Global Cement gets the details on Asia Cement’s Pukrang plant in Thailand, ahead of the field trip by delegates attending the inaugural CemFuels Asia Conference in Bangkok on 4 February 2026.
Global Cement (GC): Please could you introduce the Pukrang plant to our readers?
Ahmed Moustafa (AM): Asia Cement Public Company Limited (ACC), was founded in August 1989. Shortly afterwards, it started to build its flagship facility in Pukrang, Saraburi, to meet growing demand for high-quality cement in Thailand’s infrastructure and construction sectors. Today, the plant, 135km from Bangkok, is a cornerstone of Thailand’s cement industry.
Operations began in 1993 with the launch of the plant’s first production line. This had a design capacity of 2.0Mt/yr supported by a modern dry-process kiln system. In 1996, ACC introduced a second production line to boost the plant’s capacity to 5.0Mt/yr. This firmly established the Pukrang plant as one of the largest cement plants in Thailand.
ACC’s growth continued in 2003 through a merger with Jalaprathan Cement Public Company Limited, which added two more cement plants in Takli and Cha-am districts, increasing ACC’s total cement production capacity to more than 7.0Mt/yr.
GC: Please can you outline the production process, as it stands in 2026?
AM: Production at ACC begins in its own quarries, where high-grade limestone, clay, shale and laterite are extracted. Advanced drilling and blasting techniques ensure precise fragmentation of the rock, while heavy-duty excavators and haul trucks transport the raw materials to the crushing stations. The quarry delivers 5.5Mt/yr of limestone to sustain operations.
Once extracted, the raw materials undergo primary crushing to achieve uniform size of <80mm. Limestone is processed using Hazemag crushers with a capacity of 1200t/hr on Line 1, and Kawasaki crushers with a capacity of 1600t/hr on Line 2. Shale is crushed by a 500t/hr FLSmidth system on Line 1, while clay is crushed by Bedeschi equipment at 2 × 300t/hr on Line 2. After crushing, the materials are stacked and reclaimed using FLSmidth systems, ensuring a consistent chemical composition before grinding.
The crushed materials are then finely ground to produce raw meal. On Line 1, Fuller mills operate at 2 × 240t/hr, while Line 2 uses Loesche mills with a capacity of 2 × 350t/hr. The ground raw meal is stored in silos with capacities ranging from 30,000 - 40,000t, which provides a stable and continuous feed for the kilns.
Line 1, equipped with Fuller technology, has a clinker capacity of 5500t/day, while Line 2, from FLSmidth, now reaches 8000t/day. Clinker coolers from Fuller (Line 1) and CPAG (Line 2) cool the clinker prior to storage in a huge 150,000t dome.
Finish grinding is taken care of using ball mills equipped with roller presses. On Line 1, Fuller ball mills with HRC technology operate at 2 × 170t/hr, while Line 2 uses FLSmidth ball mills with Köppern HRC technology at 2 × 270t/hr. The finished cement is stored in eight concrete silos, each with a capacity of 12,000t, along with two 1000t steel silos.
RotoPackers from Haver & Boecker handle the packing, with Line 1 operating four 100t/hr packers, and Line 2 using six 120t/hr packers. A Ventomatic palletiser handles 2000bags/hr. Bulk loading is facilitated by six lanes on Line 1 and eight lanes on Line 2.
GC: What recent projects or upgrades have there been at the plant?
AM: In 2024 ACC advanced its sustainability efforts with the Limestone Separate Grinding project, converting one finish mill into a dedicated limestone unit. This innovation enabled low-clinker cement production, reduced the clinker ratio by 3.5%, and reduced CO2 emissions by ~110,000t/yr, reinforcing ACC’s commitment to eco-friendly practices.
ACC also expanded its renewable energy portfolio in 2024 by commissioning a 20MW solar farm. It then added another 10MW of solar capacity in 2025. These projects, alongside a 21MW waste heat recovery system established in 2013, now supply 39% of the plant’s electricity from captive renewable sources. Together, they have reduced CO2 emissions by about 66,000t/yr, underscoring ACC’s commitment to cleaner, more sustainable operations.
GC: What types of fuel are used at the plant?
