AN ORGANIZATIONAL STUDY ON

THE INDIA CEMENTS LIMITED

Submitted by
ABHIRAMI S
Reg. No. 962922631002
Of
VINS CHRISTIAN COLLEGE OF ENGINEERING
A SUMMER INTRNSHIP REPORT
submitted to
THE DEPARTMENT OF BUSINESS ADMINISTRATION
In partial fulfillment of the requirement for the award of the degree of

MASTER OF BUSINESS ADMINISTRATION

ANNA UNIVERSITY
CHENNAI 600025
AUGEST 2023
 DEPARTMENT OF MANAGEMENT STUDIES
VINS CHRISTIAN COLLEGE OF ENGINEERING
Chunkankadai - 629807

CERTIFICATE
This is to certify that summer training report titled “An organizational study at THE INDIA CEMENTS
LTD”, in partial fulfillment of the requirements for the award of the degree of Master of Business
Administration is a record of original training undergone by ABHIRAMI S (Reg No 962922631002)
during the year 2022-2024 of her study in the Department of Management Studies, Vins Christian College
of Engineering under my supervision and the report has not formed the basis for the award of any degree
or other similar title to any candidate of any university.

Place:
Date:

Counter Signed Signature of Guide

Mrs. D. J. Delphin Jameela MBA, M.Phil., Mrs. T. Prabha, BBA, MBA,
Head of the Department, Assistant Professor
Dept. of Business Administration Dept. of Business Administration
Vins Christian College of Engineering Vins Christian College of Engineering

Submitted to the Department of Management Studies, Vins Christian College of Engineering for the
examination held on______________.
 DECLARATION

I do hereby declare that the summer internship report entitled, “An organizational study at
INDIAN CEMENT LIMITED, THIRUNELVELI” submitted to Department of Business Administration,
Vins Christian College of Engineering, Chunkankadai in partial fulfilment of the requirement of the
degree in Master of Business Administration originally carried out by me under the guidance of Mrs. T.
Prabha, BBA, MBA, Assistant Professor.
I also declare that the report is the result of my own effort and has not been submitted to any other
university earlier for award of any degree.

SUBMITTED BY: ABHIRAMI S

 ACKNOWLEDGEMENT

First, I thank God almighty who has showered his blessing on me for the completion of my Summer
Internship.

I extent my grateful thanks to our Principal Dr. V. Dyana Christilda, M.E, Ph.D., Vins Christian
college of Engineering, for providing me this great opportunity to undertake this Summer Internship.

I take pleasure to show my deep gratitude to Mrs. D. J. Delphin Jameela MBA, M.Phil., Head of the
Department, Department of Business Administration, for her moral support throughout our Summer
Internship.

I express my sincere thanks to guide head of department Mrs. T. Prabha, BBA, MBA, Assistant
Professor, Department of Business administration, Vins Christian college of Engineering for her valuable
guidance.

I am also thankful to all the faculty members of the valuable suggestion, guidance towards the summer
training. I extend my sincere thanks to all our department staff members.

I acknowledge my deepest sense of gratitude to MR. NARAYANASAMY [Senior HR manager, The

India Cements Ltd] for giving me this opportunity and MR. K. P. MUTHU KUMAR [HR Manager, The
India Cements Limited] for guiding me through this internship.

ABHIRAMI S
962922631002
 TABLE OF CONTENTS

CHAPTER TITLE PAGE NO

I INTRODUCTION
1.1 Introduction
1.2 Objectives of the Study
1.3 Scope of the Study
1.4 Sources of Data
1.5 Limitation of the Study
II PROFILE
2.1 Industry Profile
2.2 Company Profile
2.3 Product Profile
2.4 Organization Structure
III FUNCTIONAL DEPARTMENT
3.1 Human Resource Department
3.2 Financial Department
3.3 Production Department
3.4 Quality Assessment Department
3.5 Marketing Department
3.6 Research and Development Department
IV SWOT ANALYSIS
4.1 Strength
4.2 Weakness
4.3 Opportunities
4.4 Threats
V SUGGESTIONS AND CONCLUSION
5.1 Suggestions
5.2 Conclusion
BIBLIOGRAPHY AND REFERENCE
CHAPTER - 1

6
 INTRODUCTION

1.1 INTRODUCTION
Organization study deals with critical evaluation and analysis of all aspects of a particular
firm. It gives a clear idea about the function and practice of various department heads and
operational efficiency of the department as a whole. This particular study gives a clear idea about
the functions, practices and delegation of authority of The India Cements Ltd. With this study
gives an overview about the practical situations, which a company is functioning an also help to
reveal that how things are coordinated in real time situations.
India is the second-largest producer of cement in the world. It accounts for more than 8%
of the global installed capacity. India has a lot of potential for development in the infrastructure
and construction sector and the cement sector is expected to largely benefit fromit.
Furthermore, on the back of rising rural housing demand, the consumption of cement in
India has been growing consistently as it is one of the cheapest products to buy in terms of Rs.
/Kg. Strong expansion of the industrial sector, which has fully recovered from the COVID-19
pandemic shock, is one of the main demand drivers for the cement industry.
As a result, there is a strong potential for an increase in the long-term demand for the
cement industry. Some of the recent initiatives, such as the development of 98 smart cities, are
expected to significantly boost the sector.
Aided by suitable Government foreign policies, several foreign players such as Lafarge-
Holcim, Heidelberg Cement, and Vicat have invested in the country in the recent past. A
significant factor which aids the growth of this sector is the ready availability of raw materialsfor
making cement, such as limestone and coal. Currently, the installed cement capacity in India is
553 MTPA with a production of 298 MTPA.

