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The Free Library > Business and Industry > Business > Indonesian Commercial Newsletter > April 1, 2012
The Free Library > Business and Industry > Business, international > Indonesian Commercial Newsletter > April 1, 2012
The Free Library > Date > 2012 > April > 1 > Indonesian Commercial Newsletter
Clinker expansion by cement companies.
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BACKGROUNDS
The country's cement industry has expanded from year to year to follow the trend in the
development of the property and infrastructure sector. The largest consumers of cement in the
country are the housing sector.
In 2011, the country's cement production grew 14.4 percent to 45.2 million tons from 39.5
million tons in 2010. The production capacity was recorded at 56,8 million tons per year in 2011
or an increase of t 7.2% from 53 million tons per year in the previous year.
A number of cement producers are seeking to expand their capacity as some of the have been
operating almost at full capacity. In addition, demand for cement is expected to continue to
grow in the coming years. PT Indocement Tunggal Prakarsa expanded its production capacity
by 2.5 million tons to 21.1 million tons per year in 2011. PT. Semen Gresik increased its
production capacity by 600,000 tons to 9.7 million tons per year.
The capacity expansion is to keep pace with growing market demand to follow the economic
growth and brisker development. In addition some old and inefficient factories need
revitalization by replacing machines. Expansion of capacity would improve operation efficiency
and make factories more competitive in the market.
Small producers like Semen Kupang, Semen Baturaja, and Semen Bosowa seek to steal a
market share in area not covered by big producers such as in eastern Indonesia. Big producers
still concentrate in western part of the country mainly in Java which accounts for 55.2 percent of
cement consumption in the country. Sumatra is the second largest market of cement
accounting for 23 percent, followed Sulawesi and Kalimantan each accounting for 7% of the
total consumption.
A number of factors are also considered by investors in building cement factories like the
distance of location from market, transport facility and availability of energy or fuel.
Energy is an important factor as energy makes up a considerable part of the production cost.
Currently many investors seek to use cheap secondary energy to fuel cement factories.
Currently a critical factor considered in capacity expansion by cement producers is the
availability and the price of coal fuel. Cola has been the main fuel for cement factories. Investors
or cement producers have asked the government guarantee in coal supply before building new
factories. The country is one of the world's largest coal producers but most of its coal
production has been exported as the prices are better in international market. In addition many
producers have been bound by long term contracts with coal buyers abroad.
TYPES OF CEMENT PRODUCED
There are several types of cement produced in Indonesia. The main type is OPC (Ordinary
Portland Cement) or Portland Cement Type I which accounts for 80 percent of the country's
total production. Other types include composite and pozzolan cement.
PRODUCTION CAPACITY GROWING 7.2% IN 2011
Based on data at the Indonesian Cement Association (ASI), the country's production capacity
increased 10.5% to 53 million tons in 2010 from 47.9 million tons in the previous year. The
increase came from five producers expanding their production capacity with an investment of
US$ 645.6 million. The new production facilities on line in 2011 included a cement mill of
Indocement in Cirebon with a capacity of 1.5 million tons, and reconstruction of the 2004's
tsunami destroyed factory of Semen Andalas with a capacity 1.6 million tons in Aceh.
The capacity utilization of the country's cement industry averaged 79.6% in 2011. Privately
Article Details
Pri nter fri endl y Ci te/l i nk Emai l Feedback
Title Annotation: INDUSTRY PROFILE
Publication: Indonesian Commercial Newsletter
Date: Apr 1, 2012
Words: 8736
Previous Article: Development of infrastructure
pressing.
Next Article: Ceramic industry facing problem
over limited supply of gas.
Topics: Building materials industry
Cement industry
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The capacity utilization of the country's cement industry averaged 79.6% in 2011. Privately
owned cement factories now are largest in production capacity compared to factories of state
companies. They account for 60.5% of the total capacity with state companies having only
39.5% of the total capacity.
In 2011, the country's production capacity rose again to 56.8 million tons or an increase of
7.2%. The additional capacity followed expansion by a number of large producers including
France's.Lafarge which built a new factory of PT. Semen Andalas in Lok Nga, Mangrove Aceh
Darussalam which came on stream in March 2011 to replace one destroyed by the tsunami in
2004.
Lafarge invested US$300 million to build the new factory with a capacity of 1.6 million tons per
year. The factory needs 1.2 million tons of clinker per year.
In 2012, the country's production capacity is expected to rise 6.8 million tons to 63.6 million
tons with the construction of new factories by PT Semen Gresik Indonesia, PT Semen
Tonsasa, and PT Holcim Indonesia.
The industry ministry has required cement factories to reduce the use of clinker cutting the
content from 90% to 80% to be more energy efficient but not reducing the quality to be low SNI.
PRODUCERS
PT. Semen Gresik, Tbk (PT. SG)
PT. SG has 3 factories located in Tuban and Gresik with a production capacity of 9.7 million
tons per year. PT. SG has two ports special for cement in Tuban and in Gresik, 1 unit of
cement packing plant in Ciwandan, Banten and 11 units of buffer warehouse Java and Bali. In
2011 cement production PT. SG reached 9.7 million tons.
PT. SG acquired PT. Semen Padang (SP) and PT. Semen Tonsasa (ST) in 1995 to join in the
Semen Gresik Group (SGG) with 99.9% owned by SG.
SP is located in Indarung Padang, West Sumatra supplying cement mainly for Sumatra. It also
supplies cement for Java and exports part of its production mainly to other Asian countries. SP
has six cement packing plants in Padang, Medan, Banda Aceh, Batam, Jakarta and Banten.
SP also has 14 buffer warehouses a special cement port in Padang's Teluk Bayur, and in
Ciwandan of Banten.
SP produces various types of cement including Ordinary Portland Cement (OPC), Portland
Pozzoloan Cement (PPC), Portland Composite Cement (PCC), Oil well Cement (OC) and Super
Masonry Cement (SMC).
In 2011, its production totaled 6.2 million tons or an increase of 8.7% from 5.7 million tons in
2010.
ST located in Pangkep of South Sulawesi has three units of factories producing the types of
OPC and PPC. ST is the largest supplier of cement in eastern Indonesia including Sulawesi,
Kalimantan, Nusa Tenggara and Maluku, Papua. ST has 8 units of packing plant in Makassar,
Bitung, Samarinda, Palu, Banjarmasin, Ambon and Bali and 5 units of buffer warehouse. ST
also has cement special port in Biringkassi.
