Puzzolana- Indian innovator leaving footprint across the world

Puzzolana Plant no dust

Adding new verticals, launching new products, expanding global network

With five decades of expertise in delivering effective, economical and environmentally compatible engineering solutions for infrastructure development in the country, Puzzolana, a business conglomerate, headquartered in Hyderabad, is continually growing and expanding its business territories to fulfil its ambition of becoming Asia’s largest construction and mining equipment manufacturer in the next few years.

A pioneer in infra machinery manufacturing, Puzzolana offers comprehensive solutions in design, manufacture, supply, installation and commissioning of construction and mining equipment, including crushing & screening plants on turnkey basis. Since inception, the company has not digressed from its core values of manufacturing only the best quality products, customer-centric solutions, competitive pricing, and reliable after-sales service.

Puzzolana is the brainchild of Mr. Prakash Pai who revolutionized the entire Crusher Industry with several in-house technical innovations in the machinery to offer the right solutions for diverse needs. With his astute sense of business, relentless hard work, and sheer determination, Mr. Pai not only carved a niche for the Puzzolana brand in the country’s construction equipment industry, but also steered the company to become a market leader in the Aggregate Crushers business in India. Today, Puzzolana is positioned as the first Indian manufacturer with 100% in-house technology and sourcing capabilities for construction and mining equipment manufactured by them.

Under the stewardship of their Managing Director, Mr. Prakash Pai, Mr. Ananth Pai, Joint Managing Director, and President Mr. Abhijeet Pai, the company is set to add three more business verticals, which Team Puzzolana is confident will achieve the same growth trajectory as their crushing and screening vertical have been achieving. With an approximate 60% served market share in the crushing and screening industry, Puzzolana aims to grow by threefold in the next few years with their existing and new business verticals. They are also keen to establish their brand in international markets such as Africa, Middle East, South East Asia, and the Americas. A step towards achieving this goal was the recent appointment of Tata International as the company’s distributor for the African region. Puzzolana is in the process of establishing its diributorship in other countries as well.

S.A.Faridi, in an exclusive interaction with Mr. Prakash Pai and Mr. Abhijeet Pai, gathered insights into the company’s future plans, strategies for growth, and their vision for 2020. Excerpts:

You have lived the 50+ years of Puzzolana passionately, building and growing the company to make it one of India’s largest home-grown CE brands. How has the journey been?

Puzzolana Machinery Fabricators was incorporated in 1964 as an equipment manufacturer of mini cement plants. In 1998, we started manufacturing 100-200 and 300 tph jaw and cone crushers as well. However, till 1998, we were doing fabrication and structures, cement plants, etc, but not of the highest technology and quality. In 1999, we decided to foray into the crushing space, which we believed had a lot of scope for innovation and growth, and where we could also give the customer considerable cost saving. So, our journey really began as an attempt to fill a need for quality products and effective solutions. We can proudly say that in the 50-year journey of Puzzolana, we have always tried to be a technology provider.

We had to work very hard to reach this stage where we are positioned as one of the largest and most cost-effective crushing and screening equipment manufacturers. Now, our plans are all firmed up to grow from the present level, organically as well as inorganically.

You are one of the very few entrepreneurs to be associated with the construction equipment industry for over 5 decades. How do you see the transformation of the CE industry over the years?

In the last 5 decades, the industry has definitely evolved, especially in the sphere of technology. From the early 70s up to the 90s, technology was being primarily sourced from the Western countries, and which we were using under license from the Western providers. Till the late 90s, the industry was moving slowly, but it was during 2000 that the country saw the establishing of Indian manufacturers. During 2003–2005, for the first time, the road sector began to take off in a big way. Right from stone to concrete, everything was being used to construct roads and highways. In 2007, the market picked up pace and began to experience rapid growth. Unfortunately, we saw recession after that!
Prakash Pai

Mr. Prakash Pai “At Puzzolana, our focus is on R&D for giving the right solutions to our customers. We are investing around 3% of our turnover in technology upgradation as we want to introduce many new products, and one day become India’s largest CE manufacturer and a billion-dollar construction group. For us, quality and innovation are the success factors behind Puzzolana’s many achievements and progress over the years.”
 

