KCP’s Cement Business is over 60+ years old with manufacturing plants in Macherla & Muktyala in the state Andhra Pradesh with captive supply of high grade limestone and producing a combined annual capacity of 4.3 million tons of the finest quality premium grade cement in India.

Why KCP Cement ?

Proven record for over 60+ years as one of the India’s oldest producers of High Grade Cement.
Various Landmarks projects in India like Nagarjuna Sagar Dam, SriSailam Dam and Prakasam Barrage, Godavari Railroad Bridge in Andhra Pradesh.
Manufactured by ISO 9000 quality certified plants to National & International Quality standards.

Primarily used in building foundations structures like Columns, Beams, Slab and other concrete structures and hence popularly called Concrete Cement.

Products

Grade 53 Ordinary Portland Cement (OPC)

Also known by the name 'grey cement', 53 Grade OPC (Ordinary Portland cement) is a high strength cement that meets a diverse portfolio of consumer needs, as well as produces higher-grade concrete at a very economical rate. For certain specialized works, such as pre-stressed concrete and certain items of precast concrete requiring consistently high strength concrete, 53 Grade OPC is found to be very useful. Conforming to the IS 12269 and tested as per IS4031, this cement meets the BIS requirements of minimum 28 days compressive strength which should not be less than 53 MPa (IS : 269 - 2015).

Portland Pozzolana Cement (PPC)

Cement of International quality from the house of KCP, the uniqueness of this product lies in its high compressive strength, better workability and durability of blended cement as well as its compliance with all the requirements of national and international standards. Produced in a dust free environment, it is one of KCP's signature products (IS: 1489 - 2015).

KCP Cement is sold in India in Telangana, Andhra Pradesh, Karnataka, Tamil Nadu, Kerala, Maharashtra, Madhya Pradesh, Chhattisgarh and Orissa. We also export cement to Sri Lanka, Bangladesh & Myanmar. We have been delivering high-quality cement to prestigious and large infrastructural projects including leading infrastructure developers, private companies and major cement manufacturers who source our products as they stands out in strength & efficiency.

Plants

Macherla Cement Plant

Macherla Cement Plant

Commissioned in 1958, it is one of India’s oldest cement plants and South India’s Ist dry process Kiln with technology from KHD Humboldt, Germany. Starting with an annual capacity of 200 tons, it has been gradually expanded and modernized to a current annual capacity of 0.8 million tons with additional technology from Fives Lille, France and later FLSmidth, Denmark (Fuller, USA).

In 1999 an 8.25 MW Hydel Power Plant was set up on the Nagarjuna Sagar Dam right canal generating clean & sustainable power. A 2.3 MW Waste Heat Recovery Power plant was set up by utilizing waste fuel gases exhausted from the pre-heater and cooler chimneys. With Strong emphasis on new technology characterizing all operations at the Macherla plant, we facilitated India’s first dry process kiln of 400 TPD, an installation by Humboldt, Germany, in 1958. In 1962 a 600 TPD wet process kiln in collaboration with Fives Lille Cail France was installed.

Today, our 100% modernized cement plant has a World Bank funded outlay of 36.70 crores and incorporates the latest advancements in technology, such as an energy-efficient dry process with two support kilns, and a five-stage preheater with a flash calciner. The plant also incorporates a state of art centralized process system using hardware and software from FLSmidth Automation, Denmark to help enhance productivity.

Muktyala Cement Plant

Muktyala Cement Plant:

A Greenfield plant setup in 2011 is one of India’s most modern, highly automated, cost efficient and Eco Friendly plant with an annual capacity 1.86 m tons expandable to 3 m tons. Built with world class Pyroprocessing technology from KHD Humboldt-Germany, Grinding technology from GEBR Pfeifer-Germany and Plant Automation & Automated Packing technology from FLS Smidth-Denmark, world leaders in Cement plant technologies. KHD Humboldt, Germany designed an energy-efficient plant that could deliver an annual capacity of 1.55 million tonnes of Clinker and 1.86 million tonnes of Cement. In 2019, this plant’s capacity was expanded to 3.52 million tonnes per annum by addition of a separate line of operation. The plant is also enhanced with Captive Power Generation of about 20 MW (Thermal & Solar).