AM: Fuel preparation is handled by Loesche coal grinding mills, with Line 1 operating at 2 × 28t/hr and Line 2 operating at 2 × 40t/hr. In addition to coal, the plant is equipped with advanced alternative fuel (AF) feeding systems for the kilns’ calciners. These systems can handle solid, liquid and powdered fuels, offering exceptional flexibility to accommodate a wide range of AF. Various types of AF are fired, including biomass, refuse-derived fuels (RDF) and industrial wastes such as carbon black, waste oils, shredded tyres and chopped rubber.
Since 2006, the plant has expanded its use of AF, with a thermal substitution rate (TSR) of 27% in 2025. The plant now targets a TSR of >60% by 2030. To help, ACC installed a chlorine bypass system for Line 1 in September 2025. Built to handle high-chlorine fuels and prevent preheater blockages, the system will enable the use of more complex waste-derived fuels, helping to raise the TSR to 60% on Line 1. This will cut CO2 emissions by ~65,000t/yr.
GC: What emissions abatement systems are used?
AM: The Pukrang plant employs various systems to ensure compliance with stringent environmental regulations and to minimise its impact on air quality. Key systems include bag filters and electrostatic precipitators, which are installed across raw mills, coal mills, kilns and cement mills to capture particulate matter. These systems maintain dust emissions well below Thai and international standards. The plant also has continuous emission monitoring systems to ensure real-time monitoring and regulatory compliance of dust, NOx, SOx, and mercury emissions. Finally, low-NOx burners and combustion systems reduce NOx formation in the pyroprocess.
GC: What other environmental initiatives are being taken at the plant?
AM: Asia Cement remains deeply committed to reducing greenhouse gas emissions and advancing sustainability in line with both national priorities and international environmental commitments. The United Nations Industrial Development Organization, in partnership with the Thai Cement Manufacturers Association and the Royal Thai Government, is leading the Decarbonization of the Cement and Concrete Sectors in Thailand project. This initiative is supported by the Government of Canada through its Green Fund, under the Environment and Climate Change Canada agency.
As part of this effort, the Pukrang plant has been selected as the first candidate for a feasibility study and conceptual design of a mobile carbon capture unit, scheduled for installation in 2026. This unit will serve as a pilot, enabling testing and evaluation of the feasibility and performance of carbon capture technology within our production processes.
Furthermore, ACC plays an active role in the Saraburi Sandbox, a regional sustainability initiative designed to accelerate low-carbon industrial transformation. Through this programme, the plant works with government agencies, industry peers, and local communities to promote CO2 reduction technologies, increase the use of AF, develop renewable energy projects, and share best practices for circular economy and resource efficiency.
GC: What social initiatives is the plant involved with?
AM: ACC’s Pukrang Plant is deeply committed to creating shared value with local communities and advancing sustainable development beyond. The plant supports students in Saraburi province through scholarship programmes that provide financial assistance for higher education, while also improving school infrastructure by renovating classrooms, donating learning materials, and enhancing facilities. To promote community health and safety, it collaborates with local authorities on campaigns to reduce traffic risks around the plant.
In addition, the plant invests in skills development by offering technical training programmes that boost employability for students in technical schools and universities. Environmental awareness is fostered through community tree planting initiatives, and cultural and social engagement is strengthened by supporting local festivals, sports events and cultural programmes.
Market focus
GC: What types of cement are produced by the Pukrang plant?
Wanya Yangtara (WY): Asia Cement offers a comprehensive portfolio of products that serve diverse markets and customer requirements, from large-construction projects to specialised plasters. Our current range includes: Type I Portland Cement (OPC); Type III Portland Cement (High Early Strength); Type V Portland Cement (High Sulphate Resistance); Class G Well Cement (Grade HSR); Type GU Hydraulic Cement (CEM II/A-L 52.5N, CEM II/B-L 42.5R, CEM II/B-L 32.5R); Type HE Hydraulic Cement (CEM II/A-L 52.5R) and
Masonry and Plastering Cements.
Driven by a commitment to sustainability, we have consistently prioritised the development of ‘Go Green’ solutions designed to reduce CO2 emissions. Our Portland limestone cements exemplify this. These environmentally-conscious products accounted for 84% of our portfolio in 2025.
GC: Where are the plant’s main markets?