1.2 OBJECTIVES OF THE STUDY

• To get an organizational exposure.
• To understand the organizational structure hierarchy of each department.
• To understand the practical aspects of the management.
• To study the Mission, Vision and Quality process.
• To monitor and understand the actual functioning of the organization.

1.3 SCOPE OF THE STUDY

7
 The study is intended to attain first hands experience of the overall function of the
organization. It also provides to chance to see the constraints faced by the manager while outing
the theory.
1.4 SOURCES OF DATA
Data is collected through both primary sources and secondary sources. The study is based
on both the primary data and secondary data.
Primary data:
Primary data are those which are a fresh and for the first time and thus happen to be
original in character. Primary data were collected by the direct observation and direct interviews
with department head, management staff, workers etc.
Secondary data:
Secondary data are those which have already been collected by someone else and which
have been passed through the statistical process.
Secondary data are collected from:

• Company supplements

• Annual reports

• Company website

• Department guidelines

• Journals and Magazines

• Brochure and Booklets

1.5 LIMITATIONS OF THE STUDY

• The time was limited for a deep study and analysis of the organization.

• The personal interviews may be affected by personal bias.

• As it is a government firm, certain data and documents are considered to be

confidential which are not available.

• The study is mainly based on qualitative data so there is possibility of errors and
accuracy of the information is in doubt.

• The personnel resources of the company limited it was a challenge to collect data
without interpreting normal operation of company.

8
CHAPTER - 2

9
 PROFILE

2.1 INDUSTRY PROFILE

Cement is a material that hardens and sticks to other materials to hold them together.
Portland cement is a common kind, and made from quicklime (heated limestone) and clay. Cement
is used to make concrete and mortar. Cement is widely used for plastering and rendering.
Plastering is done for the inner walls, and cement rendering is done for the exterior walls. Cement
rendering is also used to clad brickwork on either exterior, interior, or boundary walls. This keeps
brickwork protected from rain and water.

The word "cement" can be traced back to the Ancient Roman term opus caementicium,
used to describe masonry resembling modern concrete that was made from crushed rock with burnt
lime as binder. The volcanic ash and pulverized brick supplements that were added to the burnt
lime, to obtain a hydraulic binder, were later referred to as cementum, cimentum, cäment, and
cement. In modern times, organic polymers are sometimes used as cements in concrete.

Joseph Aspdin developed Portland cement in the 19th century. He heated ground limestone
and clay mix and then pulverized the mixture into fine powder. In 1824 he also obtained a patent
for his creation. Portland cement is suitable for wet climates and can be used underwater.

The global cement market is estimated to be around $340 billion. China is the top cement
producer, followed by India and the USA. The rising population is driving the cement demand.
Countries in Asia, the Middle East, and Africa are improving their infrastructure which is resulting
in the growth of the global cement industry.

India is the second-largest producer of cement in the world. It accounts for more than 8%
of the global installed capacity. India has a lot of potential for development in the infrastructure
and construction sector and the cement sector is expected to largely benefit from it.
2.2 COMPANY PROFILE

10
 THE INDIA CEMENTS LIMITED
The year was 1946. It was then The India Cements Ltd. began its humble moorings in the
form of a cement factory at Thalaiyuthu, an almost unmapped tiny hamlet in Tirunelveli
district, Tamil Nadu. As one of the oldest Indian corporates, the company set up its first plant
in Sankar Nagar [Thalaiyuthu].
The India Cements Ltd. is indeed a pioneer enterprise during the post-independence era
to become a public limited company. The first annual report appeared on 21.4.1947. The
company’s prospectus was favorably received and the public issue was oversubscribed. “There
is no stronger foundation than the one built with vision.”

S.N.N. SANKARALINGA IYER T.S. NARAYANASWAMI

[1901- 1972] [1911-1968]

India cements Ltd was founded in the year 1946 by two men, Shri S.N.N. Sankaralinga
Iyer and Sri T. S. Narayanaswami. They had the vision to inspire dreams for an industrial India,
the ability to translate those dreams into reality and the ability to build enduring relationships.
Sri T. S. Narayanaswami, the banker turned industrialist, was the catalyst who saw the project
cross through numerous hurdles and emerge as a viable and marketable proposition. Helooked
beyond cement and ventured into aluminium, chemicals, plastics, and shipping. India
Cements celebrated the Birth Centenary of Sri T. S. Narayanaswami on November 11, 2011.
The Indian Postal Department released a Commemorative Postage Stamp in Honour of
Sri T. S. Narayanaswami on November 11, 2012.
From a two-plant company having a capacity of just 1.3 million tonnes in 1989, India
Cements has robustly grown in the last two decades to a total capacity of 15.5 million tonnes
per annum. After the approval of a Scheme of Amalgamation and arrangement between
Trinetra Cement Ltd and Trishul Concrete Products Ltd with The India Cements Ltd, all the

11
 cement assets have come under one roof - India Cements. India Cements has now 8 integrated
cement plants and two grinding units, one each in Tamil Nadu and Maharashtra.
While retaining cement over the years as its mainstay, India Cements has ventured into
related fields like shipping, captive power and coal mining that have purposeful synergy to
the core business. This also stemmed from the company’s strategy of emerging as an
integrated pan India player to combat uncertainties in securing energy and other inputs in the
supply chain at competitive costs.
VISION
To create value on a sustained basis for all stakeholders of India Cements through lofty
standards of transparency, accountability and responsibility, innovation, leadership in cement
manufacture.

