1. Company overview & snapshot

JK Cement’s Nimbahera–Mangrol cluster is a strong process and relationship fit. Integrated cement production combines continuous kiln systems, very large mill drives, fans, crushers, conveyors, captive thermal generation and waste-heat recovery. Manish Toshniwal owns both sites, while Yagyesh Gupta and Sameer Bharadwaj publicly participate in the NCB–IIT Roorkee–JK Cement carbon-capture collaboration. The account is still only 8/10: group revenue exceeds Stamped’s sweet spot, JK Cement has ISO 50001 and mature energy programs, and corporate procurement can slow a plant proof. The narrow wedge is owner-assigned closure of a mill/kiln/WHR cost deviation—not energy monitoring or decarbonisation consulting.

1.1 Legal identity & corporate structure

JK Cement Limited is a listed Indian public company, incorporated in 1994 as the corporate vehicle for a cement business whose Nimbahera operations began in 1975. It trades on NSE under JKCEMENT and BSE. The company is associated with the Singhania promoter group and is headquartered through offices in Kanpur and Gurugram. Legal identifiers should be taken from the current invoice/annual report before contracting; this dossier does not rely on an aggregator CIN.

The company operates grey cement, white cement and wall-putty businesses in India and international/subsidiary capacity. FY2024-25 integrated reporting shows consolidated grey-cement capacity of 24.34 MTPA, white cement and putty capacity of 3.05 MTPA, and revenue from operations of ₹11,093 Cr. These are group figures, not Nimbahera or Mangrol allocations.

For sales, distinguish JK Cement Works Nimbahera, JK Cement Works Mangrol, the Bamania captive-power assets, the Jharli grinding unit in Haryana and other plants/subsidiaries. The first 90-day scope should have one legal electricity account, one plant sponsor and one finance owner. A cluster-level sponsor can support later replication but should not blur meter boundaries.

1.2 What they make & where money comes from

JK Cement manufactures grey clinker and cement, white cement and value-added building products. Nimbahera and Mangrol are integrated grey-cement plants in Chittorgarh district with limestone mining, raw-material preparation, pyroprocessing, clinker handling and cement grinding. Company materials also identify multiple integrated plants and grinding units across Rajasthan, Karnataka, Madhya Pradesh, Haryana, Uttar Pradesh and other states.

The Mangrol environmental-compliance report describes an integrated scope of 5.65 MTPA clinker and 7.05 MTPA cement, with captive coal-based power and WHR. A Nimbahera legal proceeding references environmental clearance for expansion to 5.2 MTPA clinker, WHR changes and a reduction in captive-power capacity. Treat these as project-specific permitted scopes and verify current operating capacity rather than adding them to group capacity.

Cement economics depend on clinker factor, fuel, electricity, logistics, limestone, additives and utilisation. Kiln thermal energy is usually larger than electrical energy, while grinding, fans, crushers and conveyors dominate electricity. A Stamped program should keep fuel/thermal and electrical savings separate, then reconcile both only where the action affects both. Product quality, kiln stability and dispatch must not be traded for a lower peak.

1.3 Plants, addresses & footprint

The target plants are JK Cement Works, Kailash Nagar, Nimbahera 312617, District Chittorgarh, Rajasthan and JK Cement Works, Village Mangrol, Tehsil Nimbahera, District Chittorgarh, Rajasthan 312620. Industry directories publish Nimbahera numbers 01477-220087/220098 and Mangrol 01477-246324; these should be verified against current company routing.

Nimbahera is the legacy integrated plant. Mangrol is a large integrated expansion site and the location tied to the IITR-linked CCU collaboration in internal research. Bamania captive thermal power and WHR history are part of the Rajasthan cluster’s energy narrative. The practical pilot recommendation is Mangrol because Manish Toshniwal has direct unit authority and the institutional bridge is specific enough to request an introduction to electrical and commercial owners.

Jharli in Jhajjar, Haryana is a grinding unit under plant head Gopal Gupta and provides an alternative North India grid-bill use case. It has a simpler process and likely clearer DISCOM boundary but lower thermal-process richness. Current NGT scrutiny at Jharli makes it a sensitive opening and a poor unsolicited “efficiency” target until the regulatory context is understood.

