About the company - sajjan€¦ · About the company… • A leading contract manufacturer with...

• About the company • Production capabilities • Environment, health and safety • Corporate social responsibility • Awards

Group companies

Key facts about the Sajjan Group

• Sajjan India Limited (Flagship company) • Om Intercontinental •Priyata Intercontinental •Sajjan Securities •Sajjan Overseas

Manufacturing facilities

•4 manufacturing units

•18.5 Acres land area

(75,000 M2)

• 7.4 Acres built up area

(30,000 M2)

Head office in Mumbai, Maharashtra Employees - 100

•Manufacturing units in Ankleshwar, Gujarat • Employees - 450

320 KM / ~4.5 hours

Sajjan has successfully transformed into India’s leading contract manufacturer

• Jute and textiles

Strategy

Product portfolio

1905-1960s 1970-2006 2007-Current

• Diversified into agro, pharma and dyestuff intermediates • Electronic and specialty chemicals

• Technical grade Active ingredients under technology transfer agreement

• Cost competitiveness • Focus on exports

• Cost competitiveness • Focus on increasing export presence • Large scale manufacturing

• Building long term customers • Innovation • Process enhancements • Non competing approach with clients

Key highlights

• Established one of the largest textile mills in Central India

• Established direct relation with Hoechst AG • New fully DCS automated plant set up

• 62 CDAs signed and 24 product commercialised • New fully Yokogawa automated plant set up

About the company…

• A leading contract manufacturer with expertise in large scale production of Active Ingredients, Intermediates and specialty chemicals • End use application across Agrochemicals, Pharmaceuticals, Electronics and Dyes & Pigments • ISO-9001, ISO-14001, OHSAS-18001 certified • Closely held company – insulating us from stock market fluctuations • Capable of undertaking multiple step chemical processes and wide range of chemical reactions • Strong technical team with in-house engineering and process development capabilities • Undertaking continuous improvement for process optimisation, waste water reduction and product cost management

…and our value proposition

• 40+ years of strong business associations with global multinationals • 100% Export Oriented Unit (EOU) allowing us for duty free imports of raw materials, packaging, capital good and consumables • Zero Debt Company - Willing to invest US$ 10 M ++ for new projects with a dedicated production line under multi year contract • Lean management structure for quick customer response and decision making • Flexible production set-up enabling to introduce new products with minimal modifications and capex • Intellectual Proprietary Rights (IPR’S) strictly followed. • No direct marketing – we do NOT compete with clients on the finished product • 99.5% on time shipment record • Utmost focus on Environment, Health and Safety

We have a well diversified business portfolio with Agro Chemicals contributing to over 50% of total revenues

Sales by segment

Our mission to become a leading contract manufacturer is supported by well defined business strategies

Mission

To become a leading contract

manufacturer of specialty chemicals

Maintain strictly confidential cutomer IP’s & business information

Provide timely service & exceptional value

to help customers gain competitive

advantage in their markets

Maximize value of existing product through constant innovations

Support customer growth opportunities

with dedicated plants/equipments

Continuous upgrades of R&D facilities and Environment, Health and Safety standards

Conduct business as a model corporate

citizen

Our lean management structure helps us in quick decision making

Organogram

Chairman

M P Aggarwal Director

Priyanka Agarwal

VP (Marketing)

Ivan Fernandes

VP (Operations)

V K Todi

Sr. Manager (Strategy &

Business Development)

Harshil Shah

Sr. Manager

Umesh Gupta

VP (Finance & Business)

Rakesh Gupta

Sr. VP (Commercial Government

Liaison) S. J. Kedia

Purchase Dept GM (EXIM)

K .P. Parmeshwaran

GM (Finance)

Arun Mehta

GM (R&D, QC)

Dr. A. P. Pandey

GM (Commercial & HR)

P. K. Shrivastava

AVP (Projects & Operations)

Gurupad

AGM (Project & Engineering)

R. H. Savalia

Manager (System &

Safety)

Vilas Jadhav

Sr. Manager (Environment)

Kamlesh Patel •Hari Narayan (Plant 1) •C.T. Gupta (Plant 2)

•K.B Jadeja (Plant 3) •Milind Jhare (Plant 4)

Plant Managers

We also have a highly qualified advisory board that is actively involved in strategic decisions

Advisory board member

Mr. Raj Kaul

• BS in Eng. And MS in Business Management – Marketing & Finance

• Joined Bayer Crop Science in 1983 as apart of the business group responsible for R&D, production, and marketing of the agriculture division

• Director of Bayer AG, Agro Chemicals business strategy

• Director, Bayer Crop Science India Limited responsible for M&A, divestments, JVs, alliances and business strategies

• Retired as Senior VP in 2007

Dr. Jochen C. Wulff

• PhD in Organic Chemistry, University of Munich

• Expertise in M&A, integration and change management

• Joined Bayer AG in 1968 and was appointed Head of Crop protection division in 1992

• Turned around an unprofitable division into one of the worlds leading crop science companies

• Served as CEO and Chairman on Board of Management of Bayer CropScience from 2002-04

Mr. James C Borel (Jim Borel)