MISION
India Cements will strive to remain a leader in the manufacture of cement and establish itself
as a preferred supplier of products and services to its clients and enhance thebrand value for all
stakeholders.

COMPANY HIGHLIGHTS
This company is one of the largest producers of cement in south India. The company is a
market teacher within a market share of 28% in the south. It aims to achieve 35% market share
soon. The company must access to huge limestone resources and plans to expand capacityby
debottlenecking and optimization of existing plants as well as by acquisition. Company hasa strong
distribution network with over 10000 stock lists.
MANAGEMENT
The India cements ltd is a public sector company. The vice chairman and the managing
director of the company is Mr. N. Srinivasan. The day-to-day activities of the company are
managed by him and assisted by the whole-time director Mrs. Rupa Gurunath and other key
personnel in each functional area.
LOCATION OF PLANTS
• Sankar Nagar - Tirunelveli
• Sankari - Salem
• Dalavoi - Ariyalur
• Chilamakur - Kadapa
• Vishnu Puram - Nalgonda
12
 • Yerranguntla - Kadapa
• Malkapur - Ranga Reddy
• Vallur - Tiruvallur
• Parli vaijath - Maharashtra
• Banswara – Maharashtra
2.3 PRODUCT PROFILE

PRODUCT RANGE

The company offers a wide range of products line ordinary Portland cement (OPC) and
Portland Pozania cement (PPC) are manufactured regularly but other verities like Portland blast
furnace cement (PBFC) and white cement.

RAW MATERIALS

• Lime Stone
• Red Mud
• Coal
• Fly ash
• Iron ore
• Gypsum
SOURCE OF RAW MATERIALS

The important raw materials for manufacturing cement are limestone. It is obtained from
Thalaiyuthu, Nagankulam, Sellianallur, Sethurayanpudur, Vijayapathy, vallioor, Kudankulam and
they purchase a sizable quantity for private parties. For a smooth functioning, it needs 4500 tonnes
of limestone per day and other raw materials like lime tones and coal and lignite
LIMESTONE+LIGNITE+GYPSUM=CEMENT
BRAND NAME:
There are three brand names of India Cements Ltd.
1.Sankar super power
2.Coromandel king
3.Raasi gold
1.Sankar Super Power:
Sankar super power is a six-decade brand with emotional values providing trust and
confidence for its customers over generations. It is the most popular brand across Tirunelveli.

13
2.Coromandel King:
Coromandel is a brand with rationale value offering reassurance for the strength and
durability of cement and provides value for money. A brand is mostly popular in metros.
3.Raasi Gold:
Raasi gold is a brand with sentimental value foreseeing golden times for those living in
their stronger homes. A household name in Andhra Pradesh and Orissa, it has stood the test of time
over three decades.
2.4 ORGANIZATION STRUCTURE

14
CHAPTER - 3

15
 FUNCTIONAL DEPARTMENT
FUNCTIONAL DEPARTMENT
The India Cements Ltd has separated and department duties for each department.
Departments are based on functioning basis. Each department specializes in its own area of
operation and the various function of the organization is carried out through various department.
The process of assigning various tasks or activities in the different segment on a horizontal basis is
called departmentalization. Its helps for proper administration of the company.

DEPARTMENTS

1. Human Resources Department

2. Finance Department
3. Production Department
4. Quality Department
5. Seles Department
6. Research and Development department

3.1 HUMAN RESOURCES DEPARTMENT

The HR department is the process of discovering potential applicants for permanent
requirement monitored and carried out by the top-level management.
The HR department is responsible for discovering potential applicants for accomplishing
their organizational requirement monitored and carried out by the top-level management. There are
4 employees in Sankar Nagar HR department. They are as follows

 Senior HR Manager

 HR Manager

 Senior Manager

 Assistant

FUNCTIONS OF THE HR DEPARTMENT

• Recruitment of personnel
• Maintaining employee details
• Pay Roll Management
• Over time compensation

16
 • Vocation policies
• Leave maintenance
• Performance Appraisal
• Training programme
• Time office administration
• Managing industrial relations
• Addressal of employees grievances
• Quarters allotment
• Monitoring discipline of employees

EMPLOYEE WELFARE SCHEMES

• Quarters
• Sports activities
• Club activities
• Occupational health centre

OTHER SCHEMES

• Group Mediclaim
• Group Personal Accident Scheme
• Bonus
• Super Annuation

TIME OFFICE
It is responsible for maintaining attendance card of employees and they check every
employee and worker who entered into the plant.

FUNCTIONS OF TIME OFFICE

• Attendance maintenance.
• Shift time control.
• Leave record maintenance.
• Allowance details.

MAINTAINING ATTENDANCE CARDS

17
 Time office maintain and check the attendance card daily to see that workers are properly
punched on time office. If they punched, it means they reported for work.

COLLECTING EMPLOYEE’S PERSONAL DOCUMENTS

Time office as an integrated part of the HR department and carries the responsibility of
collection of employees personal documents etc.,

SENDING ABSENTEES REPORT FORMS

Time office sent absent report regularly to the AGM (HR) so that he can take appropriate
action on the habitual absentees.

LEAVE AND HOLIDAYS

Time office is invariably required for maintaining all leave records of workers in the
company.

ACCIDENT DETAILS

In case of any accidents time office should report to HR department and other respective
department.

