Annual Integrated Report 2022-23


Scaling up for the next level of growth

We consistently invest in augmenting our capabilities and best-in-class equipment and machinery to achieve excellence in manufacturing and ensure safe and efficient operations. Our integrated operations, efficiency-enhancing efforts and capacity expansion projects set us up well for an accelerated growth path.

Material issues addressed

  • Supply chain efficiency and logistics management

Key risks considered

  • Raw material risk
  • Operational risk

SDGs impacted

Augmenting manufacturing capabilities

Leveraging our robust manufacturing infrastructure and extensive expertise in chemistry, we have emerged as a key partner for major Indian and international conglomerates. We see significant opportunities going forward which will necessitate us to enhance our capacities and competencies. FY 2022-23 has been a year in which a lot of our growth initiatives have taken shape.

We are making significant strides towards scaling manufacturing capacities. Debottlenecking is a crucial development as it enables us to enhance production. As Phenol capacity utilisation has peaked, we are undertaking debottlenecking of the Phenol facility which will increase production by about 10% from current levels; and is expected to come on stream in the first half of FY 2023-24. We have successfully commissioned the installation of SAC unit which has significantly enhanced sustainability at Nandesari plant. Our photochlorination and chlorination plants are slated to be commissioned in the third quarter of FY 2023-24 and the acid project in the fourth quarter of FY 2023-24. Both these plants will significantly enhance profitability once commissioned and fully ramped up. It will also cater to internal captive consumption needs.

Our MIBK and MIBC plants are scheduled for commissioning by next year. These are derivative products of acetone and the objective is to captively use acetone to manufacture MIBK and MIBC thereby going into downstream value-added products. Our hydrogenation and multipurpose distillation facility has been approved marking further progress in our expansion plans. With multiple brownfield and greenfield projects underway to be commissioned in the coming year, we are poised to deliver improved performance and growth. More significantly, we have also approved investment to set up a facility in Oman to manufacture key chemicals and benefit from low-cost inputs of raw materials and energy to serve global markets.

Recognised for quality excellence

  • ISO 9001:2015 - Quality Management System
  • ISO 14001:2015 - Environment Management System
  • ISO 45001:2018 - Occupational Health, Safety and Management System
  • HALAL Certification
  • Responsible Care Certification
  • GOTS Certification
  • Responsible Care
  • TfS (Together for Sustainability) Certification

Operational excellence

We focus internally to enhance our operational excellence. Multiple initiatives such as process optimisation, productivity improvements and energy conservation are implemented across our manufacturing facilities. We continue to work towards cost optimisation through backward integration and recycling as well as maximising asset utilisation for enhancing return on investment.

Key initiatives undertaken in FY 2022-23:

A. Advanced Intermediate Segment:

  • Implementation of LIMS – Laboratory Information. Management System in QC Lab
  • Installation of RO Plant at ZLD unit
  • Installation of 40Kwp Solar rooftop system to use renewable energy
  • Received international award in Quality circle forum for the best kaizen presentation
  • Migrated from Chlorination method to Evaporation method for nitro effluent treatment
  • Recycling of wastewater from Cooling tower blowdown and domestic sewage
  • Treatment of effluent water at ETP by bio-degradation method instead of Stripping at MEE plant, thereby saving steam and power

B. Phenolics Segment:

  • Debottlenecking of Phenol capacity by 10% from current level, expected to be operational by H1-2023-24.
  • Stabilisation of second Boiler, Captive Power Plant (CPP) at Phenolics facility.
  • Operated Phenolics facility on islanded mode through CPP, which helped avoid ten to twelve stoppages due to power disturbances
  • Phenolics Facility received Responsible Care Certification.
  • IPA received certification to meet requirements of Indian, US and British Pharmacopeia
  • During the year, Phenolics business achieved major milestone of cumulative production of 10,00,000 MT of Phenol since commencement of operations
  • With sustained plant utilisation above 120%+ capacity, highest yearly production of Phenol was achieved

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