• Graduated in Agriculture Business from Iowa State University

• Served as Executive VP and member of DuPont’s Chief Executive Office till early 2016

• Currently serving as Director of Farmers Edge

• Also on the Advisory Board of River Glen Venture Partners, Arsenal Capital Partners and Agree

• Trustee of the University of Delaware, The Farm Foundation and Alpha Gamma Rho Educational Foundation

We have four plants with a total installed capacity of 12,300 TPA and reactors primarily in the range of 12-25 kl Plant 1 Plant 2

Plant 3 Plant 4

Our plants are capable of handling various types of reactions and adhere to highest safety standards

Plant capabilities

• Commenced in 1997 to manufacture Agro and Pharmaceutical intermediates. • Key reactions undertaken - Metal Catalytic Hydrogenation, Cyclization, Oxidative Chlorination, Sulfonamide reaction, Condensation, and Bromination

Plant 2

Plant 1

• Commenced in 2001, for manufacturing Chlorinated Pyrimidine Derivatives for Agrochemicals and Dyes & Pigments. Vilsmeier Reaction, Oxidation, Pinner Reaction and Friedel Craft’s Reaction are the core competencies of this plant. It is also used for generating high purity dry HCl gas using a special technology where no waste is generated.

Plant 3

• Commenced in 2006 to manufacture Active Ingredients, Electronic Chemicals, Agrochemicals Intermediates. The plant is fully automated using Delta V Automation system. Multi step chemistry like Friedel Craft, High pressure & Temperature Coupling, Selective Chlorination, Amination, Benzylation and Steven's Rearrangement are undertaken in this plant.

Plant 4

• Commenced in 2017, for manufacturing of Technical Grade Active Ingredients for a leading multinational company. The plant adheres to highest safety standards and is fully automated using a Yokogawa system

Our plants backed by strong in-house R&D capabilities

Key insights

• Spread over 500m2

• 52 PhD and Scientists

• 8 molecules under development at any

point in time

• One dedicated team for cost

improvement activities

• Developed various innovative and cost effective processes involving

multi step synthesis

• R&D is supported by a well equipped analytical laboratory

We successfully scale up from lab to Kilo to commercialisation due to our well established Pilot Plant

Key insights

• Kilo lab capacity up to 5kg • Thin Film Evaporator and Julabo machine for reactions ranging from -40oC to 170oC • Multipurpose reactors with distillation facilities for recycling of solvents • Equipments include:

o Hastelloy, Stainless Steel, Glass Lined and Glass Assembly - Upto 2.5kl o High pressure Autoclaves 2 litre capacity - 65 bar o Hydrogenator - 150 liters - 10 bar o Glass Assembly with Fractionation Column - 200 liters o Agitated Pressure Nutsche Dryer o Vacuum Dryers & Filters

Our well equipped laboratory helps us adhere to the highest standard of quality control

Key insights

• Quality checks at every stage of production - from purchase of RM to delivery of final goods • Continuous development and validation of our analytical methods

• Fully documented standard operating procedure • Easy access to top labs across India for collaborative and specialized analysis

List of equipments

•Atomic Absorption spectrophotometer •UV / VIS Spectrophotometer •Macbeth 7000A Spectrophotometer •Gas Chromatogram (GC) •HPLC •HPTLC •Digital pH Meters •Digital Melting Point Apparatus •Auto Titrators •Karl Fisher Titrator •Tintometer •Brookfield Viscometer •Ion Chromatography 2100 - Thermo fisher •KF Coulometer - 831 Metrohm

We have fully integrated plants with a wide range of reactors, distillation columns and closed filtration & drying systems

Commercial plant equipment list

EQUIPMENT CAPACITY TEMP RANGE

PRESSURE RANGE NUMBER

Glass lined reactors 12.5m3 – 22m3 2000C Up to 6 kgs/cm2 70

SS 904L reactors 4m3 – 20m3

3000C

Up to 25 kgs/cm2 06

SS 316 & Carbon Steel reactors 1m3 – 30m3

100 - 1700C

Up to 20 kgs/cm2

115

Hastelloy C22 reactor 1m3 – 10m3

2000C

10 kgs/cm2 02

Agitated Pressure Nutsche: •SS & Vinyl Ester lining • Hastelloy

2.5m3 – 10m3

10m3

100 - 2000C 2000C

4 kgs/cm2

10 kgs/cm2

18 02

Dryer: •Rotary vacuum (SS316) •Fluidizied bed (SS316)

2 m3 – 6m3

0.8MT/Day

5MT/Day

130 - 2000C

4 kgs/cm2

04 02

Distillation columns – Glass lined, SS and Carbon Steel (Lead Bonded)

Height: 6 - 10 meters Diameter: 0.4 - 0.6 meter

125 - 1500C

09

Fractional vacuum distillation columns

Height: 25 meters Diameter: 0.8 meters

1250C

03

Our plant is energy efficient with full backup to ensure uninterrupted production

Key insights

• Electricity o State grid as primary supply – 3MW o Natural gas Genset as backup supply – 3MW o Diesel Genset as secondary backup – 2MW

