We possess inbuilt strength and expertise to develop and manufacture HIGH QUALITY Organic Fine Chemicals in addition to BULK-INTERMEDIATES & API’s. The plant is versatile & multi purpose to take care of varied reactions. The Plant is commissioned to meet cGMP norms for which Inspection is due by the nominated Agency. Plant is approved by Indian FDA and ISO 9001:2000 accredited since 1999.

Some of the reactions carried out by us are

We have a very well equipped research and development laboratory with facilities for conducting various types of reactions encompassing the following facilities :

a) Teflon coated high vacuum pump (Make Vacuu brand, Germany)
b) Glassware for chemical synthesis ranging from 100 ml to 20 ltrs.
c) Fuming chambers for carrying out hazardous reactions – Bench types & walk in chambers.
d) High Pressure autoclave of 2 ltr capacity for undertaking reduction reactions up to 35 Kgs.
e) 5lt., 10lt.,& 20lts. Stand alone glass assemblies with all utility support.
f) Analytical instruments like HPLC,GC & FTIR for monitoring the results.
g) Glass distillation units of 5, 50 & 20 Ltrs with column, condensor & reflux.
h) Glassware for Chemical Synthesis ranging from 100 ml to 20 Ltrs.
i) High vacuum pump for HVD.
j) Technically sound and competent team of 20 people headed by PHD working continuously to develop new molecules.

The equipment available in this laboratory is:

The Equipments / Instruments available here are:

We have bulk storage facility for raw materials and finished products irrespective of their nature as Liquid or Solid. The material handling equipments are as under:

We also have facility for container stuffing at our factory

We have multipurpose utility system with minimum temperature -10°C and maximum temperature 250°C.

We have a full fledged Primary effluent treatment approved plant. Being the founder member of Common Effluent Treatment Plant (Sponsored by World Bank) in the Vicinity, we are permitted to send our primary treated effluent to them (through Road Tankers / isolated drainage system) for it’s Secondary treatment & disposal as per norms of State Pollution Control Board. We have a valid concent from State Pollution Authorities for next 5 years i.e. till year 2010.

GMP is the need of the hour and to cater to this requirements, Sarex incorporates system which evolve appropriate methodology and procedures which are well documented. Special emphasis and care is taken so that there is no cross-contamination of products and clean room areas with forced ventilation and having controlled parameters designed within the facility. The Plant is local FDA approved and WHO-GMP compliant. Actions are being initiated to get US-FDA at least before the end of 2007.

Sarex gives special emphasis on safety of environment and human safety as well. Use of personal protective equipment like helmets, gloves, goggles, safety mask, safety shoes, face shields etc. is made mandatory for everyone working in the plant whenever required. Air pollution is taken care of by using scrubbers and liquid effluents are primarily treated before being discharged. Vessels are provided with rupture disk and safety valves. Earthing and bonding of all equipments & solvent lines, lighting arrestor provision is done as a safety requirement. Company has carried Hazop studies for its critical products. Disaster control / onsite emergency plan is also made to the satisfaction of Dept. of Health Safety. Periodic trainings are being conducted to ensure safety. A Safety Committee is appointed to ensure all parameters of safety are achieved.

A new multipurpose manufacturing hub was inaugurated by Dr. Klaus Ruf, Head, Technical Operations, CIBA – BASLE, Switzerland, on 4th June 2008.

The new facility comprises of Six distinct blocks:

1. Manufacturing Block

The manufacturing block is 35 m long x 13 m wide and has 4 floors to accommodate various equipments. The equipments are arranged in such a manner that in most of the cases gravity transfer of liquid & solid is achieved. This reduces choke up problems, contaminations & cleaning during change of batch / product, pumping in terms of hold up & draining etc.

The complete building is constructed on concrete to avoid corrosion. Majority of the building is open from all sides to avoid entrainment of gases in case of emergency and provide better environment to people working within.