Currently the total production capacity of SGG is 20.6 million tons per year including PT.
Semen Gresik (9.7 million tons), PT. Semen Padang (6.3 million tons) and PT. Semen Tonsasa
(4.6 million tons).
In 2011, PT. SG set aside US$ 533 million for capital expenditure. The fund has been used to
build a new factories in Tuban, East Java and other factories as well as a power plant in
Tonsasa, South Sulawesi.
In 2012, PT. SG sets aside Rp5 trillion for capital spending. Around 20% of the fund would be
used to finance the construction of a new factory in Sumatra to cost Rp7 trillion to be disbursed
in three years of construction. The construction of the new factory will 70% financed with a bank
loan.
Cemex shares sold to Blue Valley Pte. Ltd.
A conflict between the government and CEMEX as co-shareholders of PT SG ended with
Cemex selling its 24.9 percent stake in SG to the Rajawali Group through its investment vehicle
company Blue Valley Pte. Ltd. at a price of US$ 337 million.
The Rajawali Group, which is owned by tycoon Peter Sondakh acquired the stake after the
government said it would not use its right to acquire the stake under conditional sale and
purchase agreement/CSPA) signed on 17 September 1998.
Under the agreement co shareholder was the first to receive the offer to buy shares for sales.
With the deal, Cemex also agreed to drop its lawsuit filed with an international arbitrage court
against the government.
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against the government.
Currently PT. SG is 51.01 percent owned by the government, 24.0% by Blue Valley Hodings
Pte and 24.09 percent by the public.
PT Holcim Indonesia Tbk
PT. Holcim Indonesia Tbk (HI) was, formerly known with the name of PT. Semen Cibinong.
Holcim acquired 77.33 percent of PT. Semen Cibinong in 2001. Its name was changed on 1
January 2006. HI has two factories--one in Narogong and another in Cilacap.
Holcim is the world's largest cement producer based in Switzerland. It has stakes in cement
factories in 70 countries in the world.
In 2011, HI operated a new factory in Tuban, East Java with a production capacity of 1.7 million
tons per year built with an investment of US$ 450 million
The cement production capacity of HI increased to 8.7 million tons in 2011 from 8.3 million tons
in 2010. Its production totaled 7.1 million tons in 2011, and most or 64% of the production is
disposed of on the domestic market with 36% for exports.
PT. Indocement Tunggal Prakarsa, Tbk (PT. ITP)
PT. ITP was established in 1985 by the Salim Group. In 2001, Heidelberg Cement Group from
Germany acquired the majority 65.14 percent stake through its subsidiary Kimmeridge
Enterprise Pte. Ltd. In 2003, Kimmeridge Enterprise Pte. Ltd transferred the shares of PT. ITP
to HC Indocement GmbH. In September 2006, HC Indocement GmbH was merged into
Heidelberg Cement South-East Asia GmbH which became the owner of PT. ITP.
ITP operates 9 factories in Citeureup, Bogor, the second largest unit of factories in the world, 2
factories in Palimanan, Cirebon, West Java and 1 factory in Tarjun, Kotabaru, South
Kalimantan. ITP produces various types of cement including PCC, OPC, OWC and White
cement. ITP is the only producer of white cement in the country.
By the end of 2010, the clinker production capacity of the company was 15.6 million tons per
year and its cement production capacity was 18.6 million tons per year. The operation of new
units of cement mill in Palimanan and Citeureup in 2011, brought the total production capacity
of the company to 21.1 million tons per year.
In 2008, Heidelberg Cement AG handed over its entire stake in ITP to Birchwood Omnia Ltd.
Therefore, shareholders of IPT now include Birchwood Omnia Ltd (51%), PT. Mekar Perkasa
(13.03%) investing public (35.97%).
PT. Lafarge Cement Indonesia
It was formerly named PT. Semen Andalas Indonesia, before it was destroyed by tsunami late
2004. In 2007, a replacement was built for its factory. During the time that it could not produce
cement it imported cement from Lafarge unit in Malaysia to supply cement in Aceh and North
Sumatra, to maintain its market foothold in northern Sumatra.
In 2010, PT SA resumed operation and its name was changed with PT Lafarge Cement
Indonesia.
In 2011 the clinker production capacity of the company was 1.2 million tons/year and cement
production capacity was 1.6 million tons/year.
PT Semen Bosowa Maros (PT. SBM)
The factory of the company was built in 1995 and c came on stream in April 1999. PT. SBM is
owned by local tycoon Aksa Mahmud.
In 2007, PT. SBM completed the construction of a packing plant in Samarinda, East
Kalimantan.
By 2011, the clinker production capacity of the company rose to 1.8 million tons per year from
1.71 million tons per year in the previous year. Its cement production capacity also rose from
1.8 million tons to 3 million tons per year. The production capacity includes those of Semen
Bosowa Maros 1.8 million tons and Semen Bosowa Batam 1.2 million tons.
In 2011, the cement production of PT SBM totaled 1.9 million tons. The main market of cement
production of PT. BSM is eastern Indonesia.
PT Semen Kupang (PT. SK)
PT. SK is a state company coming on line in 1984 in Kupang, East Nusa Tenggara. In 2011, its
clinker production capacity was 300,000 tons per year, and cement production capacity was
570,000 tons per year. PT. SK is wholly owned by the government.
PT. SK has been outdated in technology that it is no longer competitive and efficient. The
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PT. SK has been outdated in technology that it is no longer competitive and efficient. The
company then built a new second factory, but it still could not operate efficiently. The company,
therefore, was facing financial problem and was forced to stop operation. By the end of 2007,
PT. SK resumed operation with financial injection from the state budget of Rp 50 billion. The
fund was used as working capital and to buy new spare part for the new factory Semen Kupang
II and to pay for coal fuel from Kalimantan. The main market of PT. SK is East Nusa Tenggara.
PT Semen Baturaja (PT. SB)
PT. SB is wholly owned by the government. PT SB is located in Kota Baturaja, South
Sumatra having three packing plants in Ogan Komering Ulu (OKU), Tarahan (Lampung), and
Kertapati, Palembang.
In 2011, the production capacity of PT. SB was 1.250 million tons of clinker per year and 1.2
million tons of cement per year.
PT. SB produces Portland I with the brand of Semen Tiga Gajah. The basic material is
abundantly available in Baturaja. Its main markets are southern Sumatra including South
Sumatra, Lampung, Jambi and Bengkulu and Banten in Java.
