SAMS Consultant & Associates is an engineering consulting firm founded in 2017 in Hyderabad, India that provides services for process design, environmental engineering, and operational excellence across industries including pharmaceuticals, chemicals, and biotechnology. The company has expertise in areas such as process design, mixing technology, heat transfer solutions, and solvent recovery plants. SAMS works on projects from concept engineering through commissioning and also provides technical consulting services.
1. Company Profile
SAMS Consultant &
Associates
Plot No 13/B, H.No.2-22-311/18/1APart, Addgutta Society Western
Hills, Opp KPHB Colony, Kukatpally, Medchal, Hyderabad-500072
(India).
Phone : 9951101742/7999670407/6360165251
Email : mklal@rediffmail.com
Web site : www.smasconsultants.com
GSTIN : 36ADNFS8707N1Z7
PAN : ADNFS8707N
2. Greetings from SAMS
Consultant!!
SAMS Consultant & Associates is founded in 2017 at
Hyderabad, a hub for pharma, as emerging
process design & engineering, consulting &
advisory services firm, based on fundamental
principle on the competent consulting & technical
backgrounds of professional experience.
We provide end to end engineering single platform,
reliable & cost effective solutions to client with
collaborative approach, transparency and high
level of integrity whose primary belief is building
long term relationship.
We have an extensive network of associates/
service provider with independent expertise & all
the associates/ service provider are specialized &
highly experienced in the specific area of
technology & engineering.
We are team of competent engineering
professional, a perfect blend of Knowledge,
Experience & committed, with a vast industrial
experience in the pharma & EPC industry.
We take care of entire responsibility & ownership of
project execution from concept to commissioning
with all the co-ordination by our internal team/
associates/ & service providers, as when required.
We are small consulting firm and prefer to work with
our strategic partner and associates.
Industry Sector
Why Us
Expertise, Experience & Domain Knowledge
Process , Technology & Engineering Oriented People
Cost Effective Solution Provider
Ownership & Commitment
Maintain trust, Integrity & Confidentiality
Utmost Importance to GMP, Safety & Cost
Collaborate & partner with Client
Single window for all solutions
Delivery & Quality
Bulk Drug & Intermediates Industries
Organic Chemicals Industries
Agrochemicals Industries
Fine Chemicals Industries
Specialties Chemicals Industries
Biotechnology & Biochemical Industries
Food, Flavor & Fragrance
About Us
3. Green Field & Brown Field
Projects
Pre-Basic/Concept
Engineering
Basic Engineering
Detail Engineering
Mechanical/Piping
Civil, Structural,
Architectural
HVAC & Clean Room
Electrical
Instrumentation &
Automation
Fire & Safety
Project Management
Construction Management
Procurement Assistance
Process Design Services
Chemical Engineering Design &
Solutions
Reactor Design & Advance
rxn technology
Mixing Technology
Heat Transfer Technology
Solvent Recovery system
Separation Technology
Membrane separation
technology
Fermentation Technology
Filtration & Drying Technology
Purified Water System
Technology
Environmental Engineering
Design & Solutions
Effluent Treatment Plant
Raw Water Treatment Plants
Sewage treatment Plants
Effluent Recycle ZLD Plant
RO Reject Concentration
Plant
Emission control systems,
Utility blow down water
treatment
Condensate Polishing Unit
Design Scrubber, Cyclone,
Dust Extractor
Performance Assessment of
Effluent Treatment Plant
MOEFF Preparation
Modification & Up gradation
of existing ETP
Process Engineering Design &
Solutions
Concept Design
Process Design & Calculation
Crystallization & PSD Control
Plant Trouble Shooting & De-
bottlenecking
Facility Re-vamping
Technical Due Diligence
Plant Performance vs Design
Adequacy
Process Simulation
Process Hazard Analysis
Services
Safety Design Basis for
Plant/Process
Exothermic/ Runaway Rxn control
techniques
Process Safety Information
HAZOP/FMEA/WHAT-IF
PHA
Explosion Investigation
Vent Sizing
Emergency Relief System Design
Static Electricity & Powder Safety
Fire Suppression/ Protection
system design
Operational Excellence
Services
Plant & Process Optimization
Water Conservation
Energy Cost Reduction
Solvent Management
Process & Utility Automation
c GMP Gap Analysis /Audit
Process Simplification
Technical Standards
Balanced Score Cards
Technology Services
Process / Technology
Intensification
Process Development/ Scale up/
Technology Transfer
Technology Development
Product Costing/OPEX/CAPEX
Business Services
Overview
4. “
.