WY: The Pukrang plant primarily serves key markets across Metropolitan, Central, Western and Eastern Thailand, reflecting the strong demand for bulk cement driven by large-scale infrastructure and industrial projects in these regions. In 2025, our production units in Cha-am, Takli, and Pukrang successfully delivered products to over 60 provinces nationwide, underscoring our strong distribution capabilities and commitment to supporting Thailand’s development. All logistics are efficiently managed through a fleet of trucks, ensuring reliable delivery across our markets. With innovation at the core of our strategy, ACC continues to shape the industry by combining performance, sustainability and customer-focused solutions.
GC: How is the cement market in the Central Thailand region at present?
WY: The cement market in Central Thailand is experiencing a pronounced slowdown, primarily driven by weak private sector activity. Data from the Real Estate Information Center shows a substantial contraction in permitted residential construction areas, both low-rise and high-rise, alongside steep declines in industrial and commercial developments such as hotels, offices and retail spaces. These reductions, estimated at 20 - 40%, have directly suppressed cement demand, reflecting cautious private investment and slower initiation of new projects across the region. This pattern aligns with the broader nationwide market downturn.
Government infrastructure projects continue to provide some support, but their pace slowed in 2025 compared to 2024. This sector remains insufficient to counterbalance private sector weakness. Crucially, the bulk of cement sales in Central Thailand stem from the private sector, particularly homeowners and small contractors, demand from whom is further constrained by falling purchasing power and flooding in parts of the region.
GC: What is the biggest threat to the Pukrang cement plant in the next five years?
WY: The biggest threats over the next five years are likely to arise from regulatory, economic, technological and environmental pressures. The Climate Change Act of 2 December 2025 will introduce carbon pricing mechanisms that will raise production costs. Stricter emissions standards may also require substantial investments in emissions abatement technologies and upgrades.
Economic uncertainty compounds these risks. Domestic growth remains subdued, projected at 2.0% in 2025, 1.6% in 2026, and 2.3% in 2027 (World Bank, June 2025), all below the 2024 level of 2.5%. Combined with global market volatility, this weak outlook is expected to dampen cement demand, particularly from the private sector. As a result, production capacity, sales and profitability will be constrained.
Technological developments add further pressure. Advances in smart construction are likely to optimise material usage and reduce cement intensity per project, gradually dampening demand. Environmental risks also loom large, with recurring flooding in Central Thailand threatening to disrupt construction schedules, delivery and production.
GC: What are the biggest opportunities for the plant over the same timeframe?
WY: The biggest opportunities for the plant also lie in the growing emphasis on sustainability and rising demand for low-CO2 cement. With consistent access to high-quality raw materials, the plant can ensure product reliability while positioning itself as a leader in sustainable cement production.
This shift is reinforced by public and private sector commitments to decarbonisation, creating a steady increase in demand and opening the door to stronger partnerships with clients who are actively seeking ‘greener’ solutions.
Thailand’s continued investment in transportation networks and industrial zones, particularly under the Eastern Economic Corridor (EEC), will further stimulate demand for construction materials in the central and eastern regions. Saraburi’s strategic location places the plant in an ideal position to capture this growth, serving both infrastructure projects and industrial estates. Central Thailand’s role as a manufacturing and logistics hub, with strong concentrations in automotive, electronics, food processing and construction materials, adds another layer of opportunity by connecting the plant directly to diverse sectors and their evolving needs.
Asia Cement is therefore ready to support Thailand’s infrastructure and industrial development by combining sustainability with strategic positioning. By delivering reliable and innovative products, the plant will not only consolidate its leadership in sustainable cement, but also build lasting partnerships with clients, empowering them to achieve their construction and transformation goals. Together with our customers, Asia Cement will drive a greener, more competitive future for the country.
GC: Thank you both very much for your time today and for hosting our field trip.
AM/WY: Thank you - We very much look forward to welcoming your delegates!
Ahmed Moustafa is the Plant Manager at Asia Cement’s Pukrang Plant, where he oversees operations, maintenance and strategic development. Beyond managing daily activities, his focus is on driving long-term sustainability and strengthening the plant’s competitiveness within Thailand’s cement industry.
As Commercial and Logistics Director at Asia Cement, Wanya Yangtaraw brings more than 30 years of experience within the company. Her work centres on optimising supply chains and commercial operations, with the goal of delivering superior products and services to customers across Thailand, while ensuring sustainable business growth.