SB plans to sell 30% of its share through initial public offering (IPO). It hopes to raise Rp1
trillion from the share sales planned in 2013. The fund will be used to build a new factory South
Sumatra with a production capacity of 1.5 million tons per year. The new factory is to maintain
its market foothold. It hopes to maintain its market share of 29% in the region in 2013. The new
factory will need an investment of Rp 2.35 trillion which will include Rp1.3 trillion in loan.
The company also built a new cement mill with a capacity of 300,000 tons per year to cost
around Rp 325 billion. The new mill built in its complex in Baturaja came on line in 2011.
ENERGY REQUIREMENT
Cement factories need large supply of energy in the process of production. Energy makes up
40%-50% of its production cost including for heating and power plant. Currently most cement
plants use coal for fuel. Coal consumption in the country, therefore, has increased rapidly.
Lately some cement factories begin to use charcoal or husk for fuel.
Coal consumption by cement industry in the country 2011 totaled 7.6 million tons. The
consumption is forecast to rise again in the coming years with more cement producers planning
expansion of production capacity. In 2010, there were five cement producers coming in line or
expanding capacity including PT. Semen Andalas Indonesia, PT Semen Padang, PT
Indocement Tunggal Prakarsa Tbk, PT Semen Gresik and PT Semen Tonsasa, which is
expanding capacity and building new factory with an investment of US$ 645.6 million to be
operational in 2012.
Most of the new factories will be built outside Java. The problem outside Java is shortage in
power supply forcing cement factories to build their own power plants to guarantee power
supply.
SG for example needed coal for 10 coal-fired power plants with a total capacity of 410
Megawatts (MW) operational in 2011. The power plants are needed to support its plan to
expand capacity until 2012. In 2012 the production capacity of SGG will be increased to 23.9
million tons.
SG has established a subsidiary PT SGG Energi Prima to be in charge of coal procurement for
its cement factories.
The entire factories of Semen Gresik Group needed 4.2 million tons of coal in 2011. This year
the requirement is predicted to rise with the growing number of its factories including new ones
in Tuban and Tonasa, Pangkep, South Sulawesi.
In long term the country's cement industry will increase the capacity of its power plants to 200
MW to support capacity expansion by 14.5 million tons, from 44.89 million tons to 59.39 million
tons in a 2015.
Indonesia has one of the largest coal reserves in the world that cement producers should not
worry about coal supply in the future, but most of the country's coal production have been
exported resulti8ng in constraint in coal supply in the country. In 2010, the country's coal
production totaled 275.2 million tons, and 188 million tons of which were exported. In 2011 the
coal production rose to 290 million tons, but supply on the domestic market was still short of
requirement.
PRODUCTION OF CEMENT TOTALED 45.2 MILLION TONS IN 2011
The country's cement production has continued to increase--reaching 45.2 million tons in 2011,
up from 39.5 million tons in the previous year or an increase of 14.4%.
The global crisis since late 2008, resulted in weak demand for cement in export market.
Indonesia has exported cement to Srilanka, Bangladesh, Maroco, Madagascar and Middle
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Indonesia has exported cement to Srilanka, Bangladesh, Maroco, Madagascar and Middle
East. Indonesian producers compete sharply in international market such as with Thai
producers.
In 2012, the country's cement production is forecast to reach 60 million tons with additional
production from a number of new factories.
PRODUCTION PER COMPANY
In 2011 all producers increased production to meet growing demand.
Production of ITP was recorded at 18.6 million tons in 2011 or an increase of 23.2% from 15.1
million tons in the previous year. However, exports by ITP declined to 25,300 tons from 28,300
tons because of high demand on the domestic market. ITP's market share also rose to 33.4
percent in 2011 from 31.8 percent in 2010 as a result of an increase in production from its new
factories.
Semen Gresik Group recorded an increase in production,--Semen Gresik to 9.8 million tons in
2011 from 8.9 million tons in 2010, Semen Padang surging to 6.2 million tons from 5.7 million
tons and Semen Tonsasa from 3.7 million tons to 3.9 million tons.
PT. Holcim Indonesia (PT. HI) recorded a sharp increase in production from 5.6 million tons in
2010 to 7.2 million tons in 2011.
PT. Semen Kupang and PT. Lafarge Cement Indonesia (formerly PT. Semen Andalas)
suspended operation in 2010 and 2011 on financial problem and process of rebuilding factory.
SEMEN GRESIK GROUP HAS A 4% SHARE OF THE MARKET
In 2009 the Semen Gresik Group (GSG) had the largest market share of 44% in the country.
GSG groups Semen Gresik with production of 9.8 million tons (with a market share of 21.7%),
Semen Padang with production of 6.2 million tons (13.7%) and Semen Tonsasa 3.9 million tons
(8.4%).
The second largest in market share was Indocement with production of 15.1 million tons or a
market share of 33.4%, followed by Holcim Indonesia with a market share of 15.7% or a
production of 7.1 million tons.
Other smaller producers included Semen Bosowa Maros producing 1.9 million tons (4.2%) and
Semen Baturaja 1.2 million tons (2.7%). Semen Andalas and Semen Kupang had no record of
production in 2011. Semen Andalas was still in the process of acquisition by Lafarge, and
Semen Kupang was beset by financial problem.
SGG, ITP and Holcim have continued to dominate the market.
EXPORTS--IMPORTS
Most of Indonesia's cement production is disposed of on the domestic market. A small part is
exported. In 2011, exports made up 2.5 percent of the total sales.
Exports in 2011 totaled 1.187 million tons down 59.1 percent from 2.904 million tons in 2010.
ASI said producers are not interested in exporting their production as the prices are not good on
tight competition in international market.
In 2011, Holcim Indonesia exported 78,300 tons of cement, the largest compared to exports by
other producers.
Exports by the SGG have been made mainly by PT. Semen Padang as it has better export
price. PT. Semen Tonsasa, another subsidiary of SGG, exported 76,800 tons in 2011. Total
exports by the SGG reached 96,000 tons or down 65.3 percent from 276,800 tons in 2010.
Semen Gresik has exported cement to South Africa and Middle East. Around 10% of SGG's
exports are made to the two regions, where SGG has established good market foothold. Semen
Padang exports cement to Sri Lanka, the Maldives and Bangladesh. Semen Tonsasa has
exported only to Timor Leste.