OOuurr PPllaanntt DDeessiiggnn EExxppeerrttiissee
c GMP Kilo Lab
c GMP Pilot Plant
c GMP Multipurpose API Plant
c GMP Dedicated API Plant
c GMP HPAI’s Plant
c GMP Steroids & Hormones
Hydrogenation Plant
Grignard Rxn Plant
Butyl Lithium Rxn Plant
Nitration Rxn Plant
Chlorination Plant
Hazardous Handling Plant
c GMP Sterile API Plant
Continuous Crystallization Plant
Continuous Reactor Plant
Fermentation & Biotech Plant
Solvent Recovery Plant
Effluent Treatment Plant
Evaporation Plant
Water Treatment Plant
DM Water Plant
Purified Water Plant
Scrubbing & Exhaust System Plant
PSA Based solvent drying Plant
Plant Design
Expertise
5. CCoonncceepptt EEnnggiinneeeerriinngg
User Requirement Specification (URS)
Project & Quality Plan
c GMP Layout
c GMP Flows
PFD’s
Clean Room & AHU Zoning
Automation Philosophy
Budgetary Estimates
TTeecchhnnoollooggyy EEvvaalluuaattiioonn
Technology Evaluation & Assessment
Hazard & Risk Assessment
Process Technology Package
Project Feasibility Report
Conceptual Design Report
Techno Economic Feasibility Report
Detailed Project Report
BBaassiicc EEnnggiinneeeerriinngg
Process Flow Diagram (PFD’s)
Utility Flow Diagram
Equipment List with key parameters
Batch cycle time
Mass balance, Energy balance
MOC Selection for Equipment & Piping
Process Equipment Design
Preparation of P&ID’s
Options of Plant Layout as per GMP
Man & Material Flow Diagram
Preparation of Process data-sheets
equipments
Process & Utility Pipe Sizing with
insulation requirement
General specification for pipes & pipes
fittings
Control Philosophy & related
Instrumentation
Estimating Peak Utility requirement
Estimating the power load list
Effluent ( Liquid, Solid, Gaseous) Load
List & possible treatment
Fire Fighting System design
HVAC, Clean Room & Room Data
sheet
Preparation of Line list
HAZOP study
DDeettaaiill EEnnggiinneeeerriinngg SSeerrvviicceess
Mechanical
Piping Engineering
Utility Engineering
Civil, Structural & Architectural
Engineering
Electrical
Instrumentation & Automation
HVAC System & Clean Room
Insulation & Painting
Fire & Safety System
Additional auxiliary detail engineering
services
Effluent Treatment
Solvent Recovery
Project Management
Construction Management
Procurement Assistance
Basic & Detail
Engineering Services
6. MMiixxiinngg TTeecchhnnoollooggyy
Agitator Selection & Design
Sizing Agitator Shaft & Critical Torque
Mixing Time , Residence Time Calculation
Gas –Liquid /Solid- Liquid Mixing System
Solid-Solid Mixing System
Scale up
Agitation Efficiency Improvement
Polymer reactor agitator design
Bioreactor Agitator Design
Enzyme Reactor Agitator Design
Fermenter Agitator design & scale up
Fermenter mass transfer calculations
Design of Static Mixer for Mixing intensity improvement
HHeeaatt TTrraannssffeerr TTeecchhnnoollooggyy
Heat Exchanger & Condensers
Finned Tube Heat Exchanger
Air Cooled Heat Exchanger
Vent Condenser
Kettle Re-boilers/Thermo-siphon Re-boiler
Multiple-effect Evaporators (Falling /Rising/Forced /MVR)
Wiped Film /Agitated Thin Film Evaporator
Steam Stripper
Closed Loop Cooling Tower System
Hot Oil System/TCU’s
Single Fluid heat transfer system(SFHTS)
Tank & Fermenter Cooler
Continuous media sterilization system
Overall heat transfer coefficient calculation
Advance continuous reactor technology with static
mixer
SSeeppaarraattiioonn TTeecchhnnoollooggyy
Steam Stripper
Batch and Continuous Distillation Columns
Azeotropic Distillation Column
Divided Wall Distillation Column
Side stream Distillation Column
Reactive Distillation system
Extraction Columns
Scrubbers and Absorption Columns
Decanters
Crystallizers
Membrane based solvent recovery
Our Services
Concept Design
Process Design
Technical Consulting
Advisory Services
Chemical Engineering
Design & Solutions
7. Solvent Recovery
Plants
Design & Solutions
OOuurr EExxppeerrttiissee
Batch Distillation
Continuous Distillation
DDiissttiillllaattiioonn CCoolluummnn TTyyppee
Azeotropic Distillation ( without Entrainer)
Azeotropic Distillation ( With Entrainer)
Extractive Distillation
Reactive Distillation
Steam Striping
Adsorption
Membrane Distillation
OOuurr SSeerrvviicceess
Design, Engineering & Supply
Our Services is process design & mechanical
design of distillation column.
