In a landmark achievement for sustainable industrial engineering, Spray Engineering Devices Ltd. (SED) has successfully commissioned a major sugar refinery capacity expansion and energy optimisation project for Shri Dutt India Private Limited (SDIPL) at its Kandla facility in Gujarat.
Completed in under twelve months, the project increased the refinery’s capacity from 1,000 tonnes per day (TPD) to 2,500 TPD, while retaining the existing boiler infrastructure. Notably, SED achieved the expansion without any additional boiler investment, setting a new benchmark for rapid and energy-efficient industrial scale-up in India’s sugar sector.
Setting New Benchmarks in Rapid, Sustainable Scale-Up
Among the fastest large-scale expansions in the Indian sugar industry, the project highlights how modernisation of existing assets can unlock significant capacity gains. Instead of deploying capital-intensive new utilities, SED optimised the refinery’s core process systems, proving that sustainable growth and accelerated execution can go hand in hand. As a result, the project establishes a compelling model for refineries seeking higher throughput under tight timelines and energy constraints.
Leadership Perspectives on Engineering Innovation
Commenting on the milestone, Vivek Verma, Managing Director, Spray Engineering Devices Ltd., said the project underscores the role of process innovation in sustainable manufacturing. “This project demonstrates the capability of our latest Batch Crystallisation Pans to operate at extremely low Delta T levels. By optimising heat transfer, we enabled Shri Dutt India to more than double its output while retaining its existing steam generation infrastructure. It reinforces that engineering innovation is central to sustainable industrial growth.”
Echoing this view, Jeetendra Dharu, Director, Shri Dutt India Private Limited, emphasised the execution excellence behind the project. “The entire project—from concept to commissioning—was completed in less than twelve months. This reflects seamless coordination between teams and SED’s strong commitment to meeting aggressive execution timelines.”
Key Project Highlights
*2.5x Capacity Expansion: Scale-up from 1,000 TPD to 2,500 TPD
*Infrastructure Optimisation: MVR-based system eliminated the need for new boiler investments
*Proprietary Technology: Honeycomb Calandria Batch Pans operating at an industry-leading 20–25°C Delta T
*Fast-Track Execution: Concept-to-commissioning achieved in under 12 months
Advanced Process Integration Drives Energy Efficiency
At the core of the project is SED’s proprietary integration of Mechanical Vapour Recompression (MVR) with Batch Crystallisation Pans. These pans feature Honeycomb Calandria technology. Operating at an ultra-low temperature differential of just 20–25°C, the system significantly enhances heat transfer efficiency while sharply reducing steam consumption. This advanced configuration allowed SDIPL to unlock higher capacity without increasing energy demand. It demonstrates a practical pathway to low-carbon industrial expansion.
Delivering World-Class Outcomes with Lower Carbon Impact
Reflecting on the project’s complexity, Priti Ruparel, representing the leadership at SDIPL, noted the technological and execution challenges involved. “This was a significant challenge in terms of both time and technology. We placed our trust in SED’s technical expertise, and they delivered a truly world-class sugar refinery.” As per the press release, by eliminating the need for additional boiler infrastructure, the refinery achieved a 2.5x capacity increase with a significantly reduced carbon footprint. Ultimately, the project sends a clear message to the industry. Technological innovation—rather than added utilities—is the key to sustainable, high-impact industrial growth.
Tata Consulting Engineers (TCE) acquired US-based CDI Engineering Solutions to strengthen its global design, engineering, and project management capabilities. The move enhances TCE’s presence in North America and its ability to deliver sustainable and innovative projects worldwide.
n Energy Leader
Adani Petrochemicals and Thailand’s Indorama have formed a 50:50 JV, Valor Petrochemicals, to develop petrochemical projects. Its first venture is a two-million-ton PVC plant in Gujarat, aligning with Adani’s $4-billion petrochemical expansion strategy.
L&T will invest ₹48,000 crore over ten years to set up six green ammonia plants at Kandla Port, Gujarat. Developed in phases, the 300 KTPA units will support industrial decarbonisation and target global export markets.
India is strengthening rare earth and atomic mineral supply chains through IREL’s Chatrapur plant expansion, boosting production and jobs. Record output and lifted US restrictions on key institutions are enabling stronger India–US cooperation in critical minerals and clean energy.
Waaree Group has begun construction of a 300 MW alkaline electrolyser manufacturing facility in Valsad, Gujarat. Supporting India’s National Green Hydrogen Mission, the plant will boost domestic manufacturing, reduce imports, create jobs, and strengthen India’s clean energy leadership.
India and France will collaborate on developing small modular nuclear reactors to strengthen energy security and cut emissions. India’s planned nuclear liability law reforms aim to boost foreign investment and support its target of 100GW nuclear capacity by 2047.
The 18th ICC India Chemical Industry Outlook Conference highlighted India’s $220 billion chemical sector poised for $1 trillion by 2040. Focused on AI, sustainability, and innovation, it emphasized R&D, industry-academia collaboration, and global competitiveness in eco-friendly chemicals.
India and Saudi Arabia agreed to deepen energy cooperation, ensuring stable oil, LPG supplies, strategic reserves, and joint refinery projects. The partnership also targets downstream ventures, innovation, and renewables, strengthening strategic ties amid shifting global oil import dynamics.
Reliance Industries plans a ₹75,000 crore investment in new energy and petrochemicals, expanding solar capacity to 10 GW by 2026 and developing lithium iron phosphate batteries, positioning renewable ventures to rival traditional oil-to-chemicals earnings by FY31.
