S. Suresh, Operations Head – Pharma Manufacturing, Hikal Ltd says that the biggest challenge faced by the manufacturing industry is to remain competitive, efficient, and compliant in all aspects of operations. Quality, environment, safety, labour, ethics compliances are paramount in manufacturing.
Hikal offers solutions across the life sciences value chain. We provide world-class active ingredients, intermediates and R&D services to global pharmaceuticals, animal health, biotech, crop protection and specialty chemicals companies. Suresh says, “Maintaining high levels of productivity and quality while keeping costs low is a major challenge. This includes continuous improvement and innovation in production processes. Laws and regulations pertaining to emissions, hazardous wastes, permits and licenses, health and safety, and other topics evolve along with political systems. To tackle these challenges, Plant Head may implement a comprehensive safety program, invest in advanced technologies to curtail environmental impact, implement effective supply chain management strategies, optimize the production processes and use data analytics to monitor and control costs, and implement quality control measures to ensure product consistency and reliability. Technology is also an excellent means of meeting changing needs and constraints.” He believes it is important for a plant head to be updated about the changes in policies and regulations.
Hikal has grown without increasing its environmental footprint because they conserve natural resources. “At Hikal, we understand the importance of environmental stewardship, and our commitment is reflected in our extensive efforts to create impact through a reduction in emissions, improved energy efficiency rates, efficient wastewater management and having a Zero Liquid Discharge (ZLD) facility at our plant. We have undertaken several measures to increase our renewable energy usage and reduce our carbon footprint. We continually focus on the backward integration of key raw materials (KRM) as well as improvement in processes. Backward integration of the KRMs reduces the risk of supplier concentration as well as geographical dependence, contributing to better margins and supply sustainability,” Suresh gives an insight into Hikal’s commitment to sustainability.
As the one who puts principles into practice, Suresh talks about a practical roadmap with a plan of action. “Combating problems that afflict the global economy might be made easier by transitioning to a circular chemical economy. Additionally, it aids in reducing chemical industry waste because every waste serves as some kind of input for other sectors. We have labs dedicated towards working exclusively on waste treatability studies. We aim to convert the by-products generated through the manufacturing processes into raw materials or co-products, which could either be used for captive consumption or sold separately. These initiatives are driving cost efficiencies and leading to enhanced yields while contributing positively to our sustainability initiatives. Establishing clear goals and targets for sustainability and circular economy, such as reducing carbon footprint, water consumption, and waste generation is paramount. At the same time, it is crucial to create a detailed plan of action that outlines specific steps and timelines for achieving the set goals and targets. This plan should include measures to optimize resource efficiency, reduce environmental impacts, and promote a circular economy.
Suresh talks about the motivations that is driving the deployment of Industry 4.0 in the chemical industry. “The rise of digital technologies is transforming businesses to produce, enhance, and distribute their goods more efficiently. Further, technologies like the IoT, cloud computing, analytics, AI, and machine learning are bringing a complete overhaul in operations resulting in increased efficiency and reduced costs. The use of IoT and AI in chemical manufacturing can help improve quality control and reduce the risk of errors. It can help chemical companies predict when equipment or machinery will need maintenance, reducing downtime and increasing productivity. Additionally, it can help chemical companies optimize the use of resources, reducing waste and increasing sustainability. The right utilization of technology can enable chemical companies to comply with decision-making and reporting requirements related to safety, environmental impact, and other issues. It will require significant investments and a change in the way companies operate, but it has the potential to improve performance and reduce environmental impact.