Study of Existing System and Improving Solvent
Recoveries
VOC Emission Reduction
Solvent Storage, handling & transfer &
Dispensing System
Design of Integrated Solvent Management
Systems
Design of new Solvent Recovery Plants
Simulation Studies for difficult separations on the
most advanced process simulator called Aspen
Tech.
Distillation Column Automation
.
8. MMeemmbbrraannee
SSeeppaarraattiioonn
TTeecchhnnoollooggyy
Product Concentration
with NF Membrane
Product with high
volume water
separation
Water recovery from
effluent with RO
Membrane
Pervaporation : Solvent
drying with membrane
assisted technology
USP Water Generation
WFI Plant
FFeerrmmeennttaattiioonn &&
BBiioo EEnnggiinneeeerriinngg
Design of seed
fermenter
Commercial fermenter
Media Sterilization
system
Enzyme Reactor
Down-stream processing
Our Services
Concept Design
Process Design
Technical Consulting
Advisory Services
Membrane Separation,
Fermentation &
Bio-Engineering
9. CCoonncceepptt DDeessiiggnn
Mass & Energy Balance
PFD, UFD, HFD
Layout
P& ID
Hazardous Area
Classification
HVAC & Clean Room
Purified Water System
N2 Plant Distribution
Compressed Air Plant
Steam Distribution
Hot Water Distribution
Cooling Water Distribution
Chilled Water Distribution
Chilled Brine Distribution
DM Water Distribution
Vacuum System (L,M,H)
SFHTS/Hot Oil Distribution
Equipment Automation
Utility Automation
Preliminary Project Cost
Technology Evaluation
MOC Selection
Hydrogenation Plant
Steroid, Hormone Plant
HPAI’s Plant
MPP API Plant
Dedicated API Plant
Scrubber System
Effluent Treatment Plant
Chemical Compatibility
Material Interaction
Vessel Inerting System
CCoonncceepptt DDeessiiggnn
Reactor Inerting System
Centrifuge Inerting System
Hydrocarbon Sensor
Solvent Dispensing &
Distribution
On line Reactor Sampling
Catalyst Preparation System
Catalyst Filtration System
Powder Transfer System
Reactor Solid Charging
System
H2/N2 Pressure Reduction
System
Hazardous Material
Charging
CIP/SIP System
ML Collection System
High Vacuum Distillation
System
Short Path Distillation System
VOC Emission Control
System
Dust Explosion &
Containment
Emergency Relief System
Reactor Vent Sizing
Molecular Sieve Solvent
Drying
Solvent Storage Day Tank
Solvent Yard
Hazardous Drum Yard
Smoke Detection System
Sprinkler System
Deluge System
Solvent Storage Tank Vent
Emission Control
Dust Extraction & Control
Fume Control System
PPrroocceessss DDeessiiggnn
Reactor Distillation Time
Heating/ Cooling Time
Batch Time cycle
Chemical Spill
Evaporation rate
Fire Water Load
Process Equipment
Surface Area
Multiple Effect
Evaporation system,
Flash Evaporation
Distillation column,
Steam Stripper,
Vapor-liquid separtor
Pump Hydraulic
Presssure drop
Equipment Heat Loss,
Pipe Heat Loss
(VOC) Calculation
Packed Bed Scrubber ,
Venturi cum Packed
Bed Scrubber
Air Leakage Rate
Liquid Jet Ejector,
Steam jet Ejectors
Dry Vacuum Pumps
Water Ejectors
Control Valves,
Orifice
Plant Heat Load,
Plant Lighting & Power
Load
Insulation thickness (Hot
& Cold)
Cooling Peak Load for
exothermic rxn.