LEAVE BENEFITS

GRADE WAGE BOARD MANAGERIAL

Annual leave 15 days 33 days

Sick leave 12 days 15 days

Casual leave 8 days 14 days

SAFETY,HEALTH AND ENVIRONMENT

• The India cements limited believes that safety, health and pollution control practices
contribute to individual well-being and organization moral.
• Their commitment to safety, health and environment stretches beyond statutory obligations.
• They are committed to manage and continuously improve the overall safety, health and
environment.
• India cements limited provides safety appliance and continuous training for safety of their
employees and contract workers to ensure safety and achieve the target of zero accidents.
18
 • They protect the environment by prevention of pollution and promote green environment.
• They develop safe working methods and practices to remove unsafe working conditions.
• Management should fulfil its responsibility to inform, educate and motivate the employees
and others to understand and comply with this policy and applicable laws.

SAFE INSPECTION

• Ensure Line clearance for mill, mill fan and classifier.

• Ensure hot gas dampers are fully closed and inform that the workman is engaged in
maintenance work activity.
• Ensure relevant lifting tools and tackles and maintenance tools are in working condition.
• Wear applicable PPE’s like Safety helmet, shoes, hand cloves, Safety belts and nose masks.

RULES FOR WORK SAFETY

• All accidents are avoidable.

• Do not take shortcuts, always follow the rules.
• If you are not trained, don’t do it.
• Use the right tools and equipments and use them in a right way.
• Never wear loose clothes or slippery footwear.
• Do mot indulge in horse play while at work.
• Practice good housekeeping.
• Always wear PPE’S
• Safety is as simple as ABC:
✓ A – Always
✓ B – Be
✓ C – Careful

3.2 FINANCE DEPARTMENT

Finance is required to bring a business into existence, to keep it alive and to see it growing.
The management of finance is essential for the success of business. Finance is regarded as the life
blood of a business enterprise. This is because in the modern money-oriented economy, finance is
one of the basic foundations of all kinds of economic activities. It has been rightly said that
business needs more money to make more money.

19
 Finance manager is the head of Finance Department. He looks after the budget, finance,
posting and audits of accounts. The senior officer accounts take charge to look into the day-to-day
activities of financial of the company. The senior officer establishment deals with calculating
employee wages provide, provident fund, ESI etc. Finance department do not maintain separate
balance sheet and profit & loss account. The accounting details are sent to the head office and they
are preparing the financial annual reports for every year. There are 6 employees in this department.
They are

 Joint General Manager

 Manager
 Senior Assistant Officers-2
 Officers-2

There are 2 sections in this department. They are as follows

▪ Bill section
▪ Cost section

BILL SECTION

This section is handled permanent employees salary, provident fund, medical bills,
travelling bills and it also pays to the extra expenses like co-operative store, schools, canteen
etc.

COST SECTION

This section maintains all the bills related to the production expenses. It also
prepares cost sheet on a monthly basis which is verified by the financial head of the unit and
send to head office for future verifications.

INCOME TAX

This section is an unavoidable aspect of a company. This section calculates the

income tax to be paid by every employee of the company this done depending up on the tax
rates and this is reduced from the salary of an individual.

CASH PAYMENT

• Provident Fund
20
 • Employees state insurance
• Excise duty payments
• Service tax
• Sales tax
• Electricity bills

CENTRAL EXCISE

This is the section where the central excise is calculated to be paid by the company
every month.

RATIOS OF THE INDIA CEMENTS LIMITED [2019-2023]

PER SHARE RATIOS

21
RETURN RATIOS

LEVERAGE RATIOS

GROWTH RATIOS

22
ANNUAL INCOME STATEMENT OF THE INDIA CEMENTS LIMITED [2019-
2023]

OVERALL REVENUE [2019-2023]

23
BALANCE SHEET OF THE INDIA CEMENTS LIMITED [2019-2023]

24
3.3 PRODUCTION DEPARTMENT
Production department plays an important role in The India Cements Ltd. Production is the
functional area responsible for turning inputs into finished output through a series of production processes.
The production manager is responsible for making sure that raw material was provided and made into
finished goods respectively. They must make sure that work is carried out smoothly, and must supervise
procedures for making work more efficient and more enjoyable.

This department is responsible for producing the cement in expected quality. They are producing
cement at mass level [16 million] tons per annum. There are 3 shifts for producing cement. They are
as follows
• Shift 1- 6.30am to 2.30pm

• Shift 2- 2.30pm to 10.30pm

• Shift 3- 10.30pm to 6.30am

VARIETIES OF CEMENTS BY THE INDIA CEMENTS LIMITED

The company produces both PPC and OPC cements whose composition are as follows.

1. Portland Pozzolana Cement

• Gypsum – [5%]
• Limestone – [4%]
• Slag – [5%]
• Fly Ash – [28%]
• Clinker – [58%]
2. Ordinary Portland Cement

• Gypsum – [5%]
• Clinker – [95%]
PRODUCTS BY THE INDIA CEMENTS LIMITED

• Sankar superpower
• Conkrete super king

25
 • Coromandel king
• Halo super king
• Raasi gold

MANUFACTURING PROCESS OF CEMENT

This manufacturing process is monitored by Central Control Room [CCR]. They monitored and
controlled every process that takes place in manufacturing of cement. Cement is manufactured by burning
a mixture of limestone and clay at high temperatures in a kiln, and then finely grinding the resulting
clinker along with gypsum.

Mines Crusher

Crusher Silo Vertical Raw Mill

Kiln
Pre Heater

Clinker Silo Great Cooler

Cement Mill Packing Mill

26
STEPS INVOLVED IN THE PROCESS

▪ Extracting of limestones from mines.