1.4 Leadership & CRM map

Manish Toshniwal, Vice President & Unit Head — Nimbahera and Mangrol, is the primary plant sponsor. His profile describes direct operating responsibility for both plants and strategic leadership in operational excellence and sustainability. He is named in the NCB–IITR–JK Cement CCU project. LinkedIn: https://in.linkedin.com/in/manish-toshniwal-7a8992241. manish.toshniwal@jkcement.com is inferred and low confidence.

Yagyesh Gupta, Chief Manufacturing Officer / Manufacturing Head, Grey Cement, is an enterprise sponsor and publicly celebrated the NCB–IITR collaboration. LinkedIn: https://in.linkedin.com/in/yagyesh-gupta-14979b43. Public search results expose yagyesh.gupta@jkcement.com, which is a higher-confidence route than inferring Manish’s local part. Use it for warm routing, not mass cold email.

Sameer Bharadwaj, Head — Manufacturing Excellence, can assess repeatability and incumbent systems. Gopal Gupta, Plant Head — Jharli, is an alternate plant owner. The likely path is IITR institutional reference → Manish/Yagyesh routing → plant electrical/energy and operations owners → finance/AVVNL plus captive-power reconciliation → IT/OT/procurement. Do not call any of these leaders IITR alumni; the verified connection is institutional collaboration.

1.5 Recent news (24 months) & timing for Stamped

FY2024-25 marked JK Cement’s 50th year in grey cement. The company reported 51% green power mix, expanding renewable/WHR assets, alternative fuels and progress toward larger grey-cement capacity. In late 2025, public leadership posts referenced lighting up a second production line at Panna, illustrating continued group expansion and management attention on ramp-up.

The NCB–IIT Roorkee–JK Cement consortium received a DST-backed CCU project award for cement decarbonisation. This is a legitimate bridge: Stamped’s founders can reference the shared institution and ask how operating cost and energy evidence will support plant decarbonisation. It is not permission to claim an IITR alumni relationship or to lead with carbon.

Green power above 50% and a target of 75% by FY30 create a dispatch and verification question. WHR, captive and grid generation must be reconciled to actual production and bills. A mature plant may have the data but still lack a fast owner-level workflow across electrical, kiln/mill operations and finance. That is the hypothesis to test.

2. Energy profile

DISCOM / supply (name early): AVVNL (Ajmer Vidyut Vitran Nigam Limited) is the regional utility context for Nimbahera–Mangrol; verify each account, voltage and open-access/captive arrangement from the invoice.

2.1 Bill band, tariff & demand

No current AVVNL invoice, sanctioned demand or grid-import profile was found. An integrated 5–7 MTPA cement site with large mills and kiln auxiliaries is certainly above Stamped’s threshold. A planning net electricity/captive-cost equivalent of ₹15–₹40 Cr/month [~] per major integrated site may be reasonable depending on utilisation, captive/WHR generation and tariffs, but it is not a public bill.

The billing model must separate AVVNL energy and demand charges, open-access or renewable settlement, captive thermal variable cost, WHR near-zero marginal energy, banking, PF/reactive charges and duties. Gross “grid bill saved” is invalid if a captive unit burns more coal. Ask for three invoices, generation statements and 15-minute import/feeder data.

MD may spike when raw mill, cement mill, crushers and large fans overlap during starts or after trips. Continuous kiln requirements constrain load movement; cement grinding and selected auxiliaries may be more flexible. Contract-demand optimisation should follow observed import, not group capacity.

2.2 Generation, fuel & renewables

JK Cement has a long history of captive thermal and WHR. FY25 group reporting cites 77.50 MW captive coal-based power and 184.14 MW green power across the portfolio. Those are group numbers. Mangrol’s compliance report references 35 MW coal-based captive power and 20 MW WHR within a 60 MW described power scope, with an amendment to expand WHR to 30 MW. Nimbahera documents reference WHR and captive-power changes.