The largest countries of destination are in Asia. In 2010 and 2011, the largest countries of
destination were Bangladesh. Exports to Bangladesh totaled 520,600 tons in 2011, up from
451,100 tons in 2010. Bangladesh has imported cement from Indonesia since 2002.
Exports to Australia totaled 218,300 tons in 2011.
CEMENT CONSUMPTION IN 2011 TOTALED 47.9 MILLION TONS
Cement consumption in the country has continued to increase though the growth rate tended to
fluctuate to follow the economic trend.
In 2011, a high growth of 17.7 percent to 47.9 million tons was recorded in the domestic
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In 2011, a high growth of 17.7 percent to 47.9 million tons was recorded in the domestic
consumption of cement, up from 40.8 million tons in 2010. The surge in consumption followed
brisk property development. Demand also increased from infrastructure projects of the
government. The relatively favorable economic condition in 2011 contributed to expansion of
cement industry. Big property and infrastructure mainly toll road projects were built in 2011. The
government has number of big infrastructure projects under the program of Master Plan of
Acceleration and Expansion of Indonesian Economic Development (MP3EI). The condition
necessitated an increase in supply of cement in the country.
It is predicted that in 2012 cement consumption would grow by a higher rate than in 2011 with
the property and infrastructure sectors remain the largest consumers. This year cement
consumption is forecast to reach 54 million tons, or an increase of 12.7 percent.
Capacity utilization of cement industry is also expected to rise to 85%-90% from 80% in 2011.
CONSUMPTION GROWTH HIGHER IN OUTER REGIONS
Java has become the largest market for cement in the country. Java accounts for around 55.2%
of the country's cement consumption.
The highest growth of consumption, however, was recorded in Sulawesi in 2011--up 15.8%. In
2011 other regions outside Java such as Nusa Tenggara and Kalimantan also recorded a high
growth in cement consumption up 19% and 17% respectively .
The shift in growth from Java to other islands followed the brisker development of infrastructure
projects needing cement in the outer regions. Meanwhile, the growth of infrastructure projects
needing cement in Java has slowed down.
With the growing cement consumption in the country, the prospects of business in cement
industry are expected to remain good. In 2012, ASI predicted cement consumption in the
country would grow 10% - 12% to 54 million tons. The growth is attributable to property projects
mainly housing projects and infrastructure projects financed by the government. In 2013, ASI
predicted cement consumption would grow 10%.
RAPID EXPANSION
The growing consumption has encouraged producers to expand their capacity by building new
factories or expanding production capacity through optimization. Some producers build new
factories outside Java such as Sulawesi in Tonsasa, Maros, etc.
A number of new factories are expected to come on stream in 2013 and 2014.
PT Semen Gresik has built new factory with a production capacity of 2.5 million tons per year.
The new factory in Tuban, East Java, was built with an investment of Rp3.5 trillion starting
production earlier this year.
PT Semen Gresik Tbk is also building a cement factory in Manokwari, Papua, with a capacity
of 600,000 tons to cost around Rp1.2 trillion. It also plans to build a packing plant and a 150-
meter quay in that area that could be used by ships of 10,000 dead weight tons (DWT).
PT Semen Gresik Tbk has also built new factories, SGG-III, in Sumatra and SGG-IV in Java
each with a production capacity of 3 million tons per year, to cost Rp3.25 trillion (US$352.09
million) and Rp3.717 trillion (US$402.59 million) respectively.
PT Indocement Tunggal Prakarsa Tbk is building a new cement mill with a capacity 2 million
tons per year in Citeureup, Bogor, West Java to come on stream in 2013. In 2014, Indocement
hopes to start operation of a new factory in Bau-bau, Southeast Sulawesi with a capacity of 1.9
million tons per year.
The entire factories of Indocement have a total production capacity of 21.1 million tons per year.
The factories are located Citeureup, Palimanan, and Tarjun Kotabaru. It also has 17 factories
producing ready for use concrete in Jakarta, Bogor, Depok, Tangerang, Bekasi, and a number
of cities in Central Java with a total capacity of 1.3 million cubic meters per year.
Holcim Indonesia, a local unit of Holcim Ltd from Switzerland, the world largest cement
producer, also plans to increase production. Currently Holcim Ltd relies expansion on its units
in emerging markets in Asia and Latin America.
Holcim Indonesia plans to build a new factory with a capacity of 1.7 million tons per year. The
new factory to be built in Tuban, East Java, will cost around US$ 450 million. It will have a
loading and unloading port to be operational in the first half of 2013. The factory will support
market expansion by Holcim in East Java, Bali, Kalimantan, and Eastern Indonesia.
The new factory in Tuban will add to the production facilities and distribution systems Holcim
already in the country. Holcim already has two cement factories one in Narogong of West Java,
and another in Cilacap of Central Java. It also has a cement mill center.
Currently Holcim Indonesia has a production capacity of 8.3 million tons per year from its two
factories. The new factory will increase the production capacity to 10 million tons per year.
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factories. The new factory will increase the production capacity to 10 million tons per year.
PT Semen Baturaja plans to build a cement mill with a capacity of 300,000 tons per year to
cost Rp 350 billion. The factory to be built in Baturaja, South Sumatra, will come on stream by
the end of 2012.
Semen Baturaja cooperates with Loesche GmbH of Germany to provide the machines of the
cement mill at a price of 7.9 million euro. The machine could process ordinary Portland cement
up to 125 tons per hour and Portland composite as much as 130 tons per hour.
PT Semen Baturaja also plans to build a new cement factory with a production capacity of 1
million tons per year in the first phase to come on line by the end of 2012. The factory will be
built in Muaradua, Ogan Komering Ulu, South Sumatra over an area of 3,000 hectares with a
limestone hill that could supply it with the basic material over a period of up to 150 years.
Currently Semen Baturaja has three factories with a total production capacity of 1.250 million
tons per year, respectively located in Baturaja and Palembang, South Sumatra, and in Panjang,
Lampung.
In 2011, the Lafarge Cement from France acquired the entire shares of PT. Semen Padang,
which was then renamed PT. Lafarge Cement Indonesia (PT.LCI). In mid 2011 PT. LCI built a
new cement factory with a capacity of 1.5 million tons per year. The new factory was built with
an investment of Rp 5 trillion in Langkat, North Sumatra. PT. LCI chose the location in Langkat
as it has large reserve of basic material enough to supply it for 30 years.