▪ Crushing of limestone rocks into small stones [size upto 0.50mm-
1.50mm]
▪ Grinding of limestones, clay or bauxite, iron ore or laterite in VRM.
▪ Storing the mixture in crusher silo.
▪ Cindering in rotary kiln at temperature upto 1400 degree Celsius.
▪ Cooling of mixture in great cooler at temperature upto 100 degree -150degree
to reduce heat and the cement formed into small lumps.
▪ Storing of cement lumps in clinker silo.
▪ Grinding of cement lumps into a fine cement powder adding gypsumto it in
cement mill then storing it in silo.
▪ Finally testing the quality and packing of cement in packing mill.
CRUSHER
Raw material, such as limestone, clay, shale, or other minerals, is first transported from the quarry
to the cement plant. The raw material is then fed into the rotary crusher through a feedchute.
Inside the rotary crusher, the raw material is subjected to the mechanical force of rotating hammers
or blades that strike and break the material into smaller pieces. This initial crushingprocess reduces the
size of the raw material to a more manageable size suitable for further processing.
After the initial crushing, the crushed material is screened to separate out fines and ensure that the
desired size range is achieved. The oversized material that doesn't pass through the screens isreturned to
the rotary crusher for further processing. The materials which are crushed by the crusher are then stored in
form of pile. When thematerials required for next stage, they convey materials through conveyor belt.
VRM (VERTICAL ROLL MILL)

It plays a vital role in the cement manufacturing process by reducing the size of the particles. The
raw materials are fed into the vertical roller mill from the top and pass between the rotating grinding table
and the grinding rollers. The rollers exert pressure on the raw materials, crushing and grinding them into
fine particles. The grinding process can involve a combination of crushing, impact, and attrition, resulting
in the reduction of particle size.

27
 The hot gases from the kiln or a separate drying system are introduced into the mill, helping to
remove moisture from the materials. This is crucial to prevent issues like material buildup and to ensure
efficient grinding.

As the ground material is carried upward by the airflow, a separator separates the finer particles
from the coarser ones. The finer particles are collected and sent to the next stage of the cement production
process, while the coarser particles are returned to the grinding table for further grinding.
The VRM reduce the size of the material into powdered form and its size is 120-micron level. The output
was stored in the blended silo.
COAL MILL
A coal mill is a crucial component in the cement manufacturing process as it is responsible for
grinding and pulverizing raw coal to fine powder that is used for burning in the kiln. The cementindustry
depends on the thermal energy generated from the combustion of pulverized coal in the kiln to produce
clinker, which is the main ingredient used to make cement.
Raw coal is fed into the coal mill for grinding. The coal is crushed and ground into a fine powder
by rotating rollers or balls, while hot air is introduced to dry and transport the coal particles. The grinding
process ensures that the coal is pulverized to a consistent fineness suitable for efficient combustion.
The introduction of hot air into the coal mill helps in drying the coal and transporting the pulverized coal
particles from the grinding area to the furnace or kiln where the actual combustion takes place. Proper
drying of the coal is essential to prevent clogging and ensureefficient combustion.
The finely ground coal powder is injected into the kiln or furnace, where it undergoes combustion.
The heat generated from the burning coal is used to raise the temperature within thekiln, facilitating the
chemical reactions that transform the raw materials (such as limestone, clay, and others) into clinker.
In some cases, the fuel is used in the composition of 80%coal and 20% alternate fuel. Alternatefuel
consists of saw dust, wood waste, cloth waste, sugarcane waste, etc.
STACKER AND RECLAIMER
Stacker is used to arrange coal in piles. Reclaimer is used to take from piles and transport tohopper
so that same composition is maintained, it works 360degree.
HOPPER
Hopper is used store coal from reclaimer and is transport to raw coal hopper from where it is
transferred to mill.

28
BELT CONVEYOR
Belt conveyor is used to convey coal from hopper in coal yard to raw coal hopper which is
transported to mill via belt conveyor and weigh feeder.
MILL

Coal mill consists of two chambers. The first chamber lifts the material and send it to the second
chamber, and the second chamber crushing the coal.

PFISTER AD FK PUMP
To transport the coal stored in bin certain pressure is required which is provided by these pumps.
The Pfister rotor weigh feeder is designed for dosing pulverized fuel, such as lignite coal dust, pet coke or
oil shale. But all PFISTER rotor weigh feeders use the same weighing and dosing principle. Material is
extracted from the storage silo and transported in the rotor chambers from the inlet to the outlet.
Fuller-Kinyon (FK) pump for easy pneumatic conveying of free-flowing bulk material. FK pump is
used to transport coal to kiln.
KILN

This section holds an unavoidable significance as the most important component of cement which
is clinker is produced here. The chemicals like dicalcium silicate, tricalcium silicate, tricalcium aluminate
and tetra calcium alumino ferrate are present in clinker are responsible forstrength, heat of hydration and
other physical properties of cement. The equipments involved in this unit are bucket elevator, preheater,
rotary kiln, grate cooler,deep bucket conveyor and clinker silo.
The mixture of limestone, slag and iron ore which are grinded into fine particles are stored in
blending silo. With the help of air slide at the bottom of blinding silo, the materials are transported to
bucket elevator which conveys the material to the top most floor. From there they are distributed to
preheater cyclones. It is a 4th stage cyclone and there are totally nine cyclones and are named as 1A, 18, 2,
3A, 3B, 4A, 4B, 5A and 5B. This arrangement is to heat up the material before it enters into kiln so that
the material reacts in a proper to form clinker. The hot air is taken from the kiln which is produced by
coal. The hot air is blown by preheater fan which goes from down to up and the material falls from up to
down. In this way heat transfer occurs and the material gains temperature and the air lose its temperature.
The kiln inlet is to be maintained at a temperature of 400°C which is done by coal firing. After the is
reached the materials are sent inside the kiln. Coal firing is done at both inlet and outlet of kiln. The kiln
rotates so that the materials move towards the outlet.

