Building on
Stronger Foundation.
Responsibly.

Case Study

SGC is committed to improve its environmental footprint across the product lifecycle. Periodically we undertake the GreenPro-certification for our products issued by the CIIGreen Business Council (CII GBC). To achieve certification, we conduct a comprehensive lifecycle assessment (LCA) for our major cement categories covering greenhouse gas emissions, resource consumption, overall environmental impact, raw material sourcing, energy water efficiency and waste management.

In 2024, our Sustainable Product Portfolio included PPC, CC, PSC and GGBS.

Case Study

With an aim to lower thermal power consumption and thus reduce energy costs and carbon footprint, we installed a smart preheater with a height of 153 meters at our Dachepalli plant. The project began in February 2024 with the construction of a new preheater building, featuring a six-stage cyclone system with a pyroclone for better heat recovery.

Case Study

GreenCo certification
for multiple plants

Reiterating our commitment to sustainable cement manufacturing, 3 out of 6 SGC plants have received GreenCo certification. Mattampally and Bayyavaram plants received 'Gold' and 'Platinum' ratings in 2023 and 2025, respectively. The Gudipadu plant, previously certified 'Gold', has also commenced the renewal process with a focus on expanding renewable energy installations including solar and waste heat recovery projects. We benchmarked our plants against national and international sustainability standards.

The teams at Mattampally and Bayyavaram implemented best practices for adoption of solar, hydel, and waste heat recovery systems to increase renewable energy usage, established zero water discharge systems and integrated alternative fuels into the production process. These measures significantly improved energy efficiency, waste management and emission reduction. Independent audits were conducted by CII GreenCo-accredited assessors confirmed that both plants met the required scoring criteria, enabling them to secure Gold and Platinum certifications.

We are now going for the 3 remaining plants for the GreenCo Certification. Capacity-building efforts will play a crucial role in this journey. During the year we organised extensive training programmes and workshops to enhance employee awareness about energy efficiency, emissions control, material management and safety.

Case Study

We have installed a 6 MW bifacial solar power plant at the Gudipadu unit to enhance green energy ratio, reduce carbon emissions and accelerate the Company's transition to renewable energy. Commissioned in January 2025, this project is equipped with 10,276 bifacial mono PERC modules and the plant generates an estimated 26-38 MWh energy per day, contributing around 10% of the unit's total energy consumption. The system is estimated to generate nearly 10 Million kWh of clean energy. The use of bifacial modules, benefits from the ground albedo effect, observes 3-5% gain in energy generation compared to monofacial panels.

The project will reduce CO₂ emissions by approximately 7,160 metric tonnes annually, equivalent to planting 3.58 Lakhs trees annually.

Case Study

A pilot programme with six EVs was launched to assess their real-world performance, in emission reduction A high-capacity charging stations were installed within three plants: Mattampally, Bayyavaram and Dachepalli to enable efficient charging during shifts. Drivers, mechanics, and operators were trained to ensure smooth integration. Data analytics tracked key metrics such as energy consumption and maintenance costs, confirming notable reductions in fuel dependency and operational expenses. EV loaders at Mattampally and Dachepalli, along with EV trucks at Bayyavaram, demonstrated strong energy efficiency, with loaders consuming an average of 23.50 kW per hour and trucks operating at 1.36 kWh per kilometre.

The transition reduced 327 tCO₂e emissions while improving worker safety and health through reduced exposure to harmful emissions. Productivity levels were maintained, and the initiative strengthened the Company's environmental credentials, attracting interest from sustainability-focused investors. It has resulted in lower operational costs, enhanced regulatory compliance and reinforced our long term commitment to sustainable growth.

Case Study

At the Dachepalli plant, the operational team faced a challenge - prolonged idle compressor hours during fly ash unloading. The single unloading point caused delays, increasing energy consumption. To address this, a second unloading point was strategically installed alongside the existing system. With two tankers unloading simultaneously, unloading time per tanker dropped from 60 to 40 minutes. Although compressor power usage rose slightly from 58 kWh to 60 kWh, the reduction in idle hours resulted in a net power saving of 19 kWh.