The plant is arranged in such a way that all liquid day tanks and solid charging hoppers are planned on the top floor with a gravity closed transfer system. All other floors are provided with reactors, centrifuges, filters, pumps and various types of dryers for various process requirements.
This plant is a Batch process plant and most of the activities are automated by Programmable Logic Controller (PLC). All the process related interlocks such as temperature, pressure, level & flow are built in the PLC along with safety interlocks. The basic feature of the plant is that, though it is designed for the bulk production of a particular product, it is multi-purpose and it can be adapted for the production of speciality products for various industries like Plastic, Textile, Pharma. Some of the reactions which can be carried out are Fridel Crafts reaction, Condensation reaction, Sandmayer reactions and many more. Highlights of the equipments installed are as follows:

1.01 High Pressure Reaction / Hydrogenation Section

The high pressure reactor and associated systems are designed to carry out high pressure reaction as well as high pressure hydrogenation. This equipment is designed by Omega Kemix to take 35 kg / cm2 working pressure. The high speed agitator is specially designed for gas induction and it is magnetically coupled with driver to avoid any leakage during high pressure reaction.

The reactor is provided with its catalyst filtration system, sampling system, hydrogen gas manifold and nitrogen gas manifold . The reactor is installed in a separate bay in the building surrounded by blast proof concrete walls and weak roof with concrete grids to avoid effect of accident to surrounding area and contain explosion within the room. The reactor is provided with all safety systems like safety valve, rupture disc, knock out pot, sufficient amount of instrumentation & safety interlocks. Fire doors are also provided for he hydrogenation block.

As a part of high pressure reactor section, solvent concentration reactor system, high vacuum distillation system and solid product centrifuge is provided for filtration. This reactor is suitable for all types of catalytic reductions and Kolbe's reaction.

1.02 Reaction Section

The reaction section consist of Glass lined reactors and SS 316 reactors located on various floors of the production building to achieve maximum gravity flow of the product.

The new facility is having 11 Glass lined reactors designed for working pressure of 5 kg/cm2 along with their vapour columns, primary condensers, vent condensers, vacuum systems and receivers. These glass lined reactors are
specially designed by GMM Pfaudler and variable frequency drives to change the agitator speed for different type of reactions. These reactors are provided with specially designed agitators to give better mixing, avoid crust formation and very low volume stirring. The agitators are also provided with double mechanical seals to avoid leakage during high pressure reaction.

The Glass lined reactors are connected with PTFE lined piping on process side to graphite condensers, vent condensers and receivers. This helps in carrying out all reactions of corrosive nature. They are all connected with steam jet ejector systems to generate various levels of vacuum in the system. All the reactors are provided with multiple utilities as per the need such as steam, cooling water, chilled brine etc. The condenser cooling media used is inert to help where water contact is to be avoided with process even in case of accident. The plant also has SS 316 reactors with associated vapour column, primary condensers, vent condensers, receivers and vacuum system.

1.03 High Vacuum Distillation Section

Two sets of high vacuum distillation set-ups are provided apart from high pressure reaction section and high vacuum distillation set-up. One set is provided with Glass lined reactor having glass column, graphite condensers and PTFE/ Glass piping while the second set is provided with all SS 316 equipment and SS 316 connected pipeline. The vacuum system is a dry vacuum pump with booster to generate 0.5 Torr vacuum. The pump is designed with nickel coated impeller with PTFE coating on top to work with any corrosive fluid.

A single fluid heating and cooling system is employed to avoid the use of steam, hot water or water based brine in the utility line.

1.04 Filtration Section

The new facility is provided with various types of filtration equipments such as Centrifuges (bag lift type and bottom discharge), Neutch filters and Sparkler filters.

A combination of various types of filters help in handling various types of product filtration such as bag lift type for standard products, bottom discharge for products where external contamination, contact with air or smell is an issue and product need to be transferred in close condition. For pressure filtration Neutch filter is also provided.

The material of construction for some centrifuges are SS 316 filter any type of corrosive products. The centrifuges are full body opening type for proper cleaning and avoid contamination during product change.

