Processing and Packing

We own and operate South Asia’s biggest, independent Fly Ash processing plant with a capacity of 1.2 million tons per annum

We have multiple operations across India, backed by long-term supply agreements with thermal power plants. Our investments demonstrate our deep focus and commitment to gainful utilisation of coal combustion products.

Nellore Operations (Andhra Pradesh, India)

Fly Ash Processing and Packing Plant at Sembcorp Energy India Limited (Owned and Operated by JAYCEE)

0 km from thermal power plant

35 km from Krishnapatnam Port

200 km from Chennai Airport

1.2 million MT per annum (200 MT/hour) throughput capacity for Fly Ash processing/ classification

Packing options include bulk, bulk bags/ FIBCs and small bags; all-season warehouse and direct loading; shipping in bulk (road and sea), break bulk and containers

Direct pipeline for raw material input; dynamic, multi-stage classifier for multiple grades of Fly Ash including Ultra Fine Fly Ash; complete automation with DCS + iMCC

Truck Loading Operations at APPDCL-SDSTPS (APGENCO)

0 km from thermal power plant

30 km from Krishnapatnam Port

200 km from Chennai Airport

500,000 MT per annum loading capacity; shipping in bulk (road and sea)

Mundra Operations (Gujarat, India)

Fly Ash Packing Plant at GIDC, Dhrub (Owned and Operated by JAYCEE)

25 km from thermal power plant

8 km from Mundra Port

11 km from Mundra Airport

100,000 MT per annum packing capacity for bulk bags/ FIBCs and small bags

Packing options include bulk bags/ FIBCs and small bags; shipping in break bulk and containers

Semi-automated packing; all-season warehouse and direct loading

Fly Ash Packing and Truck Loading Operations at Adani Power Limited

Facility Owned by Adani

0 km from thermal power plant

30 km from Mundra Port

28 km from Mundra Airport

250,000 MT per annum packing capacity for bulk bags/ FIBCs

Packing options include bulk and bulk bags/ FIBCs; shipping in bulk (road and sea), break bulk and containers

Semi-automated packing; all-season warehouse and direct loading

Truck Loading Operations at Coastal Gujarat Power Limited (Tata)

0 km from thermal power plant

35 km from Mundra Port

33 km from Mundra Airport

100,000 MT per annum loading capacity; shipping in bulk (road and sea)

Jaigad Operations (Ratnagiri - Maharashtra, India)

Fly Ash Packing Plant at JSW Energy Limited (Owned and Operated by JAYCEE)

0 km from thermal power plant

2 km from Jaigad Port

400 km from Mumbai Airport

200,000 MT per annum packing capacity for bulk bags/ FIBCs and small bags

Packing options include bulk, bulk bags/ FIBCs and small bags; shipping in bulk (road and sea), break bulk and containers

Automation with PLC-based control panel; all-season warehouse and direct loading

Dahanu Operations (Maharashtra, India)

Truck Loading Operations at Adani Electricity Limited

0 km from thermal power plant

166 km from JNPT Port, Mumbai

128 km from Mumbai Airport

150,000 MT per annum loading capacity; shipping in bulk (road)

Tuticorin Operations (Tamil Nadu, India)

Fly Ash Processing and Packing Plant

12 km from thermal power plant

15 km from Tuticorin Port

20 km from Tuticorin Airport

100,000 MT per annum packing capacity for bulk bags/ FIBCs

Packing options include bulk bags/ FIBCs; shipping in break bulk and containers

Processing/ classification of Fly Ash; all-season warehouse and direct loading

Note: Our Tuticorin operations are outsourced

Quality Control

Reliable product quality backed by technical product expertise has been the foundation of our reputation.

We are the first player to obtain CE quality certification for Fly Ash in India, and are an ISO 9001 certified organization. We take complete ownership of the product, and do not compromise.

All our products go through a stringent, quality control process before they are shipped. There are various quality control check-points, and we strive to maintain top-notch product consistency and reliability.

