It was the long cherished developmental dream of the State of Kerala established a significant leap when Malabar Cements Limited, the only Portland cement manufacturer in Kerala, was incorporated in April 1978, as a state Public Sector Unit. This Company, with a capital outlay of Rs.68 crores and a paid up equity capital of Rs. 26 crores, is fully owned by Government of Kerala. The Company is continuously running on profit.
Cement is the basic construction material of the contemporary era. During the 1970s cement was a controlled commodity and Kerala had to depend entirely on other states or foreign countries for its requirements/ supplies of this construction material. In fact, this was the stimulus behind comprehending this state owned cement manufacturing unit.
The Geological Survey of India (GSI) had identified a cement grade limestone deposit in the Walayar reserve forest way back in 1961-62. Later, the Mineral Exploration Corporation Limited confirmed its efficacy.
Despite its difficult terrain and perilous conditions at the deposit, the Kerala State Industrial Development Corporation (KSIDC) had engaged M/s. Holtec Engineers Pvt. Ltd., in 1975 to study the feasibility of putting up a cement plant at Walayar. And based on this study, KSIDC subsequently obtained an Industrial License for the manufacture of cement in November 1976. The Malabar Cements Limited thus came into existence at Walayar, the then remote and underdeveloped tiny village in the eastern boundary of the Palakkad District.
After periodic and incessant construction spree, the cement plant was commissioned on the 2nd of February 1984. The commercial production since then commenced on the 30th of April on the same year.
Malabar Cements Limited is a fully owned Government of Kerala Undertaking. It contributes to the development of the State by supplying the vital construction material factory fresh, within 12 hours anywhere in Kerala without
Malabar Cements was incorporated in April 1978 with a capital investment of ₹68.01 crores.At that juncture of history, Kerala was facing acute shortage of cement for its developmental works both at Government sector and private
At MCL, perfecting the product quality is the major concern of everybody. Now, we are all-equipped to set precedence among public sector units in the state. The launch of two Superior quality products under the brand name Malabar Super and Malabar Classic,
Malabar Cements is in the path of expansion. The ultimate aim is to increase the present market share at least up to 25%.
The proposals for expansion/ diversification include capacity improvement from 0.66 to 0.8 MTA and efficiency enhancement of Walayar Plant, setting up 1 MTA additional grinding facility at Walayar, utilization of Pet Coke in the place of coal and mill modernization at Walayar plant, setting up a bulk cement and other raw materials handling hub at the Cochin Port Trust land already taken on lease by the Company and setting up of Ready Mix Concrete Plants all over Kerala.
The objective of Malabar Cements Limited is to manufacture and sell best quality cement at affordable price to general public of Kerala and remain to be an important partner in the socio-economic development of the State.
Malabar Cements manufactures cement through the most modern dry process method based on world-renowned German technology. The major raw materials for cement manufacture are limestone and laterite, which are natural minerals obtained within the state. These raw materials provide all necessary ingredients of cement like lime, silica, alumina and iron oxide. The entire manufacturing process is computer controlled from a central control room and stringent quality control measures are applied at all stages of production.The state of the art pollution control measures like bag filters are also being installed. The process generally involves three stages of production.
The limestone obtained from captive mines is enriched with quality limestone procured from nearby states as and when required. The raw mix normally contains 95% limestone and 5% laterite. The raw materials are crushed to around 20-25 mm size and the proportioned raw materials are ground in a ball mill in dry condition to a very fine powder. The resultant product is called raw meal and is stored in concrete silos where it is pneumatically homogenized to get a uniform product.
Clinker is produced in a rotary kiln, which is a cylindrical shell of 65m length and diameter 4.2m, lined with refractory bricks. The kiln is inclined at 3% and set rotating at a speed of 2 – 2.2 rpm. It is provided with a 4-stage multi cyclone pre-heater system through which the homogenized raw meal is fed to the kiln inlet by means of belt bucket elevators. The Kiln is fired with pulverized coal and maintained at a temperature of about 1450C. In the pre-heater and kiln, the raw meal undergoes a series of physical as well as chemical changes giving rise to the cement minerals. The resultant product in nodular form obtained from the kiln is called clinker. Clinker is immediately quenched in the clinker cooler to stabilize its properties and stored in the clinker stockpile.
Cement is produced by grinding clinker 3-5% gypsum in a closed circuit ball mill to required fineness. Gypsum is added to control the setting properties of cement. Grinding clinker and gypsum produces ordinary Portland cement (OPC). Fly ash / Slag at required proportion is ground along with clinker and gypsum to produce Portland Pozzolana cement (PPC) / Portland slag cement (PSC). The ground cement is stored in concrete silos and packed in 50kg bags using electronic packing machines.
Malabar Cements uses the state of the art, dry process technology for the manufacturing of super quality cement and the quality is much above the national standards. For Various applications, the company has grey cement brands viz, "Malabar Vega", "Malabar Super", "Malabar Classic", "Malabar Aiswarya" and the Sand cement brand "Malabar Drymix"
VEGA is a Special variant cement, also a portland pozzolana cement, while flyash is restricted to 18% thus gives Supreme changes to the cement quality!
A fabulous product in every sense: Super in strength, Wonderful in workability, Incredible in aging, Implausible in durability, and Fantastic in strength gain. An AMAZING performer!
Superior in its class, it offers better setting properties delayed initial set and early final set offering more working time and reduced observation time.
It brings prosperity in many ways. It increases the life of your structures by safeguarding against sulphate attack. Aiswarya offers high quality at reduced price.
Malabar Drymix is a Sand Cement and Special additive based modifier plaster. This ready to plaster is easy to use and binds better to the substrate.