Plant is equipped with computer controlled electronic packers, which ensure that cement bags are packed and sealed to 50 kg of cement each accurately. Manual check is also carried out at random to monitor computer accuracy and introduce correction as applicable.

Packing & Dispatch:

Loading of bags in the wagon/trucks is carried out automatically by means of wagon / truck loading machines, equipped with Electronic Loading Counters which accurately keep count of the Number of bags being loaded.

Efficient logistic & transportation network ensures prompt delivery of materials to the customers.

Environment: Environmental Management System Right from inception, great emphasis has been laid at Maihar Cement on maintaining ecological balance and environmental preservation so as to provide green, healthy and pollution free environment. Continuous monitoring of various Pollution Control equipments are done round the clock to maintain emission levels much below the norms specified by State Pollution Control Board. Environment Policy We at Maihar Cement are fully conscious of the environmental impacts of our activities. We also realize the need for minimizing the impacts, towards preservation of environment in keeping with the image of BK Birla Group of companies as a socially responsible organization.

We, therefore, commit ourselves to: • • • • • • •

Prevention of pollution incidental to Plant operations Adopting clean technology and eco-friendly processes in the Plant Compliance with all applicable legal and statutory requirements Conservation of natural resources Reduction in waste generation. Awareness amongst employees and business associates. Continual improvement in environmental performance by effective implementation

The plant has been accredited with IS / ISO 14001 Environmental Management System Certification. Measures Taken Towards a Cleaner Environment: •

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Installation of highly efficient Pollution Control Equipments viz., ESPs, Bag Houses and Pulse Jet Dust Collectors at every dust generating point in the Plant. Regular monitoring of all stacks and ambient air quality. Proper treatment of domestic affluent generated from residential colony in Oxidation Ponds and use of treated water for plantation purposes. Massive efforts for plantation of various species of trees for ecological up-gradation.

To control fugitive emission, following additional steps have been taken: • • • • •

Covering of Conveyor belts transporting various process materials All raw materials are stored in covered gantry. Water sprinklers have been provided on the roads to check fugitive emission generated due to movement of vehicles Concretization of roads and floors inside the Plant The Fly Ash generated from Thermal Power Plant is used as an additive for manufacture of PPC.

The Plant maintains perfect harmony with environment through effective pollution control measures in respect of air, water, and land and noise level. All efforts are made to curb pollution at grass root level.

Awards: Maihar Cement has been bestowed upon several awards both at the National as well as Regional Levels Some of the Important Awards won till date... NATIONAL AWARD FOR ENERGY EFFICIENCY FROM NCCBM • • • •

Best Improvement in Energy Performance 1991-92 Best Improvement in Thermal Energy Performance 1991-92 Best Improvement in Electrical Energy Performance 2000-01 & 2003-04 Best Improvement in Energy Performance in manufacture of Blended Cement 2003-04

OTHER NATIONAL AWARD • • • • • • •

Abheraj Baldota Environment Award for 1995-1996 from FIMI National Safety Award for outstanding performance in Industrial Safety Lowest average frequency rate as runner up for the award year 1998 Longest accident free period as runner up for the award year 2001 Longest accident free period as runner up for the award year 2003 Accident free year as runner up for the award year 2005 Accident free year - Best for the performance year

FL SMIDTH AWARDS •

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First Prize for lowest electrical energy consumption per tonne of cement & clinker produced amongst modern plants using VRM Technology situated in Chhattisgarh & Madhya Pradesh for the year from 1998-99 to 2005-06. First prize for the lowest electrical energy consumption per tonne of cement production for the year 2006-2007 amongst modern cement plants using VRM technology situated in the State of Madhya Pradesh and Chhattisgarh. First Prize for Minimum Auxiliary Power Consumption with respect to Captive Thermal Power Generation for the year 2005-06.

ISO CERTIFICATIONS • • • •

IS/ISO 9002:1994 IS/ISO 9001: 2000 IS/ISO 14001:1996 IS/ISO 14001:2004

Marketing: Marketing Policy • • • • • •

Product Quality exceeding Customer's expectations Timely Dispatches Attractive and functional packaging Quick Business Response Prompt After-Sales service Adhering to fair and ethical business practices

Customer Service Customer service cells have been established at various marketing centers which are manned by qualified and experienced technical personnel. They provide advice to customers on getting the best value from cement and offer assistance on civil construction related issues. Influencing the influencers is a plank of our marketing strategy by disseminating information about our products through one-to-one interaction with masons/architects/engineers. Marketing Network: •

Strong Network of more than 4000 Stockiest

A Growing List of Customers............. • • • • • • • • • • • • •

Bansagar Project (MP& UP) BHEL BP Koirala Institure of Medical Science Central Public Works Department Delhi Development Authority, DDA Gammon India Limited (NCL-SECL) Ganon Dunkerley & Co. Limited Hindustan Construction Company (HCC) Hindalco Industries Limited HEG Limited Housing Boards & Development Authorities Irrigation & WRD (MP, UP & Bihar) Kazima Daewoo Corporation

• • • • • • • • • • • •

Kalptaru Power Transmissions Limited Lucknow Development Authority Municipal Corporation NHPC- Teesta V Project National Mineral Development Corporation Sahara India Limited Simplex Concrete Piles (India) Limited SEW Construction Limited State Electricity Boards, MP & UP Tehri Hydro Development Corporation UP State Bridge Corporation Limited UP Rajkiya Nirman Nigam Limited

Marketing Office at Works 1) Mr. PM Intodia Joint President (Mktg) Maihar Cement Po. Sarlanagar, Dist. Satna, Madya Pradesh Tel: 07674-27842, Mob: 9425155246 Email: [email protected] 2) Mr. Ashok Maheshwari Senior Vice President (Mktg) Maihar Cement Po. Sarlanagar, Dist. Satna, Madya Pradesh Tel: 07674-27841, Mob: 9425811698 Email: [email protected]

3) HEAD - CONSUMER CELL MR. HR SHARMA TEL: 07674-277349/ 277068 Email: [email protected] Human Resource: HR POLICY Developing people to deliver results in changing environment by their training and skills by their commitment and team spirit, by their foresight and resilience and by their dedication and loyalty.

CAREER WITH US Human Resource is valuable asset to our organisation. High Calibre young professionals with proven talents in diversified fields would be preferred, who can innovate for tomorrow and will be the face of the company. We offer job enrichment and enhancement opportunities at all levels. Right environment with latest infrastructure matched by knowledge and acumen of our professional make the promising future. HR VISION • • •

Objective Selection Method, Continuous Training and Development Competitive Wage & Salary Structure

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Well Defined Systems, Rules and Procedures Goal Oriented Appraisal System and Counselling Encouraging Openness, Participation and Cooperation Synchronizing Personal Aspirations with Organisation Goals Enforcing Professional Values and Code of conduct Providing Opportunities for Growth and Advancement Prompt Grievance Redresal System Improving Quality of Life both on and off-the-job Discharging Social Responsibilities through the Institution of Seva Trust Reviewing Constantly and Improving Personnel Practices.

Central Recruitment Cell C/o. Maihar Cement P.O. Sarlanagar 485772 Dist. Satna, Madhya Pradesh Tel: 07674-277067 / 68 Fax: 07674-277806 Email: [email protected] Website: www.maiharcement.co.in