In order to achieve the highest possible quality standards in our industry and fully meet customer requirements, we:

  • Provide dynamic leadership and an open working environment that encourages active involvement of our employees together with a detailed understanding of our customers’ needs
  • Ensure all our staff work in a safe environment and have adequate on-going training to fulfil their job responsibilities
  • Ensure all testing equipment is regularly serviced and calibrated and that detailed tests are available for all deliveries
  • Build partnerships with our suppliers to ensure they are fully aware of how their actions can impact on our customers and long term demand of our products
  • Promote systems and processes that generate a quality culture and help us service efficiently our customers. This includes striving for international certifications and external audits of our quality control systems
  • Deal openly and fairly with our customers, suppliers, employees, and government.
  • Leverage knowledge from our partners and customers to ensure continual learning for our staff in all aspects of quality and service

We proactively and transparently inform our customers of any significant deviations in quality and ship only if acceptable. While we work hard to mitigate quality risks – in case there are unexpected surprises and challenges, we take complete ownership of our product and work with our customers to resolve issues.

Quality Policy

  • Embrace total quality in every aspect of its operation
  • Comply at all times with published product technical standards and relevant codes of practice
  • Continuously improve quality performance
  • Integrate quality considerations into the decision-making process at all levels
  • Communicate transparently and openly with producers, suppliers and customers
  • Work with independent, third party inspection and testing agencies as well as obtain global quality certifications such as ISO and CE to demonstrate commitment to quality
  • Share authentic historical data/ trends transparently with customers and help them make the right decisions

Coal Combustion Products (CEMGUARD®)

Quality Standards Available

ASTM C618 Class-F, AASHTO M295, DMS-4610, EN 450-1 (CE Marking + REACH), AS/NZS 3582, GB/T 1596 and IS 3812.

Fineness of Fly Ash is controlled and made as per required specification either by selective extraction from ESPs of thermal power plants, or by processing/ classification of the Fly Ash.

Quality Control Process

© 2021 - JAYCEE BUILDCORP LLP. All Right Reserved.

Blast Furnace Slag

Quality Standards Available

ASTM C989, EN 15167/ BS 6699 and IS 16714/ IS 12089.

Granulated Blast Furnace Slag (GBFS) is produced through an advanced granulation process in steel plants, and ground to a controlled fineness in a state-of-the-art grinding mill to produce Ground Granulated Blast Furnace Slag (GGBFS).

Quality Control Process

© 2021 - JAYCEE BUILDCORP LLP. All Right Reserved.

Packing in Bags

Customers often under-estimate the importance of bag quality for Fly Ash and GGBFS. Both these products are hygroscopic - they absorb moisture from the air which causes lumps and creates difficulties in handling. Standard bulk bags/ FIBCs and small bags are not adequate, as even a small moisture seepage can cause lumps. We do not compromise. Therefore, we use special custom-designed, high quality bulk bags/ FIBCs and small bags with a high-GSM PP fabric, inner liner and/ or full body lamination, UV resistance and fool-proof sealing with no leakages, to ensure our product quality is maintained during transit and handling. The bag design provides protection from moisture and external elements, thus extending the shelf-life of our product.

Our bulk bag/ FIBC loops are strong enough to withstand multi-handling, and can be stacked up to 6 layers for break bulk shipments.

A high quality bag (bulk bag/ FIBC or small bag) is not the cheapest, but it saves potential losses in the downstream supply chain.

Weight of bulk bags/ FIBCs
1.35-1.50 MT +/- 2%

Weight of small bags
25 kg/ 40 kg/ 50 kg

Supply Chain

Our ShipRight Supply Chain is multi-model, all-weather, robust and reliable, backed by significant investments in infrastructure and handling capabilities.

We are the pioneer in large dry bulk Fly Ash shipments from India. For our products, supply chain constitutes 50-75% of the delivered cost and therefore, we are continuously improving supply chain efficiencies to optimize costs for our customers.