Thermal kiln fuel—coal/petcoke and alternative fuels such as RDF, biomass and other wastes—is economically separate from electrical generation fuel. Map both. WHR output depends on kiln operation and gas conditions; a lower WHR contribution may be a production/context issue rather than poor operation.

Renewable/open-access assets and group green-power mix need site allocation. Ask about solar/wind PPA profiles, banking, curtailment, forecasting and whether cement grinding can shift toward lower-cost/green windows without affecting silo and dispatch constraints.

2.3 EnMS, PAT, ISO, BRSR

JK Cement’s FY25 BRSR states policies aligned with ISO 50001:2018, ISO 9001, ISO 14001, ISO 45001 and ISO 27001. Confirm certificate scope for Nimbahera and Mangrol, but company-level evidence is strong. Cement plants are PAT/CCTS-relevant designated-consumer candidates, and the listed parent publishes BRSR with assured core indicators.

This means an energy manager, SEC reviews, meters and formal objectives likely exist. Stamped should ask how identified deviations convert into operating tasks and how savings are normalised and reconciled to AVVNL/captive cost. ISO evidence is a data-quality advantage, not a pain statement.

The IITR CCU collaboration creates a supporting decarbonisation narrative, but the purchase case remains ₹. A evidence-verified action ledger can later support EnMS, PAT and assured sustainability data.

2.4 Likely ₹ leak categories (hypothesis)

Likely electrical hypotheses are simultaneous starts/operation of raw and cement mills, crushers and large fans; mill operation outside efficient throughput/recirculation conditions; kiln and cooler fans at higher-than-needed load within process limits; compressed air; conveying, packing and loading idle operation; PF/reactive drift; and AVVNL import peaks when captive/WHR output falls.

Thermal hypotheses include kiln stoppage/restart losses, alternative-fuel variability and excess air, but Stamped should not enter combustion optimisation without reliable process tags and kiln expertise. The safest initial scope is electrical: import-demand sequencing, WHR/captive/grid dispatch, and auxiliaries during known production states.

The cross-functional gap is promising. Electrical controls supply cost, production owns mills and kiln, mechanical maintenance owns equipment, and finance validates bills. A named WhatsApp prescription can close a deviation faster. None of these hypotheses alleges current poor operation.

3. Operations, equipment & digital stack

3.1 Process flow & critical loads

The integrated route is limestone mining/crushing → raw-material proportioning and raw mill → preheater/precalciner → rotary kiln → clinker cooler → clinker storage → cement grinding with gypsum/additives → silos → packing and dispatch. Captive power, WHR, water, compressed air, material handling and pollution-control systems support the route.

Large electrical loads include raw and cement mill drives, kiln/cooler/ID fans, crushers, conveyors, bucket elevators, compressors, pumps, packers and pollution-control equipment. Kiln fuel dominates thermal energy. Process constraints include stable kiln chemistry, clinker quality, refractory protection, emission limits, mill product fineness and dispatch stock.

One pilot boundary could cover a cement mill plus separator/auxiliaries and production tonnes; or the site import meter plus captive/WHR output and scheduled flexible loads. Do not begin with kiln combustion control.

3.2 Shifts, seasonality, production pattern

Kilns run continuously through campaigns, with planned shutdowns for refractory and maintenance. Mills can be scheduled around clinker, silo levels, power availability and dispatch. Cement demand can vary seasonally with construction and monsoon; maintenance timing and product mix affect intensity.

Normalisation should include clinker tonnes, cement tonnes by grade/blend, mill operating hours, raw-material moisture/hardness, kiln availability, WHR generation and shutdowns. Grid import can rise when WHR falls because the kiln stops, even though production also falls. The model must explain causality.

A 90-day window should avoid or explicitly model major annual shutdowns. If seasonality is high, event-level peak and idle-hour savings are more defensible than gross monthly comparison.

3.3 Automation, metering, SCADA/EMS/DCS

Large JK Cement plants likely use DCS/PLC, process historians, weigh feeders, quality systems, energy meters and captive-power SCADA. ISO 50001 and public digital-ESG initiatives support high maturity, but named vendors/protocols were not verified. Do not guess Siemens, ABB or Schneider.

