India’s chemical industry is undergoing a significant transformation as it strives for a new level of competitiveness. While scale remains important, factors like consistency, traceability, resource efficiency, and process control are now also critical to success. These changes highlight the rise of continuous chemistry as a viable pathway for reliable production, as noted by Dr. Kamlesh Fondekar, head of R&D at Godrej Agrovet.
Historically, the focus in manufacturing has been on output—how much can be produced and how fast. Although this is still important, there is now a stronger emphasis on meeting stricter quality standards while minimizing waste and energy usage. Fondekar emphasizes that the conversation in the chemicals sector is shifting from just maximizing production to mastering control over the processes involved. Given that this sector is the largest industrial consumer of oil and gas globally, achieving process efficiency is no longer just a technical matter; it’s linked to broader goals of cost management, resilience, and sustainability.
One challenge many manufacturers face is that systems that work well in the lab often become problematic in full-scale production. Variations in heat transfer, mixing, and material behavior can complicate processes, sometimes resulting in decreased yield or quality. While batch manufacturing can be flexible, it also tends to introduce variability that must be closely managed. On the other hand, continuous chemistry streamlines production by using a controlled flow system, which enhances heat and mass transfer, resulting in more stable and manageable conditions.
Another key advantage of continuous chemistry is its predictability. Plant managers are more likely to embrace a process if it demonstrates improved performance. Continuous systems allow for earlier detection of deviations, which can prevent costly issues before they arise. This proactive approach not only reduces the occurrence of off-spec batches but also enhances overall operational stability.
Sustainability discussions often focus on waste treatment and disposal, but the real opportunity lies in addressing these issues at the source. By improving selectivity and managing heat more effectively, continuous chemistry can help reduce waste generation and improve resource efficiency. The Indian government recognizes that the industrial sector is responsible for a significant portion of the country’s total energy consumption, highlighting the importance of process efficiency for both competitiveness and sustainability.
In modern manufacturing, a wealth of data related to temperature, pressure, and output quality is generated. However, the challenge lies not in collecting this data but in effectively interpreting it. Continuous systems facilitate real-time monitoring, promoting better management and accountability. Digital tools enhance visibility but must be combined with in-depth process knowledge for maximum benefit—an important distinction for Indian industries, where technology is often viewed as a standalone solution to manufacturing challenges.
As India’s chemical sector looks to grow, the focus should not only be on increasing production capacity but also on enhancing capabilities. Global clients are increasingly prioritizing consistency and reliability alongside cost, opening opportunities in specialty chemicals, agrochemicals, and advanced intermediates. Continuous chemistry will not completely replace batch processes but can complement them, particularly in scenarios where it offers a clear advantage.
The real challenge lies in building capability. While acquiring new equipment is straightforward, developing the skills and expertise necessary for effective implementation is crucial. According to Fondekar, the successful adoption of continuous processes will depend on more than just hardware investments; it will require process development, workforce training, and collaboration between industry and academic institutions.
For India, the message is clear: while continuous chemistry may not be a one-size-fits-all solution, it represents a promising approach for enhancing productivity, quality, and sustainability in manufacturing. By integrating process insights with digital tools and fostering better training, the country can advance its manufacturing landscape into a more robust and resilient sector.