2014 onwards is the period of policies and visions of ‘Make in India’ and ‘Make India the largest manufacturer base’. There has been a very critical shift in the industry. Today, India is the manufacturing hub of the construction equipment industry and it is not only supplying to the local market but also to many parts of the world. This, I think, is the most significant change in the industry.

As a technologically sound company, what investments does Puzzolana make in R&D for introducing advanced products?

In our space, especially in crushing, I think three things speak: one is quality, second is service, and the third is new products. All of these should provide customized solutions to meet customer needs. At Puzzolana, our focus is on R&D for giving the right solutions to our customers. Our R&D includes finding solutions for small issues like how to cut down consumable costs by improving life cycle, and large issues like game changing environment supporting solutions such as developing the first Indian sander.

The sander has really changed the way the government and all our contractors look at river sand. Today, there is a ban in many cities on river sand and we are very proud that we have done some amount of innovation, which has greatly changed the way the industry approaches sand. Crusher dust or crusher files were being used in the past, but now we are making 100% sand plants. For us, R&D, quality and innovation are the success factors behind Puzzolana’s many achievements and progress over the years.

We are investing around 3 per cent of our turnover in technology and R&D as we want to introduce many new products, and one day become Asia’s largest CE manufacturer and a billion-dollar construction group.
We will add three more areas in our vertical and launch many new products such as our Milling machine at Excon 2017.

A word about your CSR initiatives?

We believe in giving back to the communities as these are a very keen part of our ecosystem. We have been educating 800-1000 students, free of cost, at a school called Vanitha Vidyala for the last 8 years. This school is in a small rural area near Warangal, a backward community. The students are encouraged to come and study as they get free food, and the good results speak for themselves. Many students have excelled in sports; one was even chosen for the Beijing Olympics, and some have ranked amongst the top 10,000 in the state. We have also created community centers and we hope to support many other noble causes within our capacity so that we can give back to society what it has given to us.

Puzzolana is keen on exploring global markets; what initiatives are being taken to enter new markets?

We plan to put Puzzolana on the path of becoming India’s largest, rather Asia’s, largest crusher manufacturer in the next two years. We want to be present in all the developing markets besides Asia, the Americas, and Africa. We want to be seen as a manufacturer of the best quality products with the best prices.In the next two years, we plan to be present in about 30 countries with a wide network of distributors, and allot at least 20 per cent of our business to exports. Currently, we have distributors in 10 countries and we are in discussions with another 10.

Puzzolana Plant

We are geared to offer market-centric solutions to meet diverse market needs, say Myanmar, which has different needs to that of Bhutan or Zambia, for instance. We are studying many markets closely to understand their requirements so that we can provide tangible solutions for their specific needs. One of the key takeaway of our efforts is our tie-up with Tata International for distribution in 6 countries. We have also tied up with one of JCB’s largest dealers in Muscat Overseas. Currently, our focus is on developing markets, but we will foray into other markets as well so that we can achieve our aim of growing threefold by 2020.
Abhijeet Pai

Mr. Abhijeet Pai “Our aim is to grow our business threefold in the next few years. By 2020, our target is to reach $500 million with a distribution network in 40 countries and to become Asia’s largest crusher manufacturer.”
 

Are you looking for any technolo-gical tie-ups or acquisitions to grow your brand further?

In the crushing industry, we have introduced many innovative products, the best example being our sander. There is enough technical knowledge and expertise within our Group to develop advanced technology in-house, so we are not looking for any technological tie-ups. But as regards products other than crushers, we would like to explore opportunities for acquisitions to broaden our product portfolio, so that we can become a total solutions provider for our customers.

How do you view the status of the construction and mining industry of India?

I think the market in India for the last one and half years, has been very promising, and the industry is bound to grow, even double in the next 3 to 4 years, as construction will see a huge jump. The McKinsey reports of the past will result in solutions of tomorrow. We are very bullish about the market and we believe that in the 3-year horizon, Puzzolana will stand to gain considerably with the large-scale push that the government is trying to give the construction and mining industries, especially construction.

What would be the impact of GST on the construction and mining industry?

We believe that GST is a welcome step, but I also believe that GST has a lot of clarifications to give. There are many small issues, like the crusher, for instance, has a differential GST, but going forward a year from now, once all the standards have been prescribed, GST will be a growth driver for the industry. I believe that the Indian economy will have a 1-2 per cent additional growth opportunity with GST, especially for us in the crushing/construction space.