Path A is read-only export from EMS/historian for import, generation, mill/fan status, production and key process guardrails. Path B begins with approved CSV meter data, AVVNL/captive statements, daily production and event logs. No control writes or autonomous setpoint changes.

The data scope should be small enough for site approval: one-line diagram, tag list, meter resolution, cost rules and owner map. Every prescription should show evidence and excluded constraints, allowing operations to reject unsafe or impractical actions.

3.4 Capex / tech projects affecting energy

Mangrol WHR expansion, Nimbahera WHR/CPP configuration changes, renewable procurement, alternative-fuel systems and group expansion can all change baselines. Confirm commissioning dates, guarantees and current operating status. The company’s 51% green-power mix is group-level and should not be used as a site baseline.

Stamped can provide post-capex M&V: did a WHR expansion reduce paid import as expected after normalising for kiln availability? Are mills scheduled to use lower-cost power? It must not claim savings caused by the capex itself.

The CCU test bed may add new electrical/thermal loads at Mangrol. If operational during a pilot, meter it separately and treat research operation as a production-context variable.

4. Stamped Energy fit analysis

4.1 ICP scorecard

• Bill ≥ ₹30L/month: strong pass, exact bill/captive split unknown.
• Geography: pass, Rajasthan/North India.
• Vertical/process: strong pass, integrated cement.
• Revenue: near/fail sweet spot, ₹11,093 Cr is above ₹5,000 Cr but below mega-conglomerate scale.
• Data maturity: strong pass, ISO 50001/BRSR and power assets.
• Decision speed: medium, improved by two-plant unit head and IITR bridge.
• Champion: strong pass, Manish plant authority plus Yagyesh enterprise manufacturing sponsor.

4.2 Fit score rationale

The 8/10 score balances a large, measurable process-energy system and unusually relevant institutional route against mature incumbency and procurement. JK Cement is more commercially reachable than Tata Steel/Hindalco, but it still exceeds the intended mid-market revenue range. The account should progress only if Manish or Yagyesh identifies a plant-owned cost deviation and allows a bounded data review.

4.3 Wedge (parser-critical)

The strongest wedge is: at Mangrol, reconcile one mill/kiln-auxiliary demand event with WHR, captive and AVVNL cost; issue a process-approved ₹ prescription to a named owner over WhatsApp; and verify the result on the next power statement without replacing ISO 50001, EMS or DCS.

4.4 Objections & competitors

“We already have ISO 50001/EMS” should lead to an action-closure comparison. “More than half our power is green” does not remove peak, dispatch or idle-load economics. “WHR already gives cheap power” requires checking marginal import and scheduling. “Kiln stability comes first” is correct; keep all process guardrails and start with mills/auxiliaries.

Competitors are JK Cement’s internal energy/manufacturing-excellence teams, DCS/EMS vendors, captive-power and WHR OEMs, energy auditors, ISO consultants and enterprise platforms. Stamped is not qualified to displace kiln optimisation. It should prove workflow plus financial M&V on one electrical boundary.

4.5 Pilot design

Preferred site: Mangrol. Preferred scope: one cement/raw mill and its auxiliaries, or import/captive/WHR dispatch with two flexible load groups. Weeks 1–2: confirm invoices, generation, tags, production and constraints. Weeks 3–8: issue owner-approved prescriptions on start overlap, idle operation, PF or dispatch. Weeks 9–12: normalise and reconcile.

Success is at least one repeatable invoice/internal-cost saving with no loss of clinker/cement output, quality, kiln stability or emission compliance. Kill criteria are no data access, bill below threshold (unlikely), no controllable lever, commissioning distortion, or existing systems already provide equivalent closure. Rollout to Nimbahera or Jharli only after a verified Mangrol line.

