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- 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!! SAMSConsultant & 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 DDeessiiggnnEExxppeerrttiissee 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 UserRequirement 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 AgitatorSelection & 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 withNF 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 Providea 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 BoilerPlants 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 RawWater 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 HazardsAnalysis 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 Processintensification 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 OperationalExcellence 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 SSoollvveennttRReeccoovveerryy && 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 helpsindustries 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 KumarLal,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 ContactUs: 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