53rd Annual Integrated Report 2023-24
53rd Annual Integrated Report 2023-24
We are continually enhancing our capacities and competencies to embrace emerging opportunities with a strong focus on driving process efficiency and operational excellence.
Material issues addressed Growth & Profitability
Sustainable Supply Chain
Customer Relationships
Product Innovation
Key risks considered Supply Chain Disruption/ Business Interruption Risks
Emerging competition to our existing business
Strategic linkages Expand Capacities Enhance Margins Widen Product Portfolio
SDGs impacted
Manufacturing facilities
Planned capex by FY 2027-28
With our strong manufacturing infrastructure and expertise in chemistry, we have become a trusted partner for major Indian and international corporations. Looking ahead, we see significant opportunities that will require us to expand our capacities and enhance our competencies.
We are making notable progress in scaling up our manufacturing capabilities. A key part of this effort is debottlenecking, which allows us to boost production. In FY 2023-24, we achieved our highest-ever Phenol production of over 300 KT, underscoring our commitment to maximising efficiency and setting a high standard for operational excellence.
We are delighted to share that we are one of the very few in the country to implement Advanced Process Controls (APC) in a chemical manufacturing facility of our size. APC is a process control and optimisation technology that optimises processes on a minute-by-minute basis by manipulating variables such as feed flow, temperature settings, pressure settings and reflux flows, which are otherwise managed through manual interventions. APC has made positive impacts in multiple ways, including increased production, reduced energy usage, improved production yields, enhanced product quality and reduced emissions. Other important positive outcomes are safe and reliable operations, improved catalyst life and extended useful lives of assets.
As a results, we now lead the industry with a remarkable capacity utilisation rate of 150%+ at our Phenol plant setting high standards for operational excellence.
We have successfully commissioned the installation of a SAC unit, which has significantly enhanced sustainability at the Nandesari plant. Our Fluorination plant commissioned in March 2024.
Looking ahead, our Acid, MIBK and MIBC plants are scheduled to be commissioned by FY 2024-25. These plants, which produce derivatives of Acetone, will allow us to utilise Acetone to manufacture MIBK and MIBC, thereby moving into downstream value-added products.
With multiple brownfield and greenfield projects set to be commissioned in the coming years, we are well-positioned for improved performance and growth. Notably, we have also approved an investment to establish a facility in Oman. This facility will manufacture key chemicals and benefit from the low-cost inputs of raw materials and energy, allowing us to serve global markets more effectively.
Another significant move towards digitalisation has been our successful migration to SAP-S4 HANA, which further strengthens our resource planning and decision-making, streamlines operations and advances our agility to forge ahead.
At Deepak, leveraging technology is essential for enhancing operational efficiency, reducing costs and boosting overall productivity through process optimisation and automation. By harnessing digital tools and software solutions, we can analyse, optimise and streamline our processes to stay competitive and deliver superior quality.
One of our standout implementations is an advanced solution that automates the loading of tankers with minimal human intervention while strictly adhering to safety regulations. Seamlessly integrated with our ERP system, this system ensures a fully automated process from billing to load management.
Auto Filling is integral to our optimisation strategy, enhancing material filling operations by eliminating manual errors, reducing waste and maximising throughput, thereby achieving improved operational efficiency and substantial cost savings.
For precision and accuracy, the software integrates intelligent sensors and measurement devices for material filling, ensuring consistent fill levels and eliminating variations.
Safety remains a top priority and the software strictly follows industry regulations while implementing comprehensive safety protocols. By reducing manual handling and preventing material spillage, the Auto Filling software fosters a safer work environment for employees and ensures compliance with stringent safety standards.
“Incorporating advanced technology like Auto Filling highlights our commitment to operational excellence, demonstrating the critical role that innovation and efficiency play in achieving sustainable growth and maintaining industry leadership.”
At Deepak, our Laboratory Information Management System (LIMS) is crucial in optimising laboratory workflows, enhancing data integrity, ensuring compliance and driving operational excellence. This transformative solution revolutionises laboratory operations, data management and collaboration, empowering us to achieve greater efficiency and productivity. With the integration of LIMS, we optimise processes, reduce manual errors and ensure the delivery of high-quality products to our customers.