What is your vision and plan for 2020?

Vision 2020 is very near to our heart. In the last 2 years, we have grown by 50 per cent in one year, and by 110 per cent in the next. Our target by 2020 is to be one of the largest crushing and mining equipment manufacturers in the Asian region, and to add at least three new business verticals other than crushing; these should also have the same growth trajectory as our crushing business. We estimate that our sales should be touching USD 500 million by 2020.

What can customers look forward to from Puzzolana this year?

We are always adding new products and there is already a huge number of products in the pipeline. Customers can look forward to a family of 3 sets or 3 areas that will be added, and they will see some of them in the mega construction show Excon in December this year. We will be launching our Milling machine at the show besides many other new products, but our customers will have to wait for the show to see them first hand!

For us, our customers come first, so we strive to offer them the best products at the best price. We never compromise on quality and service . Our machines have to be operational always, and we are always doing R&D to upgrade our products. We want to offer products that give customers the right solutions as per their specific needs.

Products & Solutions
Puzzolana offers a wide variety of solutions for mining, construction and infrastructure development.


Aggregate & Sand
Puzzolana is engaged in developing machinery for Infra Industry for aggregates and sand for over 50 years. Capacities range from 100 TPH to 1200 TPH, crushing and screening plant with two/ three/quadra stages with Jaw Crusher, Cone Crusher and Vertical Shaft Impactor, Sand crushers for both concrete and plaster sand, energy-efficient circular, linear and high-speed vibrating screens, Grizzly and vibro feeders, Sand classification with wet type and dry type classifiers.

Jaw Crusher
Jaw Crusher
Puzzolana offers a complete range of single toggle jaw crushers for all types of rock, ores & minerals. Crushers can operate in the most rugged environments and need less maintenance. Available in 14 sizes 30” x 20” to 72” x 60” – up to 1000 TPH.

The heavy-duty single toggle jaw crushers have an upward facing toggle system. This produces a Flat Elliptical Movement at the bottom of the swing jaw, which increases efficiency of the crushing. The Unique Elliptical motion of the swing jaw guarantees a highly efficient production rate at every setting. The special motion of the jaw also minimizes scrubbing action common in single toggle jaw crushers. The design also permits an extra-long jaw length, which means more crushing strokes giving a high ratio of reduction.
 

Tracked Crushing & screening machines
Puzzolana has launched a new range of track mounted crushers with Primary Jaw Unit, Secondary Cone Unit, product segregation through Screening unit. For fine aggregate production, a Sander unit in capacities of 250TPH of (-) 40mm production.

Tracked Crushing & screening machines

The Puzzolan units are of Diesel – Electric tracked crushers & screens which have been developed and manufactured for the first time in India. The drives are all electric motors (except for track – hydraulic) and powered by a diesel generator. The equipment delivers higher productivity with lower cost per ton due to higher fuel efficiency and lower cost of maintenance. With its foray into track plants, Puzzolana has put in place an exclusive dedicated product team with expertise in training in operation and maintenance of track machines.

Cone Crushers

Cone Crusher


Puzzolona Cone Crushers are of Bearing Design in G & H Types with high capacity in relation to size and are used in secondary, tertiary and quaternary applications. The chamber design ensures constant product size throughout the life of wear parts (mantle & concave). Cone crushers are available in 21 models of various sizes in capacities of 50 to 500TPH.


In view of such a wide spread range and availability of multi chambers in each size of crushers, varying product sizes can be achieved depending on the need of customers. These crushers can be supplied with automation of lubrication, indication of vital parameters etc.
 

New Generation Vertical Shaft impactors
Vertical Shaft Impact Crusher

With the vast experience on Indian rocks, working closely and listening to the growing needs of customers, Puzzolana has designed and innovated the range and launched New Generation Vertical Shaft Impactors with strong body and heavy-duty bearings to suit the hard Indian rocks. Depending on the application, these VSI’s are not only used for shaping, but can also be used for crushing and production of shaped fine aggregates.