Reactor Overpressure
due to exothermicity
PPrroocceessss DDeessiiggnn
Pressure Vessel & Reactors
Storage Tanks & Vessels
Vessel thickness
Heat Exchangers &
Condensers
Press. & Vacuum Nutsch
Dryer ( Atm & Vaccum)
Cyclone Separator
Boiler Capacity
Cooling Tower Capacity
CHW Plant Capacity
CH Br Plant Capacity
Compressed Air Plant
Instrument Air
N2 Plant Capacity
DM Plant Capacity
PW Plant Capacity
HVAC Room Heat Load
Utilty Costing
Product Costing
Micronization Costing
CAPEX
OPEX
Pipe Sizing
Boil Up rate Calculation
Vapor Line Sizing
Vacuum line Sizing
Flame Arrestor Sizing
Explosion Vent Sizing for
Dryers
Rupture Disc
Safety Relief Valve
Storage Tank Breather
Vent
Reactor Vent Sizing
Chemical Consumption
Coefficent
Process Engineering
Design & Solutions
10. W a
Provide a third set of eyes to
review and find alternative
solutions to process &
engineering problems
Proper Approach towards
Problem
Focus on developing simple
solution
Subject Matter Expert
Plants are designed for some products and
with time progress it is being used for some
other products and there is compromise
between required design and current process
which creates a huge plant bottleneck, utility
mismatch and process issues. We offer our
services in:
Increasing the plant capacity from existing
one
Reduce the specific energy consumption
Increase the product yield
Process/Operation simplification
Reduced Plant down-time
Product Purity Problems
No consistency in product quality
Not meeting the PSD in micronization
Filtration & Drying Concerns
Distillation time reduction
Solvent Recovery Purity Issues
Distillation column operating Issues
Drying OVI Issues
PSD Issues/variations
Help in instrumentation and control
improvement
Reduce Operating cost of product
Process Engineering Personnel Support
Update P&ID’s
Energy Audit
Capacity Enhancement
Crystallization & PSD Issues
Plant Trouble Shooting
& De-Bottlenecking
11. UUttiilliittyy SSyysstteemm
Boiler Plants
Chilling Plant
Cooling Towers
Brine Plant
VAM Plant
N2 Plant
Compressed Air Plants
Purified Water Plants
DM Water Plants
WFI Plants
Vacuum System
Steam Jet Ejectors
Water Jet Ejectors
Steam+ Water Jet Ejectors
Vacuum System
PPrroocceessss EEqquuiippmmeennttss
Reactor
Hydrogenator
Filtration Equipment
Drying Equipment
Powder Processing
Equipment
Agitator System
Catalyst Filtration System
H2/N2 Pressure Reducing
Station
Condenser System
Receiver
Solvent Storage Tank Pump
Heat Transfer Equipment
SSaaffeettyy SSyysstteemm
Rupture Disc & Safety Valves
Scrubber System
Dust Extraction System
Spot Extraction System
Exhaust Extraction System
Fire Hydrant System
Sprinkler System
Emergency Relief System
Solvent tank Farm
Overhead /Underground Tanks
Piping Network & Header Sizing
HVAC System
Hazardous Waste Disposal Unit
Emergency Relief system
AAuuxxiilliiaarryy PPllaannttss
HVAC Plant
DG Set
Solvent Recovery Plants
Effluent Treatment Plants
Evaporation Plant
Membrane Recycling Plants
Membrane Reject
Concentration Plant
Waste Sludge Drying Plants
Inorganic Waste salt drying
plant
Incineration Plant etc.
TTeecchhnniiccaall DDuuee--
DDiilliiggeennccee
Clients looking to acquire
existing pharmaceutical
set ups can avail services
of SAMS Consultants to
assess the current
conditions. We provide
our services in assisting to
clients as below:
Review of Capacity
and product mix of
exiting production
set-up
Review of exiting
Utility set-up
Major GMP regulatory
compliance issue
issues with respect to
current facility
infrastructure and the
documentation
practices
Scope for future
expansion / capacity
increase within the
plot boundary
Estimated cost of
existing plant and
machinery
Any other issues
related to facility
acquisition.
Equipment Design vs.