This plant was designed by the KCP Team by aiming to minimize material transportation and commence complete auto operation from CCR without men and feeding equipment in the field.

Major Equipment Installed

  • Hazemag Limestone Crusher: Capacity 1100 TPH
  • Takraf Stacker & Reclaimer: Capacity 850 TPH
  • MPS 4500B Gebr Pfeiffer, Germany Raw Mill: Capacity 350 TPH
  • CF Blending Silo 20m Diameter x 45m High: Capacity 15,000 MT
  • MPS 2800BK Gebr Pfeiffer, Germany Coal Mill: Capacity 60 TPH
  • KHD Humboldt, Germany
  • ILC 6-stage preheater with pre-calciner
  • 63-support Rotary kiln 4.20m diameter x 64m long with capacity: 4700 TPD
  • PSC Cooler with cooling area of 91 Sq Mts
  • Two Cement Mills 2 x 1,850 KW each main motor: Capacity 2×120 TPH
  • FLS 2 x 16 Spots 240 TPH capacity double discharge packers

Reduced Noise Level

There has been a strong focus on reducing the noise level on the plant, and hence silencers and noise enclosures have been provided for all noisy equipment. Along with traditional noise-abating solutions, many new and unique ones have been implemented in the project. One of them is for the kiln shell cooling fans, which are among the noisiest pieces of equipment. For the first time in India a stack of centrifugal fans with noise enclosures have been used for kiln shell cooling.

Low Emission

Taking future pollution control standards into account, the main process bag filters and nuisance bag filters were designed for an extremely low emission level of < 30 mg/Nm3, the lowest level of emissions in any Indian cement plant.

Special Features

  • Availability of large reserves of high grade limestone
  • Minimum waste rock generation(< 5%) in mines
  • Limestone mine is within 1km from the plant
  • Automated Limestone stacker and reclaimer
  • High efficiency pre-heater (97 %)
  • Lowest power (43 KWh/MT Clinker) and coal consumption (690 KCal/Kg Clinker)
  • High level of plant operational, packing and dispatch automation.
  • Lowest maintenance cost

One Of The Most Energy-Efficient, Cost Effective And Reliable Plants Ever Commissioned in India.

Automation using Fuzzy Logic Operation

A state-of-the-art process control instrumentation and Fuzzy Logic Operations for the smooth functioning of the plant to maintain consistent quality.

State of Art Testing Lab

The plant is one of the most modern of its kind in India, featuring FLSmidth, Denmark supplied automation and plant instrumentation and a fully automated robotic lab facility capable of sampling and sample transportation, preparation and analysis. As a result of this focus on quality, KCP cement specifications exceed those set by BIS, SLS, ASTM by a wide margin. Strict supervision and quality control at every stage in production and packing.

Quality

KCP ROBO, Unit 2, Muktyala
State of Art Testing Lab

The plant is one of the most modern of its kind in India, featuring FLSmidth, Denmark supplied automation and plant instrumentation and a fully automated robotic lab facility capable of sampling and sample transportation, preparation and analysis. As a result of this focus on quality, KCP cement specifications exceed those set by BIS, SLS, ASTM by a wide margin. Strict supervision and quality control at every stage in production and packing.

Mobile Concrete Testing Lab

The overarching objective of the mobile concrete testing lab at KCP is to make better and durable concrete at the site, and act as the guide in adopting better construction practices. While the concrete care team checks parameters such as the grain size distribution of (jelly), coarse aggregate or (sand) fine aggregate, the concrete care engineer checks for harmful impurities in sand – clay or silt, for example. In addition to the above, samples of concrete made at the site can be tested after 7 days or 28 days as per BIS standards. The cement care van also provided for the testing of water suitability.

The mobile concrete lab is equipped to test the following parameters:

  • Coarse and fine aggregates
  • Fresh concrete workability via the slump test
  • Fresh and hardened concrete through concrete cube testing
  • Quality of water

All the above tests confirm to BIS specifications.

Mobile Concrete Testing Lab