29
 In the meantime, clinker formation takes place. The temperature of about 1400°C is maintained in
the section of kiln where the material will be in semi solid conditions and near the outlet, the temperature
is reduced suddenly which results in the formation of solid stones of clinker. From the kiln outlet the
clinker falls the grate Ithas plate like arrangement in floor of which alternate plates vibrates so that
particles move towards exit. There are small holes on the plate through which atmospheric air is sent
inside the cooler-by-cooler fans. Again, by heat transfer the clinker gets cooled from 300°C to 150°C. near
the end of cooler is a hammer crusher which is used to reduce the particle size of clinker. Those particles
fall on and conveyed by deep bucket conveyor. Very fine particles fall through the holespresent in grate
cooler. The dust arose due to these processes are absorbed by ESP and it separates fine particle from air.
The fine particles from ESP, particles from bottom grate cooler and particles from deep bucket conveyor
are transported to clinker silo.
Here first the coal is sent to kiln and fired which increase the temperature and produces hot air.The
hot air is used in the preheater to heat the materials before letting them to kiln. In grate cooler after heat
transfer the air temperature would have been increase and it is sent to kiln, preheater via TED and
chimney via vent. In preheater after the heat transfer the temperature ofair would have been reduced. So,
the reduced temperature air from preheater and cooler fan is sent to gas cooling tower to reduce the
temperature of material there.
PRE- HEATER
A preheater is a piece of equipment used to heat raw materials before they undergo further
processing in the kiln. The main purpose of a preheater system is to increase the efficiency of the cement
manufacturing process by preheating the raw materials, which helps in reducing the energy consumption
of the kiln and improving the overall production process. Preheaters are commonly used in modern
cement plants to optimize the use of energy and enhance the environmental sustainability of the operation.
A preheater typically consists of multiple stages, each comprising a series of cyclones or other heat
exchange devices. The raw materials move downward through these stages. Hot gases fromthe kiln or a
separate combustion chamber are introduced into the lower stages of the preheater system and flow in the
opposite direction, moving upward through the stages.
As the raw materials move downward, they come into directcontact with the hot gases moving
upward. This heat exchange process raises the temperature of the raw materials. By the time the raw
materials reach the bottom stages of the preheater, they are significantly preheated.
The preheated raw materials are then fed into the kiln, where they undergo further processing,

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including chemical reactions,clinker formation, and sintering, to produce cement clinker. In this pre heater
the materials are heated to the temperature of 900℃, and then feed into the kin for further process.
GRADE COOLER

It is a long tunnel like machine with three sections and two stages. It is located at the end ofkiln so
that the clinker directly falls into the cooler.
The cooler fans which blow the atmospheric air into the cooler which enters through small holes on
the floor. The floor is made of joined plates in which alternate plates vibrate so that clinker move towards
exit of the cooler. Near the exit there is a hammer crusher to reduce the particle size of clinker.
CLINKER SILO
It is used to store the clinker. It has a height of 36.5 m and a capacity of 25000 tons. When
necessary, the clinker from here has to be sent to cement mill.
CEMENT MILL

A cement mill is a crucial component of a cement plant, where clinker is ground to produce the
final cement product. It's one of the final stages in the cement production process, responsible for
producing the fine powder that is the foundation of the finished cement. A cement mill is a crucial
component of a cement plant, where clinker is ground to produce the final cement product. It's one of the
final stages in the cement production process, responsible forproducing the fine powder that is the
foundation of the finished cement.
Additives such as gypsum, fly ash, slag, or other materials are added to the cement mill to modify
the properties of the final cement product. These additives can enhance the cement's properties, such as
setting time, strength, and durability. The fine particles, which are the desired product (cement), are
collected and transported tostorage silos, while the coarser particles are returned to the mill for further
grinding.
Cement mills are equipped with various sensors and instruments to monitor parameters like mill
speed, temperature, grinding efficiency, and other factors. This data helps in maintaining the desired
product quality and optimizing the grinding process.
Once the cement is produced in the mill, it's transported to storage silos or directly to bulk storage
facilities. From there, it can be loaded onto trucks, trains, or ships for distribution toconstruction sites and
other consumers.
SILO

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 There are totally 6 silos for storing cement. Each silo is of 20 m height and is filled up to 17m.
The 3rd silo stores OPC which is manufactured for Kudankulam and rest is for PPC. Cement from belt
conveyor reaches distribution box which distributes cement to silo 1, 2, 3 and 4. From distribution box
some cement is sent to air slide which is transported to silo 5 and 6.

PACKING
This is the last unit of the industry where all unit operations and unit processes are
designed for packing the final products and delivering them to the customers. Maximum attention
is givento the packaging part as the amount of cement packed in each bag should be at the right
level, if the amount of cement is less it affects the consumers and the reputation of the company
and if the amount is more, it affects the profit of the company. Here cement of 50 kg is to be filled
in abag and the time of 1 hour is set to pack 100 tons. It works by automatic control by giving
input to belt and number of bags for each lorry.

The unit consists of the following equipments like silo, screw conveyor, bucket elevator,
vibrating screen, air slide, bag filter, hopper, Electronic Rotary Packer, hoister, printer machine,belt
conveyor and loader. We saw in the cement mill section that the cement is conveyed by belt which
is carried to silotop by a bucket elevator. There they reach at common tank from where they are
distributed to respective silos. Air slide is present at the bottom of each silo which moves cement
from silo to screw conveyor. There are totally three packers and for each packer there is a bucket
elevator.