The VSI’s are available in 5 models in over 10 configurations in capacities up to 450TPH. The standard feature of New Gen VSI is with Du flow arrangement which allows the enhancement in capacity by 20-25% without increasing the motor power. The VSI can be supplied in Rock-On Rock or Rock on Metal designs with provision to interchange the configuration . Motors can be single/dual drive, Standard Impeller with three ports is optional with four ports and Open impeller depending on the applications. VSI can be supplied with automation of greasing, and indication of vital parameters.
 


High Frequency Screen
High Frequency Screen for separation of fine particles (1mm) and in production of Plaster Sand

High Frequency Screen

Sanders
Sanders

The requirement of manufactured sand as stipulated norms of International standards, led to the development of fine and super fine Cone Crushers of floating shaft & bearings design for high reduction and high capacity in relation to size. Puzzolana Sander, a slow speed and compression crusher, is available in three sizes and can accept a feed up to 40mm and produce sand (-)4.75mm with control on (-) 150 microns up to a capacity 50TPH.

Puzzolana has also introduced the Plaster Sander, which in association with dry classification, can produce plaster sand as per iS 1542. It is available in three sizes and can accept feed up to 25mm and CSS at 3-6mm setting and produce plaster sand (-)2.36mm with control on (-) 150 microns up to a capacity 40 to 50 TPH.
 

Surface Mining
Puzzolana PMM 2205 is an economic solution for selective surface mining. Built-in features ensure high quality product sizing and mixing, and level benches ensure minimal wastage and safe operation.

Surface Mining

Cement
Puzzolana also plays a major role in the raw material preparation / crushing of cement plants, especially Lime Stone and Dolomite up to capacity of 1500TPH. Its product range covers Primary Horizontal Shaft Impactors, secondary Impactors and Hammer Mills. For raw material storage, the company manufactures Stackers & Reclaimers for capacity up to 2000 TPH.

Dredging
The highly economical and performance oriented PMF Cutter Suction Dredgers come with superior technology and robust design and ensure reliable operation and efficient output.

Support Services
Puzzolana is a market leader in India with more than 3000 Plant Installations, almost double the number of plants supplied by the 2nd and 3rd leading MNCs. Prompt and efficient after-sales & service is the company’s major plus point over competitors. It has a wide network of dealers across all regions with offices located in all major cities and crushing zones, and stock points in major towns.

Puzzolana aims to become a Total Solution Partner by providing special services like Pre-Order Support, Parts Contract and Operation & Maintenance Contract. It also supports major equipment of the plants under the program Life Cycle Support to its customers so that they can focus on their core business of making road and dam projects, with a cap on the crushing costs.

Dealer / Distributor Network
Puzzolana has a widespread dealer network and offices in Hyderabad, Delhi, Bangalore, Mumbai, Kolkata and well-established Associates (Dealers /Stockists) in all states and mining zones like Nagpur, Pune, Ahmadabad, Kochi, Indore, Vijayawada, Gaya, Jaipur, Dimapur, Aizwal and Itanagar. Its export markets include UAE, Sultan of Oman, Saudi Arabia, Africa and Far East covering Malaysia, Singapore, Indonesia, Cambodia and Sri Lanka, Nepal, Bhutan, Myanmar, etc. The company is expanding fast in other world markets.

Milestones & Achievements
  • VIKAS RATNA award for excellent performance as SSI Industry in the year 1995.
  • Certificate of Export Excellence (reconstruction and earthmoving machinery panel – SSI) for Outstanding Export Performance during the year 2003-2004.
  • Highest rating of A+ by Crisil continuously every year showing the financial stability of the company.
  • MSME1 by Crisil indicating highest performance capability and high financial strength.
  • One Star Export House by Ministry of Commerce & Industries, Government of India.
  • Award for Outstanding Indigenous Machinery Manufacturer at Baucon Exhibition held at New Delhi.
  • Actudalidad 21st Century International Award for Prestige and Quality in recognition of Management Performance.
  • SKOCH Order-of- Merit for India’s Best SMEs – 2014.
  • A panel of eminent Judges from the industry voted Mr. Prakash Pai as PERSON OF THE YEAR 2016 (survey by The Equipment India magazine).
  • Patron of The council of EU Chambers of commerce of India, Mumbai.
  • A unique achievement of 35 Cone Crusher manufacture in one month
  • Dedicated to Indian Infra market with plus 3000 Plants
Puzzolana Conglomerate

Puzzolana Conglomerate

NBM&CW July 2017

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