Operations
Ideal Operations articulates less use of human resource, machine,energy and get maximum output with less or no waste.
This stretergy is in line with ‘3P’ principle, which attributes to have the best retained ‘People’ who earn maximum ‘Profit’ with minimal adverse impact on ‘Planet’.
We offer services
- Production hike from 4MT to 6MT by line balancing and from 6.5MT to 9MT by changing crystallisation pattern.
- Reduced the time loss in equipment cleaning and validating the cleaning methods. This has directly impacted on the monthly production by 18%.
- Alteration of the hardware sequence and right combination of the equipment capacities has resulted in capacity enhancement in many API s and intermediates with minimum Capex requirement.
- Data Analysis used for reduction of Batch time cycle. Successfully reduced time cycle by 40- 50% by creating the intelligent formula for batch termination time.
- Redesigned the work up procedure which has reduced the utility cost by 18% effluent cost by 22%.
- Analytical method was aligned to the elution of all the impurities of the stages, has changed the purification method to increase the yield by 8%.
- The reproducibility of the method was streamlined where the noise, integration approach, column washing issues were re-addressed when the limits of impurities are stringent.
- More than 110 Molecules were scaled up and technology transferred for DMF filing and some of those were from the Custom synthesis.
- Executed crystallization studies in favour of reducing the crystallization time, impurities, nature of crystals, difficulties in filtration by alteration in solvent ratios, agitation pattern, seeding pattern, cooling pattern etc in more than 10 intermediates and APIs
- Using the conditions of the isolation of final solid material the residual solvent or OVI has shown the significant response to the operating conditions during isolation. This method was useful in 14 APIs for various ROS.
- By application of right fundamentals of crystallization through MSZW, robust process for stable and critical polymorphs has been established in more than 10 APIs.
- The crystal size and the robust polymorphs were tested under the minor changes like agitation speed, cooling utility temperature, solvent ratios enabled the reproducible variations as a robust process to get the consistent desired polymorph. Established in more than 20 APIs. This has resulted in the variation in the filtration and drying time – has addressed accordingly.
- The filtration and drying time are the function of the filtration area, nature of the material, particle size , operating temperature and the equipment used to commence the operations. By addressing these points, the improvement has been done in 20 APIs and the intermediates without the change in process.
- Time cycle of Crystallization was reduced from 26 hrs to 6 hrs by using Sono-crystallization
- This has resulted into the tripling the revenue generation.
- 45 / 55 Azeotrope components separated by using right entrainer.
- The amount of sale of solvent was reduced to bare minimum saving 2 Cr of cost of solvent in financial yr.
- Introduced the high through put column of 10 KL/day to reduce the turnaround time.
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