Total filters: Centrifuges - 7 nos., Neutch Filters - 2, Spakler Filters - 1 no. The centrifuges are GMP models and also provided with variable frequency drives

1.05 Drying Section

Two Double cone Rotary vacuum dryers are installed for the drying at intermediate and final stage of the product. These dryers are made of SS 316 and having capacity of 1.5 KL & 2 KL respectively. Lump breaker
arrangment is also provided to break lumps of any generated during drying process.

Double cone rotary vacuum dryer are used to ensure uniform drying at a low temperature. Vacuum drying also ensures that air or oxygen is not in contact with the product while drying. This avoids the formation of the impurities as well as contamination with the atmospheric particulates.

1.06 Miscellaneous Supporting Section

Apart from main equipments, following are the supporting equipments provided to perform various duties:

¤ HCL Generators - To generate dry HCL gas for sparging gas sub inside the reactor.
¤ Chlorine System - Chlorine cylinders with vaporizer is provided for getting Chlorine gas at constant rate to sparge in the reactor.
¤ Closed Charging System - Closed soild charging hoppers with exhaust system is provided above the reactors.
¤ Crushers/ Lump Breakers - This equipment is provided for crushing certain solid products to desired uniform size to desired uniform size before    charging them in glass lined reactors to avoid damage to the glass and reduction in particle size which enhances rate of reaction.
¤ Bulk Bag Packing System - Provided bulk bag filling arrangement just below the blender.
¤ Day tanks - For various solvents, caustic and acid charging to the reactors.
¤ Scrubbing System - Three scrubbing systems are provided for scrubbing gases evolved during various reactions. One with water, second with    caustic and third with hypochloride as scrubbing media.
¤ Knock Out Pot - All reactors are provided with rupture disc for safety reasons and the material discharged during any eventuality is connected to the    knock out pot

2. Manufacturing Block

2.01 Oil Fired IBR Steam Boiler

2 ton / hr. with 10.5 Kg/ cm2 pressure boiler is installed to take care of the heating & distillation requirement of the process. Steam is reduced to 6 kg/cm2 pressure for using in the steam jet ejector system and certain reactors for heating. Low pressure steam is used for normal heating of reactors and solven distillation.

2.02 Chilling Plant

A brine plant using Mon oethylene glycol (MEG) as brine is installed to get temperatures up to -23°C in the system.

2.03 Nitrogen Plant

25 NM3 / hr of nitrogen plant is installed to get consistent. Nitrogen supply having oxygen less than 5 ppm. Nitrogen is being used for the initiation of the reactor atmosphere as well as pressure transfer.

2.04 Transformer with 33 KV line – 1500 KVA

For high Tension electricity supply a transformer with 33 KV line and 1500 KVA capacity is installed.

2.05 Power Generator System

33 KV switch yard with 1500 KVA transformer is installed for uninterrupted power supply to the new plant. Apart from this, a back up 500 KVA diesel generator set is provided as back up power.

2.06 Air compressor

Air compressor with 100 cubic feet per minute air supply of instrument grade [dry air (-) 40 oc dew point] is installed. This is required for operating pneumatically operated valves.

3. Tank Farm Block

A provision of 6 nos. of 15 KL Tanks installation is made. 4 nos. of 15 KL Tanks are already installed. These tanks are underground and approved by Chief Controller of explosives. Adequate safety precautions are taken such as flame proof pumps, motors, earthing and bonding at various desired places.

4. Warehouse

A warehouse is constructed to store all liquid raw materials in small packs for existing & new plant with the racking system and material handling system.

5. Effluent Treatment Block

A new effluent treatment facility is designed for treating 100m3/ day of effluent with primary, biological & tertiary’s treatment to meet local pollution control board norms before discharging it to common effluent treatment facility of industrial area.

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6. Fire Water Tank / hydrant

Water Fire hydrant using unit is put up at new location to cover safety requirements of both the plants. The water hydrant unit is backed up with 400 m3 RCC overhead water storage facility dedicated for the system.