PT. Semen Bosowa Maros (BSM) in 2011 started construction of a new factory with a capacity
of 1 million tons of cement per year. The new factory is located in Maros, South Sulawesi built
with an investment of US$70 million including the cost of buying a cement ship at a price of
US$ 50 million.
Currently SBM has factories in Maros and Batam with a total production capacity of 3.5 million
tons per year. The capacity addition from the new factory will bring the total capacity of the
company to 4.5 million tons per year.
There are also new investors in cement industry in the country. Siam Cement Group from
Thailand through local unit, PT Semen Jawa, built a new factory with a capacity of 1.8 million
tons per year. The factory is located in Sukabumi, West Java with an investment of US$300
million. The factory is to start operation by the end of 2012 and its entire production would be for
domestic consumption.
Anhui Conch Cement Company Ltd or Conch Group from China plans to build 4 factories in
Kalimantan and Papua with a total investment of US$ 2.35 billion.
China Trio International Engineering Co Ltd from China will build a cement plant with a capacity
of 1.5 million tons per year in Subang, West Java.
State Development and Investment Corp will build a cement factory in Papua with a capacity of
1 million tons per year.
A cement factory needs large power supply. Around 112 kWh (kilowatt per hour) are needed to
produce a ton of cement. An addition of capacity of 5.38 million tons, therefore, will need
additional supply of 602.56 megawatt (MW) of electricity. To support expansion of capacity,
cement producers have to build own power plants as supply from PLN is not always reliable.
PRICES
Energy is a major cost component for cement industry. An increase in energy price would push
up the production cost of cement.
The prices of cement on the domestic market rose 10 percent on the average early in 2012. The
increase in the electric tariff would push up the price of cement.
ITP has power plants to meet 20 percent of its total energy requirement. ITP has always
maintained the position of a price leader in main markets resulting in slower growth of the
company in sales especially when the prices are on the decline.
MARKETING
Cement marketing in Indonesia is determined by the location and the production capacity of the
factory. Location is determinant as the transport cost could be higher than the value of the real
cement when it is too distant to the market.
The production capacity of a cement factory is also determinant in the capacity to supply the
market.
Big producers including GSG plan rationalization of the market by dividing the markets
considering the transport cost and production cost. Market division would place PT. SG among
the SGS members as the main supplier for Java and the Riau Islands especially Batam.
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The Batam market is supplied from Tuban as the transport cost is 75 percent cheaper than from
Semen Padang.
Semen Tonsasa will strengthen its market foothold in Sulawesi, and eastern Indonesia and
Semen Padang will be the main supplier for export markets mainly East Asia and Middle East.
Buyers in East Asia and Middle East will be served Semen Padang.
The distribution system of SG is supported by 30 units of warehouse in strategic areas with 15
packing plants to facilitate distribution all over Indonesia.
Meanwhile, 95% of Holcim's cement production is disposed of in Java market amid the increase
in transport cost to outer regions.
Java is expected to remain the market target for cement producers on transport efficiency. In
2011, cement sales in Java totaled 26.5 million tons.
PT. Holcim Indonesia (HI) for the time being will concentrate on strengthening its market
foothold only in Java. After having two factories--in Narogong (Bekasi, West Java) and Cilacap
(Central Java--HI will build its third factory in Tuban, East Java to be completed in 2013. The
additional capacity will be used to supply cement to East java, Bali and Kalimantan.
Currently PT. HI is seeking to expand its market by strengthening its distribution systems.
HI is focused more on dealing with retail market than corporate buyers. Before being acquired
by Holcim, Semen Kujang concentrated marketing more on projects and Semen Nusantara was
focused more on retail market.
Semen Kujang, however, failed to expand as it was confronted with big competitors. After being
acquired by Holcim it has changed marketing focus to retail markets, although retail market has
also been crowded with brands belonging to big producers like semen Gresik of PT. SG and
semen Tiga Roda of PT. ITP.
HI offers franchise partnership to investors interested in cooperation to develop retail business
opening building material stores with the brand of Solusi Rumah. Consumers could consult with
the stores on designs of new houses or on renovation of houses. The house to be built using
Solusi Rumah is faster and 20% cheaper, HI said.
The investing partner could buy the franchise at prices ranging from Rp50 million to Rp700
million covering all consultation on house construction. The partners will be trained and they are
expected to recover their investment in 3.5 years. Until 2011, there were 270 outlets of Solusi
Rumah in Java. Under this concept HI targets to open new outlets to bring the total number to
400 units in 2012.
A subsidiary of HI, PT Holcim Betons, offers franchise system in concrete industry in Indonesia.
Investment needed to open a franchise is around Rp3.5 billion. With the investment an investor
could produce 24,000 cubic meters of concrete per year. HI also provides technical support to
run the concrete business. The investor is required to pay Rp150 million in joint fee in 5 years
and 2% of the nest sale.
COMPETITION
The GSG was the market leader in 2011 with a market share of 40.8 percent, followed by ITP
with a market share of 31.5 percent and HI with a market share of 15.5 percent.
In 2011, Semen Tonsasa, a member of the GSG had a market share of 7.9% dominating the
market in eastern Indonesia (KTI).
Producers having a market share of less than 15 percent with capacity utilization of less than
80% like PT. SB, and PT. BSM could still increase their market share by optimizing their
capacity.
However, such steps is effective only in short term especially as big producer like GSG also
plans to increase its production capacity to 23.9 million tons in 2012. Increasing market share
in long term could be made by expansion of production capacity such as planned by PT. HI.
With capacity of 20.6 million tons in 2011, GSG was the largest cement producer in the
country. In 2011, GSG had a market share of 40.8%. In 2012, GSG is set to increase sales by
15.3% to 22.6 million tons.
GSG and ITP remain close rivals in the market. ITP recorded an increase in sales to 15.1
million tons in 2011 from 12.6 million tons in the previous year. Sales by PT. SG in 2011 totaled
9.9 million tons up from 8.9 million tons in the previous year.
PROSPECTS
Cement consumption in the country is expected to continue to increase form year to year
especially there is substitute for cement. Demand will increase especially from the construction
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especially there is substitute for cement. Demand will increase especially from the construction
and property sectors.
Consumption is forecast to grow 6% a year to follow the trend of economic development. The
annual growth is quite healthy for the industry.