We employ a transformative solution to tackle the complexities of managing our supply chain and logistics, intricate networks and for optimising operations and meeting customer demands. The advanced logistics planning and optimisation engine, powered by Cloud Computing, AI, ML and IoT, connect all stakeholders on a single platform with a multi-dimensional workflow. This integration enables the seamless execution and optimisation of logistics flows, including service procurement, resource planning, allocation, despatch, in-transit monitoring, delivery confirmation and vendor payments.
Tightly integrated with our ERP systems, the software generates alerts for exceptional incidents, allowing us to respond swiftly. At Deepak Group, we leverage advanced supply chain and logistics software to streamline operations, boost efficiency and deliver exceptional products to our customers.
Our commitment to efficient supply chain management, streamlined logistics operations and enhanced visibility and collaboration ensures our leadership in the chemical manufacturing industry. We continuously strive for excellence, providing superior value and service to our customers while maintaining a strong competitive edge.
At Deepak, we recognise the importance of Production Allocation and Hydrocarbon Accounting in optimising resource management, ensuring accuracy and complying with industry regulations.
By utilising advanced software solutions, we streamline processes, boost operational efficiency and enable precise reporting and informed decision-making
Our Production Allocation and Reporting (PAR) system seamlessly integrates with our ERP, collecting data through sensors, flow meters and production systems. This integration allows our software to calculate production volumes accurately and allocate them to the appropriate assets, leases, or partners. This data-driven approach optimises resource management, supports informed decision-making and ensures efficient asset utilisation.
Deepak Group utilises Production Allocation and Hydrocarbon Accounting software to boost operational efficiency and optimisation. This technology supports data-driven decisions, process optimisation and loss minimisation. Our software systems provide visibility into key performance indicators such as production rates, downtime and hydrocarbon inventories, allowing us to monitor and evaluate operations, identify areas for improvement and implement strategies to enhance efficiency and productivity.
Comprehensive reports on production volumes, revenue allocations and key performance indicators are generated by our systems, offering valuable insights into operational performance, cost analysis and revenue distribution. These reports facilitate effective decision-making at various organisational levels.
With a commitment to excellence and adherence to industry best practices, Deepak Group remains at the forefront of efficient production allocation and hydrocarbon accounting, driving value creation and operational excellence in the chemical industry.
Deepak Group is implementing Advanced Process Control (APC) to manage process nonlinearities, dynamics and constraints. Utilising mathematical models and historical data, APC predicts process behaviour and adjusts control parameters in real-time, ensuring stability and preventing disruptions. Real-time monitoring of critical variables enables APC to optimise performance and make timely decisions.
Our commitment to leveraging advanced technologies for continuous improvement is reflected in the integration and implementation of APC, which enhances our operational stability and efficiency.
We embrace the significant benefits derived from analytics in driving organisational success. By leveraging analytics, we gain valuable insights from extensive data volumes, enabling informed decision-making, optimising operations and attaining a competitive edge in the market. Our commitment to innovation ensures the delivery of high-quality products and the achievement of operational excellence. Through effective data utilisation, we achieve increased productivity, cost savings and enhanced customer satisfaction, setting new benchmarks for success in the dynamic realm of smart manufacturing.
In smart manufacturing, analytics is essential for capturing, integrating and analysing data from various sources, including sensors, machines and production systems. To enhance this process, we have implemented IP21, which efficiently captures and analyses our production data. This enables us to leverage analytics for continuous improvement and optimisation of our manufacturing processes.
Additionally, IP21 stores historical operational data, allowing us to perform retrospective analysis and generate comprehensive reports. This capability lets us compare performance over time, identify trends and conduct root cause analysis for any operational issues that arise.
Vibration monitoring system is crucial to Deepak Group’s operations, offering regular health checks for single-line equipment and other critical rotary machinery. We employ condition-based predictive analysis and performing vibration analysis, Oil Analysis, Thermography, Motor current signature analysis, corrosion monitoring and thickness surveys. With early detection and timely maintenance interventions enabled by such predictive analytics, Deepak Group ensures the optimal health and performance of its equipment, minimises downtime and maximises operational efficiency.