Performance
Verification
12. DDeessiiggnn SSeerrvviicceess
Raw Water Treatment Plant
DM Water Treatment Plant
Sewage Treatment Plant
Biological Treatment Plant
Anaerobic Treatment Plant
Effluent Recycle & Zero Liquid Discharge
(ZLD) Plant
Multiple Effect Evaporation Plant
Steam/ Air Stripper Plant
Salt Drying Plant
RO Reject Concentration Plant
Condensate Polishing Unit
Process Scrubber
VOC Scrubber
Cyclone Separator
TTeecchhnnoollooggyy && CCoonnssuullttiinngg SSeerrvviicceess
High COD & High TDS Effluent
Difficult to Degrade Effluent
Nutrient Removal (N, P)
Heavy Metals, Cyanide, Fluoride Removal
Tailor made industry specific solutions
Help Client in Identification & preparation of
effluent (solid/liquid/gaseous) likely to be
generated for MOEFF preparation.
Provide effluent treatment performance
monitoring charter for process plant for MIS.
Performance Assessment of Effluent treatment
plant-sector specific
Modification and up-gradation of the existing
treatment facilities to achieve desired results
and also to reduce operating cost.
Environmental
Engineering
Design & Solutions
13. Process Hazard
Analysis
HHaazzaarrdd AAnnaallyyssiiss
Hazards Analysis Using the Guide Word Method
Process Hazard Analysis (PHA) studies are the basis for process safety and
risk management of highly hazardous process systems. We help companies
identify hazard scenarios that could adversely affect people, property, or
the environment. Facilities that handle or process hazardous chemicals
have a responsibility to protect employees, the public and the environment
from exposure to accidental releases of hazardous chemical compounds.
Considering the complexity of today's chemical processes, the challenges
involved in facilitating a PHA study, and the potential liabilities from an
incident, your best option for completing PHAs may be to seek the
assistance of expert specialists. Our HAZOP team has experienced
engineers from diverse backgrounds including plant operations and plant
design.
SAMS Consultants uses predictive PHA techniques and methodologies such
as Hazard and Operability Studies (HAZOP), What-If Studies, and Failure
Modes and Effects Analysis (FMEA) and Major Hazard Analysis (MHA). We
provide a team leader or facilitator to work with a group of people from the
facility to conduct the PHA. We document the PHA study findings and
prepare a report on the study.
We facilitate both initial PHAs and revalidations of existing PHAs that have
been performed at your facility.
We also provide flammability diagrams that have been customized for the
chemical compounds or mixtures of chemical compounds found on your
plant site.
We also provide training/ workshop for process safety awareness, Process
Hazard Analysis, HAZOP etc.
EExxpplloossiioonn IInnvveessttiiggaattiioonn
We provide investigations of explosions in the Chemical Process Industries.
We are available on an emergency basis to assist you in pin-pointing the
most probable cause of the explosion and can recommend and
implement the required engineering and/ or procedural changes.
OOtthheerr SSaaffeettyy SSeerrvviicceess
Vent Sizing by DIERS METHOD.
Interpretation of process safety studies like DSC, RC1, thermal screening,
ARC, RSST, ARRST etc. and Help Company in translating these data to
prepare design basis of safety for plants for safe operation.
Prepare process safety information (PSI),a basic documents for PHA.
Emergency Relief System Design
Design emergency crash cooling system, dump tank, knock out pots,
scrubbing or flare system.
Provide Guideline services to static electricity & powder safety.
Design fire suppression system and fire protection system.
Training on HAZOP/What-if/PHA.
14. Process & Technology
Intensification
Process intensification has been
receiving increased attention and
importance because of its potential to obtain
innovative and more sustainable process
design alternatives. Process intensification as
an activity characterized by five principles—
reduced size of equipment, increased
throughput of process, reduced equipment
holdup or inventory, reduced usage of utilities
and raw materials, and, increase efficiency
of process equipment. Process Intensification
frequently involves combining separate unit
operations such as reaction and separation
into a single piece of equipment resulting in a
more efficient, cleaner, and economical
manufacturing process. At the molecular
level, Process Intensification technologies
significantly enhance mixing, which improves
mass and heat transfer, reaction kinetics,
yields, and specificity. These improvements
translate into reductions in equipment
numbers, facility footprint, and process
complexity, and, thereby, minimize cost and
risk in chemical manufacturing facilities.
We provide our process engineering
expertise services to process/technology
intensification
in identifying the areas of improvement
either process or technology or
equipment or hybrid one in the existing
process and provide clients a prototype
process design alternatives for feasibility
study.
Assist in development of pilot facility and
trial runs.
Recommend for final design and
commercial unit.
15. Process Development,
Scale up &
Tech. Transfer
TTeecchhnnoollooggyy DDeevveellooppmmeenntt
SAMS has the capability to draw on a wide range of
expertise to evaluate and benchmark different
technologies and provide clients with the best possible
advice and options. Our expertise covers process routes
and practical implications in terms of operation, equipment
design, risk, economics and environmental impact.