• Steam – In house generation of high pressure steam (25 Bar) with full backup

o Multiple Effective Evaporator (MEE) – Steam is used to run a series of MEE. Condensate is recycled to boiler feed o Vapor Absorption Machine – Used to generate cooling and chilling water

Our plant is self sufficient with its own utilities

Utilities

• Electricity o State grid as primary supply – 3MW o Natural gas Genset as backup supply – 3MW o Diesel Genset as secondary backup – 2MW

• Steam – In house generation of high pressure steam (25 Bar) with full backup

o Multiple Effective Evaporator (MEE) – Steam is used to run a series of MEE. Condensate is recycled to boiler feed o Vapor Absorption Machine – Used to generate cooling and chilling water

EQUIPMENT CAPACITY

Captive power plant •1MW x 3 (Natural gas) •1MW x 2 (Diesel)

Boilers (Gas based) •12 Mt/h, 17 kgs/cm²

•15 Mt/h, 33 kgs/cm² + 600 kw Turbine

•25 Mt/h, 45 kg/cm² + 2 mw Turbine

Compressed air •800 CFM, 7 kgs/cm²

•175 CFM, 7 kgs/cm²

Nitrogen plant 200 m³/hr x 2

Brine chilling plant •-20C, 25 TR/hr

•-20C, 250 TR/hr

•-40C, 50 TR/hr

•-25C, 200TR/hr

Water chilling plant +5C, 330 TR

Vapour Absorption Machine (VAM)

330 TR , + 5°c Chilling output

Ammonia Vapour Absorption Machine 250 TR, -25°c Output

Sajjan has expertise in large scale production of specialty chemicals which involves complex chemistry

Core competencies

Pyrimidine Dérivatives : Large scale handling of Chlorine Gas, Phosphorus Oxy

Chloride and Phosphorus Trichloride

Chlorination : Extremely efficient process

Bromination by Liquid Bromine : Robust process followed ensuring minimum waste

Hydrogenation : Expertise in metal catalyzed Hydrogenation.

Vilsmeier Reaction : Highly hygroscopic process is being handled efficiently

Cyclization Reaction : Cyclization using various lewis acids

Methoxylation : Use of Sodium Methoxide powder and Sodium Methoxide 25%

solution

Double Bond Reduction : Using metal catalyst of various grades at multiple

temperature and pressure range

Our plant undertakes a varied range of reactions

Main reactions

Reaction

Pinner

Chlorination of Hydroxy Aryl compounds

Stevens Rearrangement

Vilsemeir

Ammonolysis

Acetylation

Friedel Craft’s

Haloform

Reaction

Morphonolysis

Hydrogenation Catalytic

Cyclization

Oxidation

a. Methyl into Carboxylic acid

b. Thiol into Sulphone

Bromination Aromatic Ring

Our plant complies with all environmental, health and safety standards

Protecting our environment

• We are a Zero discharge unit • ISO 14001:2004 compliant • Waste water, air emissions and solid waste are managed in the most efficient way

o Waste water – Use of Multiple Effective Evaporator and Reverse Osmosis (RO) o Air emissions – Well designed scrubbers for gaseous emissions o CO – Incinerated in well designed incinerator o Solid waste – disposed in government approved disposal sites

• Equity partner with Local Government in waste water pipeline projects • Invested over USD 5 million towards green house gas abatement initiatives which are registered with UNFCCC (United Nations Framework Convention on Climate Change)

Health and safety of our employees

• Health & safety is Paramount • OHSAS 18001:2007 compliant • Adequate training provided to every employee on health & safety best practices • Safety information displayed where applicable • Employees are provided with personal protective equipment and gear • Occupational Health Centre (OHC) and an ambulance on site • Fire fighting equipment are placed at appropriate locations • water reservoir of 600m3 on-site reserved for fire fighting • Alarm system and emergency shutdown procedures in place and regularly maintained

Incinerator Multi Effect Evaporator

We firmly believe in CSR and giving back to the society

Plant Ecology Centre

• Undertakes study of plant and vegetation suitable for neutralisation of environmental gases in Ankleshwar • Also serves as an environmental data bank for scientific research and study of the environment

Inaugurated in 2009 by Mr. Mangubhai Patel - Forest and

Environment Minister of Gujarat


Education

• Dept of Chemical Engineering, Rotary Institute of Chemical Technology, Ankleshwar • Agarwal Vidya Mandir School, Ratlam • Sajjan Lions International Academy


Healthcare

• Various healthcare initiatives like: oInitialized highly intensive day care (HIDU) unit at Breach Candy Hospital, Mumbai o Research and Development Centre for Parkinson’s disease in Mumbai o Welness Centre in Boston, USA o General and Multi specialty medical camps for underprivileged residents in remote villages of Gujarat

Silver Recognition Level based on EcoVadis CSR Rating – Amongst top 13%

Gujarat Cleaner Production Award - Government of Gujarat Forests & Environment Department

Best Supplier Sustainability Award – Bayer Group of Companies India

About the company - sajjan€¦ · About the company… • A leading contract manufacturer with...

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