Process Optimisation
Project Management
Our experienced consulting engineers provide tailored solutions to meet your business needs, ensuring that your project is completed efficiently and effectively. Identifying and addressing factors affecting process performance (yield, energy consumption, product quality). Using mathematical and computational techniques to improve design and operation. Pajaka Enterprises has the expertise to work on many chemical engineering software such as Aspen, Hysys, Pro/II, gPROMS, Chemcad, etc., Maximising process performance and minimising production costs. Minimizing energy and resource consumption while reducing waste and environmental impact.
Yield Improvement & Time reduction in Manufacturing
Yield improvement and time reduction in manufacturing mean increasing the percentage of good products and decreasing the time it takes to produce them. This can be achieved through process optimization, equipment upgrades, and advanced data analysis. For example, reducing rework, improving defect detection, and optimising process steps can significantly improve yield and time efficiency. In batch processing industries, this can be achieved by optimising the reaction yields through a scientific approach using the Kinetic mechanism and conducting in vitro studies to optimise the reaction. The reactions can be initially studied in the lab and then transferred to the plant, without disturbing the running plant. It can bring in Crores of Rupees for improving 10% in the yield.
Troubleshooting
Troubleshooting a process involves a systematic approach to identify and resolve problems. It typically begins with identifying the problem, followed by analyzing its potential causes and then testing possible solutions. The process continues with implementing the most viable solution, verifying its effectiveness, and documenting the entire process for future reference.
In the drug industry, troubleshooting can be done in the form of identifying the areas where the impurities are coming from and how they can be reduced.
Process studies & Improvements
A process study in manufacturing involves analyzing and understanding the flow of materials and work within a production system to identify bottlenecks, inefficiencies, and areas for improvement. It can also involve studying the sequence of operations, time taken for each step, and the resources used to produce a product.
R&D Support and Scale-Up
We stay up-to-date with the latest technological advancements in the engineering industry to ensure that we are providing our clients with the most cutting-edge solutions possible.
As the part of development of new routes and new reactions, the reactions can be optimized right during the development and scale it up “Right First Time”. This involves, setting up the right mole-ratios of the KSMs, addition of right amounts of catalyst, monitoring the reaction as it progresses and stop the reaction when the product concentration in the reaction vessel is maximum.
As Built Drawings
As-built drawings are drawings that show all the minor and major modifications made by the contractor to the original drawing to provide an exact rendering of the project. As-built drawings are detailed documents that reflect the exact specifications and conditions of a finished construction project. They are also known as record drawings or red-line drawings and serve to compare the original design with the final construction, documenting all modifications made during the building phase. These drawings are crucial for understanding the actual layout and features of a building, as they provide a comprehensive blueprint of what was constructed, including any changes made during the construction process. Additionally, as-built drawings are contractually binding documents that can be used to prove that a contractor fulfilled their obligations to the satisfaction of the owner and relevant authorities.
Conceptual design/Studies
Conceptual studies such as Feasibility studies, Basic Engineering, Design Engineering, Construction, Commissioning and Startup of the plant can be taken-up. We have a combined experience of 80+ years that had dealt with many of the above processes.
Conceptual design and study involves the initial exploration and development of a design concept, often used as a foundation for more detailed design phases. It's a creative and iterative process focused on identifying and evaluating different design solutions to meet specific needs, constraints, and requirements.
Health & Safety
Sick units’ revival
Evaluation of the sick units and recommend the revival programs in cases w here a turn-around can be seen. Develop and recommend measures to ensure the units come out of the red zone. In some cases, a sale may be recommended and a proper evaluation will be taken up for the maximum profits out of the sick units.
Process Safety Reviews
A Process Safety Review (PSR) is a systematic, planned process for identifying and addressing potential hazards and risks within a process plant or facility. It's essentially a team meeting where safety experts, clients, and other relevant personnel work tog ether to brainstorm, assess risks, and review the effectiveness of safety measures. The goal is to ensure that the process is safe for personnel and equipment systems.
Health and Safety Reviews
It is the legal obligation of every employer to ensure that their employees operate within a safe working environment. As part of that obligation, they are required to ensure risks are appropriately managed and, where possible, eliminated.
To identify those risks and ensure that policies and processes are working effectively, employers should undertake a top-level health and safety review. It is recommended that they do so regularly, at least once per year.
Your review might reveal additional duties that haven’t been risk assessed yet, processes that could be changed to make them safer, or areas where employees require additional guidance.
As part of the review, it is recommended that senior members of staff undertake “shop-floor” inspections, looking beyond the data at what could be improved or what is working well.
On the subject of health and safety working well, you might consider publishing the findings of your review, perhaps demonstrating transparency and trustworthiness – two attributes likely to be valued by clients and employment candidates alike.
Safety / GMP training
We offer comprehensive training and support services to help you get the most out of your technology investment and to ensure that your team is equipped with the skills they need to succeed.GMP review and training programs ensure that manufacturing facilities adhere to Good Manufacturing Practices, a critical aspect of quality assurance in industries like pharmaceuticals, food, and cosmetics. These programs educate personnel on the principles of GMP, emphasising adherence to standards and ensuring that products are consistently produced and controlled to meet quality standards.
Vents and Drains analysis
Vents and drains play crucial roles in plumbing systems. Vents, typically located at high points, allow air to flow through the drainage system, preventing back pressure and sewer gas from entering the building. Drains, usually at low points, remove w and solids from the system. Proper venting and drainage are essential for efficient wastewater removal, preventing clogs, and ensuring a healthy environment.
Review & Analysis
Equipment’s performance evaluation/improvement
Equipment performance monitoring is the process of using various technologies to track, analyse, and manage the performance and condition of machinery and equipment across different industries. It involves real-time data collection and analysis of equipment status, utilisation, and performance. This monitoring helps organisations maximise equipment uptime, streamline operations, and eliminate manual inspections by setting up alerts and dashboards. The data collected can inform maintenance schedules and operational improvements, ultimately enhancing productivity and reducing costs.
GAP analysis
Gap analysis is a process used by companies to compare current performance with desired, expected performance, identify discrepancies between current and potential performance and determine whether a company is meeting expectations and using its resources effectively.
Feasibility Study and Cost Estimation
A feasibility study and cost estimation are crucial for determining the viability of a project before significant resources are allocated. A feasibility study assesses the project's technical, operational, financial, and legal viability, while cost estimation identifies the total resources needed to complete the project. This information helps decision-makers understand the potential risks, benefits, and overall financial implications of undertaking the project.
Vents and Drains analysis
Vents and drains play crucial roles in plumbing systems. Vents, typically located at high points, allow air to flow through the drainage system, preventing back pressure and sewer gas from entering the building. Drains, usually at low points, remove w and solids from the system. Proper venting and drainage are essential for efficient wastewater removal, preventing clogs, and ensuring a healthy environment.