5. Before you reach out

5.1 Discovery checklist

• Reference the NCB–IITR CCU collaboration accurately; do not claim alumni status.
• Confirm Manish Toshniwal’s current two-plant remit and preferred email.
• Use Yagyesh Gupta’s public address only for a targeted introduction.
• Obtain Mangrol/Nimbahera AVVNL invoices and captive/WHR generation statements.
• Confirm contract demand, PF, ToD, open access, banking and duties.
• Ask which ISO 50001 actions remain open or difficult to financially verify.
• Choose one mill/auxiliary or dispatch boundary with stable metering.
• Record cement grade, tonnes, mill hours, kiln availability and WHR context.
• Identify annual shutdown and recent WHR/CPP commissioning dates.
• Confirm DCS/EMS access, cyber approval and plant authority for a 90-day program.
• Ask finance to approve marginal-cost and savings rules before prescriptions.

5.2 Do not lead with

• Do not lead with carbon capture, ESG, green-power targets or an “IITR partnership” claim.
• Do not lead with dashboards, AI or a generic percentage-saving promise.
• Do not imply ISO 50001 or WHR is inadequate.
• Do not recommend kiln, fan or fuel changes outside process and environment guardrails.
• Do not treat group green power or capacity as Mangrol-specific.
• Do not target Jharli casually while the 2026 NGT matter is active.

5.3 Opening hooks (email / call / WhatsApp)

Institutional hook: “The NCB–IITR collaboration gives us a reason to ask a practical plant-cost question: how does one energy deviation close from data to owner to verified ₹?” Plant hook: “One Mangrol mill or import boundary, read-only, with kiln and quality guardrails fixed.” Sponsor hook: “If the existing ISO 50001 workflow already reconciles every action to AVVNL plus captive cost, the discovery call should disqualify us.”

6. Risks, flags, controversies & sources

• Top risk: JK Cement already has ISO 50001, WHR/captive expertise and manufacturing excellence; the institutional IITR link opens a door but does not prove an unmet need or shorten corporate procurement.

6.1 Integrity / controversy / regulatory (search explicitly)

In April 2026, the NGT took up allegations concerning JK Cement Works at Jharli, Haryana, including dust emissions, air/water pollution, open material handling and monitoring concerns. Public reporting states the tribunal asked the company and authorities to file replies for a hearing scheduled in August 2026; allegations are not findings, and this dossier draws no conclusion on liability.

A February 2026 Rajasthan High Court matter, Ramesh Chandra Kumawat v. State of Rajasthan, contains allegations and regulatory arguments regarding Nimbahera modernization, fly ash/dust and consent/environmental-clearance requirements. Extracted court material also records JK Cement’s position that configuration changes did not increase production/pollution load and references MoEFCC clearance for clinker/WHR/CPP changes. This is active legal/regulatory context, not proof of violation.

Mangrol’s October 2024–March 2025 six-monthly compliance report states that the project proponent reported no court case or violation under the EIA Notification for that project. Searches covered “JK Cement Nimbahera NGT,” “Mangrol RSPCB,” “Jharli pollution,” “lawsuit,” “show-cause,” “Yagyesh Gupta controversy” and 2024–2026 terms. No contact-specific controversy was found.

6.2 Data quality flags

• ₹15–₹40 Cr/month per site is an estimate, not an invoice.
• AVVNL is regional context; exact account and open-access/captive structure need bills.
• Manish Toshniwal’s email is inferred; Yagyesh Gupta’s public email is higher confidence.
• Plant phone numbers are directory-sourced.
• Capacity and power figures refer to different project/group scopes.
• ISO 50001 alignment/certification scope should be confirmed per plant.
• Litigation and NGT allegations must not be presented as adjudicated violations.

6.3 Sources consulted

• https://nsearchives.nseindia.com/corporate/JKCEMENT_27062025000022_finL_AR.pdf
• https://www.jkcement.com/
• https://www.jkcement.com/wp-content/uploads/2023/07/PLANT-Half-Yearly-EC-Comp-Oct-24-March-25.pdf
• https://cement.industry-report.net/j-k-cement-ltd-2/
• https://in.linkedin.com/in/manish-toshniwal-7a8992241
• https://in.linkedin.com/in/yagyesh-gupta-14979b43
• https://indiankanoon.org/doc/89449610/
• https://www.downtoearth.org.in/environment/daily-court-digest-major-environment-orders-april-17-2026
• leads/iitr-alumni/contacts.json and leads/iitr-alumni/batches/batch-02-chem-cement.md