A number of big producers have drafted plan for capacity expansion until 2013 through
construction of new factories. Among the new factories is Tonsasa V of Semen Tonasa with a
capacity of 2.5 million tons to be operational in 2011, Tuban V with a capacity of 2.5 million
tons of Semen Gresik to be operational in 2012, Indocement to have a new factory with a
capacity of 1.5 million tons in Citeureup to be operational in 2012.
A cement factory needs to have a production capacity of 2.5 million tons per year to be feasible
at present. Investment per ton of production is US$ 125 that a factory will need an investment of
US$ 312.5 million.
Construction of a new cement factory will take 2 to 3 years depending on the capacity.
Investors will build a factory to be operational at a time when demand is at least level with the
country's total capacity. The positions of capacity and demand are expected to remain
unchanged for five years after the factory comes on line. Too large capacity will add burden in
maintenance cost and opportunity cost.
Based on assumption that demand for cement will grow 5 percent a year until 2015, with
exports 3.5 million tons a year, the production capacity of a factory 2.5 million tons a year and
capacity utilization averaging 95 percent, and capacity expansion needed every 2-3 years,
capacity expansion would be needed in 2013 and 2015 by 2 million-5 million tons a year.
Table-5
Types of cement produced in Indonesia
Type of Characteristic Uses
cement
Portland This type of cement is
Type I used for general
construction like
houses, multi storey
buildings, bridges,
roads, and as
feedstock for asbestos
and ferro cement.
Portland Better resistance to Used for buildings
Type II sulfate located in areas
closed to water such
as ports, quay, dams,
etc.
Portland Dry quickly and hard Used for buildings
Type III to sustain high needing strength to
pressure. sustain early high
pressure after casting
and fast completion
such as road
construction, bridges
and airports.
Portland Used for construction
Type IV which needs low
hydration heat such as
big dams, thick
concrete construction
in dry locations.
Portland Providing better Used for construction
Type V protection against of pools for chemical
corrosion from water industrial waste,
and soil containing buildings in sea,
sulfate more than etc.
0.20%
Oil Well Could harden normally Used for construction
Cement in oil wells having of oil and gas wells
high temperature having certain depth.
Portland Easily used, lower For general concrete
Composite Cement temperature in construction, with
building concrete will stone and bricks,
reduce cracks, the cementing, gutters,
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reduce cracks, the cementing, gutters,
surface of the roads, concrete
concrete smoother fences, pre stressed
, water resistant, buildings,
sulfate resistant and prestressed concrete,
having high capacity concrete panels,
to sustain pressure. paving blocks, etc.
Portland Resistant to sulfate For two-three floor
Pozzolan Cement and moderate hydration buildings, general
heat concrete construction
, mass concrete
construction like full
plate foundation and
dams, building
construction in
coastal areas swampy
area and buildings on
ground containing
aggressive sulfuric
salt and building
construction needing
high water tightness
such as sanitation
construction, water
construction and water
pools or reservoirs.
White Cement Bright color Used as material for
terrazo tiles, or as
cement for laying
ceramics and other
decorative ornaments
Super Masonry Housing construction Used in the production
Cement and water works with of hollow brick tiles,
concrete structure of paving block, and
not more than K225 floor tiles
Sources: Indonesian Cement Association (ASI), Data Consult
Table-6
Production capacity of Indonesia's cement industry,
2002-2011
Capacity ('000 tons/year)
Year Clinker Cement Growth (%)
2002 44,425 47,490 --
2003 44,425 47,490 0.0
2004 43,340 47,490 0.0
2005 42,690 46,090 -2.9
2006 40,730 44,890 -2.6
2007 40,730 44,890 0.0
2008 39,288 44,009 -1.9
2009 40,899 47,975 9.0
2010 43,257 53,010 10.5
2011 43,670 56,820 7.2
Rata-rata 2,1
Sources: ASI, Data Consult processed
Table-7
Factories owned by Semen Gresik Group
2011
Name of companies Number of Total production
factories (units) capacity (million tons)
PT. Semen Gresik 3 9.7
PT. Semen Padang 4 6.3
PT. Semen Tonsasa 3 4.6
Total 10 20.6
Sources : PT. Semen Gresik
Table-8
Shareholders' composition of Semen Gresik, 2011
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Shareholders' composition of Semen Gresik, 2011
Shareholders %
The Indon. government 51.01
Blue Valley Holdings, Pte 24.90
Public 24.09
Sources: Semen Gresik, Data Consult processed
Table-9
Shareholders of PT. HI
Shareholders %
Holcim 77.33
Public and creditors 22.67
Sources: Data Consult
Table-10
Factories owned by ITP, 2011
Name of factories Number of Total production
factories (units) capacity (million tons)
Citeureup 9 15,9
Palimanan 2 2,6
Tarjun 1 2,6
Total 12 21,1
Sources : PT. Indocement Tunggal Prakarsa
Table-11
Shareholders of ITP, 2011
Shareholders Number of shares (units) %
Birchwood Omnia Ltd 1,877,480,863 51.00
PT Mekar Perkasa 479,735,234 13.03
Public 1,324,015,602 35.97
Total 3,681,231,699 100.00
Sources: PT. Indocement Tunggal Prakarsa
Table-12
Cement producers in Indonesia and capacity, 2011
('000 tons)
Companies Coming Clinker Cement
on line
PT. Semen Gresik, Tbk 1957 7,880 9,700
PT. Semen Padang 1910 5,610 5,410
PT. Semen Tonsasa 1968 3,680 4,600
PT. Holcim Indonesia/ ex. PT. Semen 1975 6,400 8,700
Cibinong
PT. Indocement Tunggal Prakarsa, Tbk 1975 15,600 21,100
PT. Semen Bosowa Maros 1999 1,800 3,000
PT. Lafarge Cement Indonesia 1982 1,200 1,600
(formerly PT. Semen Andalas)
PT. Semen Baturaja 1980 1,200 1,250
PT. Semen Kupang 1984 300 570
Total 43,670 56,820
Sources: ASI, Data Consult processed
Table-13
Coal requirement for cement industry
Year Coal requirement
(million tons)
2008 6
2009 7
2010 7.6
2011 8.8
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Sources: ASI
Table-14
Indonesia's cement production, 2002-2011
Designed capacity Production
('000 tons/y) ('000 tons)
Year Clinker Cement Clinker Growth Cap. Util.
