Venwiz Accelerates 11,000 TPD Greenfield Cement Plant Construction Reducing TAT by 30%

A leading cement manufacturer, with an 80-year legacy and 15 plants across 10 states, embarked on an ambitious project: the construction of an 11,000 TPD greenfield cement plant in Karnataka. This ₹2000 crore undertaking involved a complex web of packages, each requiring specialized vendors with the necessary turnover, manpower, technical capabilities, and relevant industry experience. 

Facing challenges in large-scale procurement, the manufacturer teamed up with Venwiz. This partnership streamlined vendor sourcing and ensured project success.

Vendor Qualification & Execution Challenges

The project presented several key challenges:

• Sourcing Qualified Vendors: Finding vendors with the required turnover, manpower, equipment, and, crucially, experience within the cement industry proved a significant hurdle. The project demanded seamless package execution, making the right vendor selection paramount.
• Navigating Complexity: Mapping vendors to the appropriate packages and managing the distribution of these packages added another layer of complexity to the project.

The scope of the work included:

• RCC Concrete work (1.33Lakh cubic metres)
• 140-metre-high core buildings 
• Slip-form shuttering for silos & modular shuttering for building construction
• Process buildings (silos, columns, etc.), structural steel works, equipment foundation, road construction 

Vendor Attributes

Venwiz implemented a strategic, multi-faceted approach to address these challenges:

• Strategic Project Division for Streamlined Execution: The project was meticulously divided into two primary processes (clinkerization and grinding), further segmented into 8 to 10 specialized packages. This strategic breakdown streamlined execution, accelerated vendor onboarding, and ultimately contributed to a 30% reduction in project timelines. The package breakdown included:
  • Clinkerization System:
    • Package 1: Limestone unloading, BRU, storage, and transportation system
    • Package 2: Coal handling system (wagon tippler, storage shed, transportation)
    • Package 3: Raw material handling and mills
    • Package 4: Pre-heater, kiln feed, kiln piers
    • Package 5: Coal mill, PH/AQC boilers, waste heat recovery system
    • Package 6: RCC silos (clinker, blending, reject)
  • Grinding System:
    • Package 7: Cement silo, fly ash silo
    • Package 8: Cement mill building, cement mill hopper, bagging/packing plant, cement wagon loading
    • Package 9: E&I buildings, utility buildings, non-plant and miscellaneous buildings
    • Package 10: Roads & drains, boundary wall
• Smart Vendor Selection for Complex Engineering Demands: Using Venwiz's AI-powered platform and the client's PQR, we identified 11 potential vendors. A strict evaluation of past projects, infrastructure, and financial stability narrowed it down to 6 qualified vendors.
• Cost Control through Precision Benchmarking: Venwiz's cost estimation and quote comparison tools provided transparency and ensured competitive pricing, aligning with the client's budget while upholding quality standards.
• Efficient Construction with Expert Techniques: We identified vendors specializing in slip-form and modular shuttering, enabling faster construction and adherence to stringent technical requirements.

Optimized Package Management & 30% TAT Reduction

Venwiz's expertise and strategic approach delivered significant benefits:

• Simplified Package Management: The structured approach facilitated easy package management and seamless mapping of vendors to the appropriate packages.
• Accelerated Timelines: A 30% reduction in turnaround time (TAT) was achieved through rapid vendor discovery, assessment, and facilitation of site visits.
• Cost Transparency: Internal cost estimations for each package ensured reasonable vendor quotations and a clear understanding of the Bill of Quantities (BOQ).

This case study showcases Venwiz’s commitment to excellence in capital expenditure (capex) procurement. We partner with clients to help them achieve their business goals. 

Are you expanding your brownfield or setting up a new greenfield project? From strict budgets to complex design standards, Venwiz has the expertise, network, and solutions to handle it all. 

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