The cement from screw conveyor is carried by a bucket elevator to the vibrating screen.
The vibrating screen rejects the undesirable materials and the desired particles are allowed into
hopper. There are two kinds of bags used here, a normal polythene one and a laminated one. The
laminated bags are used for transporting cement to Kerala to withstand the moisture and the
climatic conditions there. The bags are taken up by the machine called hoister and are conveyed by
belt conveyor. The MRP and other necessary details are printed on the bags by a printing machine.
Then comes the role of Electronic Rotary Packer. It has eight holding units so that at a time eight
bags can be filled. As soon as the bag is given to the packer it is held by bag holding pump. The
slide gate opens and the bags are filled with cement. There are also eight mortars to mix the
cement. The equipments like bag filter, vibrating screen, silo worm and packer drive are linked and
all belt conveyors are linked to each other. So, the stoppage of any one of the equipments will
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affect the function of others. There is a mimic panel which works by Programming Logic Control
which is used to understand and control the process. There is also a blower which is a cleaning
device used to remove dust from bags.

The packed bags. then go to truck loader through belt conveyor. It is used to arrange bags
in the truck. Each truck is given with a card which contains the details of truck number, number of
bags to be loaded, etc. The card is canned in RFID panel which permits the loading of correct
number of bags into the truck.The process is automatically controlled and stops after loading the
required number of bags. Theempty weight of truck is measured in the beginning and the loaded
weight of truck is also measured and both are subtracted to get the actual weight of bags. It is
checked with the desired weight. If both values match the truck is let out for delivery.

CCR

The control room plays a vital role in the industry processes. The processes like the speed
of conveyors, flow rate of materials, pressure to be maintained, level of materials to be maintained
are controlled and monitored by the control room.

The devices present are input, processor, output and controller. It works by PLC
mechanism. PLC calls address of a particular node and gets data from each node. By this way the
processes are monitored, controlled and data are transmitted by master and slave systems.

The primary functions of a control room include:

Process Monitoring: Monitoring the different stages of the cement manufacturing process,
such as raw material extraction, grinding, blending, kiln operations, and cement grinding, to ensure that
each step is running smoothly and efficiently.
Automation Control: Managing and adjusting the plant's automation systems, which
mightinclude programmable logic controllers (PLCs) and distributed control systems (DCS), to
optimize production and maintain consistent product quality

Equipment Surveillance: Keeping an eye on various equipment and machinery like

crushers, mills, kilns, and conveyors to identify any malfunctions or issues that could disrupt
productionprocess.
Environmental Compliance: Monitoring and managing emissions, energy

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consumption, andother environmental parameters to ensure compliance with regulations and
reduce the plant's environmental impact.
Data Analysis: Analysing real time data from different sensors and instruments to
makeinformed decisions and adjustments to enhance efficiency and productivity.
Safety and emergency response: Implementing safety protocols and procedure and being
prepared to respond quickly to any emergency situations that may arise within the plants.

3.4 QUALITY ASSESSMENT DEPARTMENT

The quality of the cement is tested in this lab. Every 3 hours the samples are taken from the
various section and tested. After testing the samples, the quality of the cement is decided. If the
quality of the cement is lacking, they will add the needed additives and ensure the quality. There
are both physical and chemical labs present here. These are to check the physical and chemical
properties of materials in each stage and to compare with the standard sample. The values are
reported to CCR. If the values are not desirable, they can be monitored, differed andmaintained by
CCR control.

For example, here heat of hydration and setting time can be determined. OPC has high heat
of hydration and exhibits early setting. PPC has low heat of hydration and exhibits low setting. By
these values the quality and composition can be changed.

Physical lab:
The main operations here are to determine strength, heat of hydration, drying state
and moisture. To determine strength, we use equipments like humidity chamber, vibrating
machine and compressive testing machine. Here 1 part of cement is mixed with 3 of sand.
Usually, 600 g of cement is taken for this process. The cement and sand mixture are sent to
vibrating machine where it is molded into cubes. This is referred to as mortar cube. It is
then sent to humidity chamber to remove the humidity and finally demolded. The strength
is found by compressive testing machine used at the last.

To determine the heat of hydration, 100 g of cement is taken and made into cube.
The mortar cube is placed in boiling water of water bath for 3 hours and is checked for
expansion. By this expansion heat of hydration can be determined

Chemical lab:
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 Samples are collected from VRM, kiln feed, preheater (hot air sample and degree of
calcination) and coal mill. The results from calorific value, proxy meter analysis, moisture, IM,VM,
litter weight, free lime, detailed analysis, fineness, setting time and SO, test are analysed.

Bomb calorimeter is used for chemical analysis of cement and clinker. Blaine apparatus is
used to determine specific surface fineness based on time of flow. X-ray is used to determine the
composition of sample. It is tested for every 2 hours and set point is done by CCR. For X-ray
analysis sample should be in pellet form. So, it is grinded and mixed well with cellulose to form
pellet. A highly advanced and efficient instrument called XRF is used. has high velocity electrons
which helps in analysis of different wavelength of material. From this we can find intensity. With
intensity and an inbuilt formula, composition can be determined. It works on standard sample and
unknown sample approach and a plot between intensity and concentration can also be obtained.

3.5 MARKETING DEPARTMENT

The major objective of this department is to distribute the goods to customers on time. The
areas covered by the India cements limited in Sankar Nagar are Tirunelveli, Nagercoil, Tuticorin,
and Ramnad [if necessary], Thiruvananthapuram, Allepey, Kozhikode, Ernakulam and the other
parts of Kerala.