(%) (%)
2002 44,425 47,490 33,248 -1,9 75
2003 44,425 47,490 32,629 -1,9 73
2004 43,340 47,490 34,886 6,9 80
2005 42,690 46,090 34,004 -2,5 80
2006 40,730 44,890 34,970 2,8 86
2007 40,730 44,890 35,914 2,7 88
2008 39,288 44,010 37,680 5,1 96
2009 40,899 47,975 35,375 -6,1 86
2010 43,257 53,010 34,515 -2,4 80
2011 43,670 56,820 37,539 8,8 86
Production
('000 tons)
Year Cement Growth Cap.
(%) Util. (%)
2002 30,720 -1.2 65
2003 30,647 -0.2 65
2004 33,230 8.4 70
2005 33,917 2.1 74
2006 33,032 -2.6 74
2007 35,033 6.1 78
2008 38,303 9.3 87
2009 36,906 -3.6 76
2010 39,475 6.9 74
2011 45,237 14.6 80
Sources: ASI, ICN processed
Table-15
Production of cement by companies, 2010-2011
(000 tons)
Producers 2010 2011
PT. Lafarge Cement Indonesia -- --
PT. Semen Padang 5,676 6,152
PT. Semen Baturaja 1,131 1,241
PT. Indocement Tunggal Prakarsa Tbk 12,638 15,102
PT. Holcim Indonesia, Tbk 5,618 7,131
PT. Semen Gresik, Tbk 8,939 9,792
PT. Semen Tonsasa 3,661 3,887
PT. Semen Bosowa Maros 1,812 1,933
PT. Semen Kupang -- --
Total 39,475 45,238
Source: ASI, Data Consult processed
Table-16
Producers and market share, 2011
Producers Production Share
(million tons) (%)
PT. Semen Andalas --
PT. Semen Padang 6.2 13.6
PT. Semen Baturaja 1.2 2.7
PT. Indocement Tunggal Prakarsa Tbk 15.1 33.4
PT. Holcim Indonesia, Tbk 7.1 15.8
PT. Semen Gresik, Tbk 9.8 21.6
PT. Semen Tonsasa 3.9 8.6
PT. Semen Bosowa Maros 1.9 4.3
PT. Semen Kupang -- --
Total 45.2 100.0
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Sources: ASI/ICN processed
Table-17
Domestic sales, exports and imports of cement, 2002-2011
Total sales n ('000 tons)
Imports
Exports (000 tons)
Domestic Total Total
Year sales Clinker Cement Exports sales
2002 27,173 4,184 3,791 7,975 35,148 60
2003 27,528 4,270 3,073 7,343 34,872 11
2004 30,192 4,673 2,946 7,619 37,810 17
2005 30,432 3,407 3,289 6,696 37,128 1,055
2006 30,695 5,023 2,245 7,268 37,964 1,280
2007 32,763 4,873 2,929 7,802 40,565 1,410
2008 36,539 3,301 1,641 4,942 41,481 1,532
2009 37,029 2,797 1,219 4,016 41,045 1,383
2010 43,683 2,141 763 2,904 46,587 --
2011 49,162 959 203 1,162 50,324 --
Sources: ASI, BPS, processed by Data Consult
Table-18
Exports of clinker and cement by countries of destination,
2010-2011
(000 tons)
Countries of destination 2010 2011
Srilanka 440,5 61,2
Bangladesh 451,1 520,6
Malaysia 651,8 136,1
Mauritius 240,0 --
Ghana 286,4 --
Australia 322,0 218,3
Madagascar 112,9 7,4
Timor Leste 98,8 121,6
Sub total 2.603,5 1.065.2
Other countries 301,2 127
Total 2.904,7 1.192,2
Sources: ASI
Table-19
Domestic consumption of cement, 2002-2011
Year Domestic consumption Growth (%) Consumption
('000 tons) per capita (kg)
2002 27,233 --- 130
2003 27,539 1.1 130
2004 30,208 9.7 140
2005 31,487 4.2 144
2006 31,975 1.5 145
2007 34,373 7.5 156
2008 38,080 10.8 162
2009 38,420 0.9 166
2010 40,778 6.1 172
2011 47,999 17.7 200
Sources: ASI, ICN
Table-20
Domestic consumption of cement by provinces, 2009-2011
(000 tons)
Regions Provinces 2009 2010 2011
Sumatra 8.872 9.690 11.028
Aceh 958 877 854
North 2.317 2.55 2.717
West Sumatra 705 927 1.025
Riau 876 993 1.316
Riau Island 701 686 720
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Riau Island 701 686 720
Jambi 383 462 485
South Sumatra 1.159 1.212 1.422
Bangka Belitung 263 318 390
Lampung 1.021 1.141 1.504
Bengkulu 491 524 595
Java 21.126 21.920 26.515
Jakarta 3.529 3.707 4.630
Banten 1.837 2.005 2.779
West Java 5.479 5.737 7.061
Central Java 4.486 4.433 5.303
Yogyakarta 601 613 763
East Java 5.194 5.426 5.979
Kalimantan 2.436 2.872 3.361
West Kalimantan 554 638 846
South Kalimantan 631 713 838
Central Kalimantan 326 453 506
East Kalimantan 925 1.068 1.171
Sulawesi 3.003 3.046 3.527
West Sulawesi 38 68 345
South east Sulawesi 297 343 1.877
South Sulawesi 1.669 1.573 85
Central Sulawesi 396 419 482
North Sulawesi 472 493 574
Gorontalo 131 149 163
Nusa 2.174 2.335 2.779
Tenggara Bali 1.102 1.142 1.372
West Nusa Tenggara 647 626 682
East Nusa Tenggara 424 566 724
Maluku 802 914 791
& Papua Maluku 330 242 246
North Maluku -- 132 147
West Papua -- 28 37
Papua 419 511 361
Total Indonesia 38.413 40.778 47.999
Regions Provinces Growth Growth Growth
(%)2009 (%) 2010 (%)2011
Sumatra -0.5 9.2 13.8
Aceh -8.2 -8.4 -2.7
North 6.2 10.0 6.6
West Sumatra -12.0 31.5 10.7
Riau -2.1 13.4 32.5
Riau Island -7.9 -2.1 4.9
Jambi 3.6 20.6 5.1
South Sumatra 4.4 4.6 17.3
Bangka Belitung -0.1 20.8 22.9
Lampung -4.6 11.9 31.8
Bengkulu 14.6 7.0 13.4
Java 2.4 0.7 21.0
Jakarta -2.9 5.0 24.9
Banten -9.9 9.1 38.6