Large and Small Dry Bulk Shipments

All dry bulk loading equipment (including compressors and 1600+ tools, tackles, mechanical and electrical items) engineered, fabricated/ procured and owned by JAYCEE. Complete stevedoring operations managed in-house, with pollution-free loading.

Conditioned Ash/ FBA/ GBFS Bulk Shipments

Break Bulk Shipments in Bulk Bags/ FIBCs

Containerized Shipments in Bulk Bags/ FIBCs and Small Bags

All-weather, warehouse stuffing of containers, with complete operations managed in-house by JAYCEE. All forklifts owned by JAYCEE.

Bulk Container Liner Shipments

Bulk container liner loading equipment engineered, fabricated/ procured and owned by JAYCEE. All-weather, warehouse stuffing of bulk container liners, with complete operations managed in-house.

Own Fleet of Bulker Trucks and Body Trucks

We use our own fleet and also employ third party transporters for bulker trucks and body trucks. Body trucks are used for small bags domestically, which can be used in small projects and site mixes.

Weight Check: The weight in all modes above is ascertained accurately by computerized weight receipts at the point of loading.

Storage Warehouses for Bulk Bags and Small Bags

Technical Consulting

Our UseRight Technical Consulting service helps customers exploit the full potential of our products in various use-cases, improve concrete performance, lower cost of construction and optimize supply chains.

Our in-house technical team with many decades of industry experience and expertise provides world-class support and solutions to our customers.

Use-Cases & Applications

  • Understanding how coal combustion products and blast furnace slag can be used in multiple use-cases, applications and value-added products
  • Project design using coal combustion products and blast furnace slag
  • Manufacturing and use of value-added products

Concrete Mix Design

  • Mix-design optimization for various projects/ applications
  • Achieving lower cost of concrete and construction using coal combustion products and blast furnace slag
  • Improving rheology of concrete, reducing heat of hydration, increasing durability and ASR resistance
  • Use of Ultra Fine Fly Ash to replace Silica Fume/ Ultrafine Slag

Supply Chain

  • Using multiple modes of shipment (bulk, break bulk and containers) as well as roads and railways
  • Setting up robust and reliable supply chains for large projects and cement producers
  • Material handling, bagging and de-bagging solutions
  • End-to-end bulk supply chain solutions

Blended Cement

  • Designing and setting up blending plants for cement producers to produce blended cement with coal combustion products
  • Creating new products, increasing capacity and lowering cost with blended cements
  • Lowering production costs, improving performance and reducing carbon footprint

Technologies for Ash Beneficiation and Power Plants

  • Ash conditioning
  • Ash classification
  • Carbon and ammonia removal
  • High carbon return to thermal power plants
  • Drying technologies for slag and ash
  • Flue Gas Desulphurization (FGD) plants

Total Ash Management

JAYCEE offers ‘Total Ash Management’ solutions to coal-fired thermal power plants to help them recycle and utilize all by-products such as Fly Ash, Furnace Bottom Ash and Pond Ash.

With a partnership driven, value-sharing approach, we offer a number of solutions based on successful global benchmarks:

  • Designing, engineering, operating and maintaining ash collection and handling systems as well as storage infrastructure
  • Managing health, safety and environmental compliance, including landfill and ash-pond management
  • Developing ash beneficiation systems and technologies
  • New product development
  • Product testing and analysis, quality control and assurance services
  • Marketing and sales of ash and ash-based products for cementitious and non-cementitious applications
  • Local and export logistics
  • Managing man power and training

Such an approach helps power plant reduce landfill, realize value from ash and comply with environmental regulations for ash utilization.

Headquarters

709, Hubtown Solaris, NS Phadke Road
Andheri (East), Mumbai - 400 069
Maharashtra, India
Tel: +91 22 6716 3900
Domestic Sales: +91 98705 55167
International Sales: +91 79776 10128
Email: hello@jaycee.com
Careers: hr@jaycee.com

We’ll be glad to hear from you.