PPrroodduucctt CCoossttiinngg
We help clients in arriving the right product costing of
manufacturing. We add our value addition in deriving
Conversion cost or OPEX calculation Model for the product
manufactured in a multiproduct facility where utilities are
shared. The calculation of OPEX in a multiproduct facility is
really a challenging and most of them are run on campaign
basis. We use all our chemical and process engineering
approach for calculating the conversion cost or operating
cost.
OOPPEEXX//CCAAPPEEXX
We help clients to build up Cost model for a multiproduct
facility so as to arrive right pricing of its manufacturing cost
and avail high gross margin of profit in product cost. Also
the facility used for manufacturing is old and plant and
machineries are depreciated, we use all financial tools to
build and create such cost factors in arriving CAPEX of the
facility. We use our chemical and process engineering
expertise in building model for CAPEX/OPEX Services
Developing a manufacturing process
from small scale to full production is a
complex task. That's because what
works at bench level doesn't always
work at production level. We offer our
rich and varied experience to process
industries to our customer in process
development, scale up and transfer of
technology services.
OUR APPROACH
We understand with your team about
your laboratory process in
understanding the scientific,
commercial, quality and regulatory
requirements.
We work out the scale of operation
and break the whole process into
chemical engineering unit operations
and possible equipments and utilities
required for carrying out scale up
activity with target yield and purity for
each step of multi step process. We
also arrive at target scale up price for
the product. We also provide our
process safety experience and advise
clients to create and build process
safety data for safe scale up.
Next we help clients for appropriate
facility in his multiproduct facility/plant.
This is very important as Right Selection
of Equipment is very important for
successful scale up. Our motto for
successful scale up
Scale up successful criteria= right
chemistry x right equipment x right
analytical support x co-ordination.
Then, using technical risk management
approach, we identify laboratory, pilot
and design tasks. And we work through
these towards a process suitable for
implementation.
16. Operational
Excellence
WWhhyy OOppeerraattiioonnaall EExxcceelllleennccee
Operational Excellence is a goal of
conducting business in a manner that
improves quality, obtains higher
yields, faster throughput, and less
waste.
In today’s process industries the
product cost and quality of product is
becoming paramount importance
and the challenges are highly
competitive, both technically as well
as managerial. Therefore it is
important to identify areas of
continual improvement and reduce
unwanted non value adding works in
the operations. Some of the key
factors impacting industry are:
Increasing demand of delivering
products at lower cost.
Improve customer supply
performance
Greater product complexity
Ongoing regulatory compliance
demands
Ever increasing process
complexity and hazards
We support in providing integrated
solutions, custom designed and
customer specific services to meet
the challenges of operational
excellence so as factory can
maintain
Consistency in product quality by
fewer deviations.
Optimized Operating facility
Cost competitiveness
Less Inventory buildup
Smooth operation work flow
OOuurr OOffffeerriinnggss
Plant & Process Optimization
Water Minimization
Energy Cost Reduction
Solvent Recovery Improvement
Process & Utility Automation
c GMP Gap Analysis /Audit
Process Simplification
Technical Standards
Manufacturing Benchmarking
Balanced Scorecard
PPllaanntt OOppttiimmiizzaattiioonn
Equipment Optimization
Operating Procedure
Down time reduction
Cutting down Batch Cycle
Time
Minimizing Make span
Revamping and Retrofitting
Capacity Expansion
Cost Reduction in Process
Operations
EEnneerrggyy CCoosstt RReedduuccttiioonn
Motors above 5 HP
Boilers & Thermic fluid
heaters
Compressed Air systems
Cooling Towers
Lighting
HVAC & Chillers
Condensate recovery
ETP,MEE, STP
PPrroocceessss SSiimmpplliiffiiccaattiioonn
Eliminate wasteful or non-
value adding actions
Reduce process cycle time
Remove defects or
disconnections between
process tasks
Increase employee
involvement
Reduce process cost
.