West Java 2.7 4.7 23.1
Central Java 9.6 -7.0 19.6
Yogyakarta -16.6 2.0 24.4
East Java 7.4 -2.2 10.2
Kalimantan -0.1 17.9 17.0
West Kalimantan -1.3 15.2 32.6
South Kalimantan 7.3 13.0 17.6
Central Kalimantan -10.1 38.7 11.6
East Kalimantan -0.2 15.5 9.6
Sulawesi 15.7 1.5 15.8
West Sulawesi -- 80.7 407.9
South east Sulawesi 17.3 15.3 447.8
South Sulawesi 21.4 -5.7 94.8
Central Sulawesi 8.9 5.8 15.0
North Sulawesi -0.4 4.5 16.3
Gorontalo 0.2 14.3 9.2
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Gorontalo 0.2 14.3 9.2
Nusa 7.8 7.3 19.0
Tenggara Bali 2.1 3.3 20.1
West Nusa Tenggara 13.4 -3.2 8.9
East Nusa Tenggara 14.7 33.6 27.9
Maluku -5.5 13.9 -13.5
& Papua Maluku -16..6 -26.5 1.5
North Maluku -- 213.2 11.1
West Papua -- 142.1 33.4
Papua -7.6 22.1 -29.5
Total Indonesia 2.6 4.4 17.7
Sources: ASI, ICN processed
Table-21
New cement factories and expansion units, 2012-2014
Name of Location Production capacity
company (tons per year)
Expansion
PT. Semen Pangkep, South Cement-2,5 million
Tonsasa Sulawesi
PT. Semen a.Tuban, East Java Cement-2,5 million
Gresik b. Papua -Cement-600,000
Packing plant and Silo
-300,000
-Quay-150 meters
PT. Semen Indarung, West Sumatra Cement-2.3 million
Padang
PT. Semen a.Baturaja, South Cement mill-300,000
Baturaja Sumatera Cement-1 million
b. Muara Dua, South
Sumatra
PT. Indocement a.Citeureup, West Java Milling
Tunggal Prakarsa b.Bau-bau, Southeast cement-2 million
Tbk Sulawesi Cement-1.9 million
PT. Holcim Tuban, East Java Cement-
Indonesia Tbk 1.7 million
PT. Lafarge Langkat, North Sumatra Cement-1.5 million
Cement Indonesia
PT. Semen Maros, South Sulawesi a. Cement-1 million
Bosowa Maros b. Cement transport
ship
New Investment
PT. Semen Jawa Sukabumi, West Java Cement-1.8 million
(acquired PT.
Jaya Boral
Readymix)
PT. Semen Karawang, West Java Cement-1,0 million
Karawang
Anhui Conch South Kalimantan Cement-10 million
Cement Co Ltd of
China
China Trio Subang, West Java Cement-1.5 million
International
Engineering Co
Ltd of China
State Papua Cement-1 million
Development and
Investment Corp
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PT. Semen Grobogan, Central Java Cement-1.5 million
Grobogan
Name of Investment Start-up
company year
Expansion
PT. Semen US$ 375 million 2012
Tonsasa (Rp 3,2 trillion)
PT. Semen Rp 3,5 trillion 2012
Gresik
Rp 1, 2 trillion 2013
PT. Semen N.a 2012
Padang
PT. Semen Rp 350 billion 2012
Baturaja
N.a 2012
PT. Indocement N.a 2013
Tunggal Prakarsa
Tbk N.a 2014
PT. Holcim US$ 450 million 2013
Indonesia Tbk
PT. Lafarge Rp 5 trillion 2013
Cement Indonesia
PT. Semen US$ 70 million 2013
Bosowa Maros US$ 50 million
New Investment
PT. Semen Jawa US$ 300 million 2013
(acquired PT.
Jaya Boral
Readymix)
PT. Semen N.a 2013
Karawang
Anhui Conch N.a 2014
Cement Co Ltd of
China
China Trio N.a 2014
International
Engineering Co
Ltd of China
State N.a 2014
Development and
Investment Corp
PT. Semen N.a N.a
Grobogan
Sources: Industry ministry
Table-22
Cement prices on domestic market, April-Mei 2012
Name of producers Brands Price per sack
PT. Indocement Tunggal Tiga Roda Rp 55,000
Prakarsa Tbk Rp 73,000 (white cement)
PT. Semen Gresik Tbk Semen Gresik Rp 53,500
PT. Holcim Indonesia Holcim a, Rp 42,000 (40 kg)
Rp 54,000 (50 kg)
PT. Semen Padang a, Rp 49,000 (40 kg)
b, Rp 51,000 (50 kg)
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b, Rp 51,000 (50 kg)
Sources: ICN processed
Table-23
Market shares of cement producers in Indonesia, 2011
Domestic sales
Companies 2010 Share 2011 Share Growth
(%) (%) (%)
PT. Indocement 12,582,611 30.9 15,121,873 31.5 20.2
Tunggal
rakarsa, Tbk
PT. Semen 8,911,382 21.9 9,974,480 20.8 11.9
Gresik
PT. Holcim 5,564,459 13.6 7,463,309 15.5 34.1
Indonesia
PT. Semen 5,260,192 12.9 5,820,858 12.1 10.7
Padang
PT. Semen 3,468,614 8.5 3,789,655 7.9 9.3
Tonsasa
PT. Semen 2,253,582 5.5 2,790,730 5.8 23.8
Bosowa Maros
PT. Lafarge 1,597,381 3.9 1,736,708 3.6 8.7
Cement Indonesia
PT. Semen 1,139,644 2.8 1,253,839 2.6 10.0
Baturaja
PT. Semen -- -- 48,442 0.1 --
Kupang
Sources: ASI, ICN
Table-24
Estimate of expansion of production capacity,
2012-2016
(000 tons)
Year Existing Additional Domestic
Capacity capacity requirement
2012 60,569 3,749 53,435
2013 63,597 3,328 56,281
2014 66,220 2,623 58,085
2015 70,220 4,000 58,995
2016 73,029 2,809 61,496
Year Exports Production Cap.
Utilization
(%)
2012 3,500 56,935 94
2013 3,500 59,781 94
2014 3,500 61,585 93
2015 3,500 62,495 89
2016 3,500 64,996 89
Sources: ICN processed
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