Case Study

The Dachepalli plant adopted portable solar lighting towers to enhance energy efficiency and lower its carbon footprint. Conventional lighting systems were replaced with solar towers to cut power consumption, minimise CO₂ emissions, and offer a flexible lighting solution suited to changing operational needs. Installation began in January and a monitoring system was set up to track energy savings and performance.

Traditional lighting towers consumed 1.20 kW/hour; solar towers brought this down to zero, eliminating grid dependency. Each tower now saves energy cost worth ` 9 per hour, totalling ` 33,696 annually. The switch has also reduced CO₂ emissions by 24 tCO₂. It has also improved operational flexibility, enabling its positioning in different parts of the plant, depending on lighting requirements.

Case Study

The Dachepalli cement plant has installed a Variable Frequency Drive (VFD) for the cooling tower water pump of cement mills. It has led to a noticeable reduction in electricity consumption and reduced 255 of tCO₂ emissions annually.

The cooling tower water pump plays a vital role in maintaining the temperature of critical equipment and ensuring smooth operation of cement mills. Previously, the pump operated at a constant speed of 1440 RPM, consuming between 64-68 kW of power per hour, regardless of actual demand. This fixed-speed operation led to excessive energy consumption, contributing to higher electricity costs and unnecessary carbon emissions.

The VFD was installed to regulate motor speed according to the actual cooling demand. This smart control system reduced the pump's average operating speed to 1000 RPM, resulting in a remarkable decrease in power consumption to just 23 kW per hour.

Case Study

The Dachepalli plant introduced paddy husk, an agricultural by‑product, into its blasting operations. Acting as a bulking agent, paddy husk helped reduce the density of explosives used in blast holes, leading to cost reductions and efficiency improvements in blasting operations without compromising safety or performance.

Case Study

At Jeerabad, where arid conditions and limited water resources pose constant challenges, we implemented a drip irrigation system around the limestone crusher plant to promote sustainable green belt development. This initiative aims to improve vegetation cover, enhance dust control and set a benchmark for efficient water management. Manual watering proved to be inconsistent and inefficient.

The team designed a sustainable drip irrigation network with pipes, emitters and automated timers. This system has reduced water consumption by approximately 40%, and manual labour requirements have been cut by more than half. It has also strengthened the plants’ drought resilience, enabling them to withstand harsh climatic conditions.

Case Study

At our Dachepalli Plant a Blue Drop STP is installed which is an Integrated Constructed Wetland also known as Phytoremediation System. These engineered systems use the natural filter media and organisms to purify the wastewater streams. Traditional STPs use chemicals and fossil energy for recycling of water. In order to limit the use of chemicals and find a sustainable solution, we have implemented a ‘Blue Drop STP’ at our Dachepalli Unit.

Case Study

The Dachepalli Plant took a major step towards improving workplace safety and efficiency by implementing an integrated work permit system, guided by corporate safety advisor Shri. T.E.C. Vidyasagar and aligned with IS 17893:2023 standards. The previous system often led to multiple permits being issued during simultaneous tasks at critical locations such as cyclones, kilns, and silos. To address this, the team expanded the number of permits from four to twelve, incorporating detailed checklists that allowed a single permit to cover multiple activities. This reduced deviations, strengthened compliance, and streamlined the overall permit process.

Training sessions for employees and contractors ensured smooth adoption of the new system. The digitised and consolidated framework reduced paperwork, cutting printing costs and limiting physical movement of permits across work areas. As a result, the Dachepalli Plant significantly lowered permit deviations, improved workflow efficiency, and enhanced safety performance.

Case Study

To strengthen the safety culture and operational discipline, we have introduced a comprehensive Driver Management System. It aims to improve the safety of personnel, vehicles and infrastructure, ensure compliance with plant policies and legal requirements.

The system involves multiple layers of checks and clear operational instructions. At the main gate, all vehicles undergo document verification, alcohol testing and PPE checks. Fire extinguishers and first-aid kits are inspected before entry. Drivers are briefed on rules for adhering to speed limits, avoiding mobile phone use and wearing safety gear while handling tanker doors. Violations, including wrong route entry or sleeping on-site, result in penalties. Regular road and fire safety training sessions are held. Health check-ups and resting areas are also offered to drivers.