FFaacciilliittyy GGaapp AAnnaallyyssiiss
Manufacturing
Warehouse Capacities
Technological Capacities
Review Previous Health
Authority Inspections
Inspection of QC facilities
and capabilities
Effluent treatment system
Plant Safety System
BBaallaanncceedd SSccoorree CCaarrdd
Loss Time Accidents
Inventory levels
Environmental
compliance
On-Time in Full (OTIF)
Cost Out
Continuous Improvement
(CI)
Assets Utilization
Asset Efficiency
Overall Asset Utilization
Rate of Quality failure
First Time Right
Adverse Notices from
GOT and Regulatory
agencies
MMaannuuffaaccttuurriinngg BBeenncchhmmaarrkkiinngg
Standards benchmarking for
manufacturing in three major
metrics as:
Total cost to manufacture
Manufacturing Cycle
Time’
Un-planned Machine
downtime
Energy Benchmarking
17. Solvent Management
& Recovery
Enhancement
SSoollvveenntt RReeccoovveerryy && MMaannaaggeemmeenntt
Solvent in chemical process industries constitutes a major
cost component and its recovery and reuse quality is
utmost importance. We provide our services in integrated
solvent management system apart from solvent recovery
enhancement. Sometimes solvent recovery from a mixed
stream is a difficult one and we provide simulation study for
right separations through ChemCad & Aspen Plus.
We also provide our services in helping client to prepare
Solvent Consumption Index & Solvent Expenditure Index for
product wise, block wise, entire plant and other multiples
sites to analyze the health of solvent cycle in plant and
thereafter providing solutions to minimize the gap.
Our Approach:
Solvent Loss Mapping
Identifying the sources and locations of solvent loss.
Quantifying the amount of solvent loss at each point.
Building up Scenarios for process simulation
Checking design and ratifying condensers in
manufacturing plant using Process Simulators.
Simulation of the columns on the most advanced
process simulator called Aspen Tech.
Develop the operational strategy based on the
simulation results.
Exactly identify the steam and cooling water
requirements that is utility requirements.
Devise the solutions.
Prepare Action Plan and Implement and execute the
solutions.
Measure the benefits
JJoouurrnneeyy ooff SSoollvveenntt
We provide our services in
assessing the entire solvent
journey in the value map and
identify the losses and provide
solutions to minimize the same
and enhance the recoveries.
18. Process
Automation
WWhhyy AAuuttoommaattiioonn
Automation helps industries in achieving
operation excellence:
Consistency & Improvement in Product
Quality
Reduction in batch time
Reduction in wastage and energy
consumption
Plant Safe Operation
Analysis of Data
Documentation & Report Generation
FFaaccttoorrss AAffffeeccttiinngg QQuuaalliittyy iinn PPhhaarrmmaa
Contamination
Air-HVAC
Water-Raw Water, Purified Water, WFI
Human Interface-BMS
Product -Cleaning/CIP
Deviation of the process from its
Validated state
End product purity/impurity
OOuurr AApppprrooaacchh
Understand Client’s URS
Collect Equipment & Process Details from
client’s
Prepare process logic and P&ID.
Provide Initial proposal & its approval from
client’s ( scheme as well as regulatory
concerns, if any)
Work out Basic Engineering and detail list
of modification required.
Provide budgetary cost for the proposal.
Provide list of suppliers
Evaluate vendor quote and its technical
approval
Assist procurement and installation.
Assist clients for final trial.
OOuurr EExxppeerrttiissee && OOffffeerriinnggss
Simple Package Unit ( FBD, RCVD, Tray Dryer
etc)
Complex Package Unit (Water System,
ANFD, ATFE, LLE, Centrifuge etc.)
Plant Wide Automation (Utility Control-
Temperature, Pressure Control, Solvent
Charging, p H, Weighing Indication/control,
Single fluid heat transfer system –SFHTS,
Little Expertise but not limited to:
Reactor & Crystallizer Automation
Layer Separation Equipment Automation
Utility Automation
Hydrogenation reactors Automation
Solvent tank farm with dispensing up to
reactors Automation
RCVD, VTD, Blenders, ANFD, ATFD, Spray
Dryers Automation
Falling film & Multi effect Evaporators
Automation
SRU & Distillation column Automation
Syrup / suspension preparation vessels with
solvent transfer system Automation
Condenser Utility Control Automation
Centrifuge Inertization/blanketing
TCU & Hot water Skids including inbuilt
chillers up to -70 deg. Ultra chilling
Special / Specific process control
Automation
Purified Water generation & distribution
system Automation
Vacuum system Automation for distillation &
drying.