India Cements Limited, typically uses a multi-channel distribution network to reach its customers.
The distribution channels for cement companies like India Cements Limited generally include:

1. Dealers and Distributors: India Cements Limited partners with a network of dealers and distributors
across various regions. These intermediaries purchase cement in bulk from the company and distribute
it to retailers, contractors, and other end-users.
2. Retailers: Cement retailers play a crucial role in the distribution channel. They buy cement from
distributors or directly from the company and sell it to individual customers, small contractors, and
construction professionals.
3. Contractors and Builders: Large construction companies, builders, and contractors often have direct
accounts with cement manufacturers like India Cements Limited. They purchase cement in bulk for
their construction projects.
4. Direct Sales: India Cements Limited may also engage in direct sales to major clients, such as
government infrastructure projects and large corporate clients.

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 5. Online Sales: In recent years, cement companies have also ventured into online sales platforms to
cater to individual customers and smaller construction projects. Customers can purchase cement
directly from the company's website or through e- commerce platforms.
6. Institutional Sales: Cement companies like India Cements Limited may have a dedicated team for
institutional sales, catering to bulk orders from institutions, government agencies, and large-scale
construction projects.
7. Export: Some cement companies export their products to international markets through partnerships
with international distributors or directly to construction projects

3.6 RESEARCH AND DEVELOPMENT DEPARTMENT

Research is conducted to improve the quality of the cement. This department is intended to control the
research and development of new products, modification in the design of the existing products and to maintain
equipment and device in inspection, measuring and testing to demonstrate calibration status and to maintain
record of calibration, flow chart, drawing and bill of materials.

RESPONSIBILITY OF R&D DEPARTMENT

• Development and product improvement of products
• Development of new products, expansion and diversification
• Production monitoring and reporting of products
• Ensuring safety practices in production of products
• Ensuring compliances to codes and standards in production of products
• Ensuring usage of right material for production related activities

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CHAPTER - 4

37
SWOT ANALYSIS OF THE INDIA CEMENTS LIMITED
India Cements is one of the leading brands in the real estate and construction sector. India
Cements SWOT analysis evaluates the brand by its strengths & weaknesses which are the internal
factors along with opportunities & threats which are the external factors. Let us start the SWOT Analysis
of India Cements
STRENGTHS
• India Cements was established in 1946. So, it has an operational experience of many
years.
• It has 7 manufacturing plants in the country.

• It owns Chennai Super kings franchise that has helped them build a strong brandvalue.
• It is one of the largest cement companies in India.

• It also employs an efficient workforce of around 7500 employees.

• The brand is also associated with IPL cricket team Chennai Super Kings.
Above are the strengths in the SWOT Analysis of India Cements. The strengths of India
Cements look at the key internal factors of its business which gives it competitive advantage in the
market and strengthens its position.
WEAKNESSESS
• India Cements is alleged to have made controversial investments in JagatiPublications and
Bharati Cements
• Its operations are majorly focused on South India and Maharashtra, so itsnationwide
awareness is lesser.
• Its export business is also very small as compared to its competitors in India.
These were the weaknesses in the India Cements SWOT Analysis. The weaknesses of a brand
are certain aspects of its business which it can improve.

OPPORTUNITIES
• It should leverage its leadership in the southern markets to expand its operation allover
India.
• It should also emphasize on increasing its exports to other countries.

• Policies of the Government would be pro manufacturing sector that would helpIndian

38
 Cements to grow.

Above we covered the opportunities in India Cements SWOT Analysis. The opportunitiesfor any
brand can include prospects of future growth.
THREATS
• It faces strong competition from global and Indian brands.

• Local players in southern markets are also posing threat to the market leader.

The threats in the SWOT Analysis of India Cements are as mentioned above. The threats for any
business can be external factors which can negatively impact its business.

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CHAPTER - 5

40
 SUGGESTIONS AND CONCLUSION

SUGGESTIONS

• Employee turnover should be minimized

• Performance appraisal system should be improved
• Advertisement and promotional activities should be improved
• Considerable care must be taken by the government to make the company run in a profitable
manner
• The infrastructure and the facilities given to the employees should be improve
• Better training for improving the skills of the workers and the officers provided by the
company
• Marketing department should add more efforts
• Experienced professionals should be appointed in research and development team
• Improve the motivational technique
• More concentration on product diversification is needed
• Introduction of innovative products is needed for the company
• Infrastructure should be established with some reputed organization

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 CONCLUSION
In conclusion, my internship experience at India Cements has been an invaluable
opportunity for my personal and professional development.
During my time at the company, I was exposed to various aspects of cement
production. I learned about the complexities of the cement manufacturing process and the
industry's contribution to infrastructure development and construction.
Moreover, the internship allowed me to apply the theoretical knowledge gained during my
academic pursuits to real-world scenarios. One of the most significant takeaways from this
experience was the importance of safety and environmental compliance in the cement industry.
Witnessing the company's commitment to sustainable practices and their dedication to
minimizing environmental impact has inspired me to consider environmental sustainability as a
priority in my future career.
In conclusion, my internship at India Cements has been a transformative experience,
offering a deeper understanding of the cement manufacturing process, instilling vital skills, and
fostering professional growth. I am excited to carry these experiences forward and build a
successful career in this dynamic and critical industry.

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 BIBLIOGRAPHY AND REFERENCE
REFERENCES
https://www.indiacements.co.in/

https://www.ibef.org/

https://www.mbaskool.com/

https://www.indiacements.co.in/

https://www. FinancialsMoneyControl.com/

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