Reactor cascade control with Agitator RPM
and temperature & Utility Automation
Flammable solvent N2 Blanketing
Automation
Compressed Air Pressure Automation for jet
mill
19. Audit,
Training/ Workshop,
Guidelines
AAuuddiitt // TThhiirrdd PPaarrttyy
Technical Audit of Plant ( assessment of infrastructure,
existing machinery set up & expansion capability
To check GMP, GLP compliance status of plant and its
capability for further regulatory
compliance
Review of Record, documentation, previous regulatory
audit and compliance report.
Prepare GAP analysis report
SSOOPP && GGuuiiddeelliinneess
We provide our advisory services customers technical
guidelines as:
Process Optimization & Development guideline
Scale up guideline
Technology Transfer Guideline
Process Equipment Selection Guideline
MOC Selection Guideline
Equipment Design Guideline
TTrraaiinniinngg && SSkkiillll DDeevveellooppmmeenntt
We provide training and skill development to personnel as:
Process Engineering
Cost Improvement Project
Solvent Recovery Improvement
Technology Transfer
Scale up & Commercialization
Process Development & Optimization
Equipment Selection Guidelines
Chemical Engineering Unit Operation to Chemists
Chemistry to Chemical Engineers
Process Hazard Analysis (PHA) Awareness
HAZOP/SIL
Water Conservation
Effluent minimization & green chemistry
Energy Minimization
Do’s & Don’ts for Clean Room practices
Thank you for
taking the time
to go through
this business
profile.
If there are any
questions or
comments,
business
inquiries please
feel free to
contacts us or
write us.
20. About Founder
Manoj Kumar Lal,M.Tech
Mr. Lal is a Chemical Engineer and holds M.Tech degree in Chemical Engineering from
the prestigious Indian Institute of Technology (IIT), Kharagpur. He has got over 25+ years
experience in the Chemical, Pharmaceutical, Biotech & EPC organization.
Mr. Lal has hands on experience in the functional areas manufacturing & operations,
process development, optimization & process engineering, technology development &
technology transfer/absorption, facility audit, solvent recovery improvements, capacity
de-bottlenecking and improvements, process intensification and new /alternate
technology, process plant design & engineering, project engineering & management,
operational excellence and operation management, Environment, Health & Safety.
He has intensively worked in the fields of process and plant design, project
management, operations management, retrofitting, debottlenecking and optimization
and process research.
Mr.Lal has worked on more than 200+ API Molecules, intermediates and various
technology platforms. He has vast experience in Process & Plant Design for Pharma,
Biotech and Effluent Treatment. He has profound knowledge & experience in process
safety, HAZOP & PHA.
Before founding SAMS Consultant & Associates,
Mr. Lal industrial credential of reputes are Shaw Wallace, Praj Industries, Paramount
Pollution Control, Dr. Reddys Laboratories, Cadila Pharma, Sanmar Chemicals, Shasun
Chemicals, Piramal Enterprises, Cipla, Aurobindo Pharma, Raks Pharma (Amneal USA),
Nakoda Chemicals & IPCA Laboratories.
Mr. Lal has worked in various capacities at senior management and his last assignment
was Head Technical Services with IPCA Laboratories.
Mr. Lal is the Founder & Managing Partner of SAMS Consultant & Associates.
SAMS Consultant & Associates
Plot No 13/B, H.No.2-22-311/18/1APart, Addgutta Society
Western Hills, Opp KPHB Colony, Kukatpally, Medchal,
Hyderabad-500072 (India).
Phone :9951101742/7999670407/6360165251
Email : mklal@rediffmail.com
Web site : www.smasconsultants.com
GSTIN : 36ADNFS8707N1Z7
PAN : ADNFS8707N
21. For Business Enquiry
Contact Us:
SAMS Consultant & Associates
Plot No 13/B, H.No.2-22-311/18/1APart, Addgutta Society
Western Hills, Opp KPHB Colony, Kukatpally, Medchal,
Hyderabad-500072 (India).
Phone :9951101742/7999670407/6360165251
Email : mklal@rediffmail.com
Web site : www.smasconsultants.com
GSTIN : 36ADNFS8707N1Z7
PAN : ADNFS8707N
SAMS Consultant & Associates
Plot No 13/B, H.No.2-22-311/18/1APart, Addgutta Society
Western Hills, Opp KPHB Colony, Kukatpally, Medchal,
Hyderabad-500072 (India).
Phone :9951101742/7999670407/6360165251
Email : mklal@rediffmail.com
Web site : www.smasconsultants.com
GSTIN : 36ADNFS8707N1Z7
PAN : ADNFS8707N