Dr. Shailaja Donempudi becomes the first woman in CSIR’s 80-year history to earn the Distinguished Scientist title, leading Business Development, advancing polymer science, fostering industry collaborations, and inspiring future generations of women scientists in India.
Vedanta is expanding its critical minerals portfolio through acquisitions, partnerships, and exploration in India and abroad, securing key resources like copper, cobalt, and graphite to support clean energy, EVs, renewables, and India’s green transition initiatives.
Essar Future Energy plans a 1 MMTPA greenfield biofuel complex in Gujarat, using sustainable feedstocks like UCO and POME to produce SAF, HVO, and naphtha. Environmental clearance and an EIA by Kadam Consultants are underway to ensure compliance.
ACME Group will build a 4,00,000-ton green ammonia facility at Odisha’s Tata SEZ by 2029, creating 1,000+ jobs. Partnering with Japan’s IHI, the project boosts India’s green hydrogen capacity, industrial decarbonisation, and renewable energy leadership.
Torrent Pharma is set to become India’s fifth-largest pharma by secondary sales after acquiring a 46.39% stake in JB Pharma. The ₹11,917 crore deal boosts domestic market share to 4.6%, strengthens cardiology and gastroenterology segments, and awaits regulatory approvals.
Godrej Industries Chemicals plans a ₹750 crore capacity expansion to triple core and specialty chemical production, targeting $1 billion by 2030. Focused on sustainability, green technologies, and innovation, the company aims to lead globally in high-performance, eco-friendly chemical solutions.
IOCL plans a nationwide green hydrogen network, starting with its Panipat refinery producing 10,000 tonnes annually by 2026. Part of its $30 billion net-zero strategy, the initiative supports clean mobility, infrastructure expansion, and potential green hydrogen exports.
Balrampur Chini Mills is launching Bioyug, India’s first industrial-scale PLA biopolymer plant, producing 80,000 tons annually from sugarcane derivatives. The ₹2,850 crore project promotes circular, renewable, and compostable plastics, supporting sustainability, rural economies, and diverse industries.
ONGC is studying a 200,000–240,000 BPD refinery in Jamnagar with an investment of ₹1.25–1.5 lakh crore. The project aligns with India’s refining expansion strategy, enhancing energy self-reliance and leveraging Jamnagar’s strategic hub status.
Godavari Biorefineries’ Sathgen Therapeutics secured a Chinese patent for its anti-cancer molecule HYDROXY-1,4-NAPHTHALENEDIONE, showing efficacy against multiple cancers. The milestone strengthens its IP portfolio, advancing global life sciences innovation and clinical-stage oncology research.
VJTI Mumbai, in partnership with Archroma India, launched the Centre for Sustainable Chemistry and Engineering, fostering hands-on learning, sustainability education, and innovation. The initiative inspires students and faculty through workshops, entrepreneurial insights, and leadership guidance for a greener future.
Laurus Labs secured 531.77 acres in Andhra Pradesh to develop the Laurus Pharma Zone, a ₹5,630 crore pharmaceutical hub. The phased project will enhance manufacturing capacity, create employment, and support the company’s long-term expansion strategy.
ACME Group won a SECI award to supply 75,000 tons of green ammonia annually to Paradeep Phosphates for 10 years under the SIGHT Scheme. The project supports India’s green energy transition, with deliveries expected within 36 months.
ACME and Japan’s IHI Corporation formed a joint venture to build India’s largest green ammonia plant in Odisha, producing 0.4 million tonnes annually, reducing 0.8 million tonnes of CO₂, and strengthening India–Japan energy ties and decarbonization efforts.
NTPC’s Vindhyachal coal plant produced methanol from captured CO₂ using Carbon Clean’s CaptureX technology, advancing India’s net-zero goals. The scalable system converts emissions into valuable chemicals, demonstrating low-carbon innovation and paving the way for future CO₂-to-ethanol projects.
Honeywell’s carbon capture technology will help Wabash Valley Resources convert a shuttered Indiana plant into a low-carbon hydrogen and ammonia facility. Backed by $1.559 billion DOE funding, it reduces 1.65 million tons CO₂ annually and strengthens U.S. fertilizer supply.
Nuberg EPC secured a turnkey contract to expand Al Ghaith Chemical’s Chlor-Alkali and Calcium Chloride plants in Oman, enhancing production, supporting industrial growth, and advancing Vision 2040 with world-class, safe, and sustainable chemical manufacturing infrastructure.
Tata Chemicals invests ₹910 crore to expand soda ash and specialty silica capacities, enhancing operational efficiency, market leadership, and cost competitiveness, while addressing rising demand, competitive pressures, and evolving customer needs across commodity and specialty chemical markets in India.
Hindustan Zinc is launching North India’s first phosphate fertiliser plant in Chittorgarh with ₹5,000 crore investment, producing DAP, NPK, and ammonium phosphate sulphate, boosting regional supply, farmer productivity, MSMEs, employment, and supporting Atma Nirbhar Bharat goals.
DuPont introduced the FilmTec SW30XLE-400/34 RO element to combat biofouling in seawater desalination, delivering up to 25% lower pressure drop, reduced energy use, less maintenance, and improved operational efficiency and membrane lifespan.
Reliance Industries launched Reliance Intelligence to drive AI innovation in India, recruiting AI talent, building Indic-language models, partnering with Google and Meta, investing ₹855 crore, and developing large-scale, clean-energy-powered AI infrastructure to strengthen India’s AI ecosystem.
L&T secured a ₹5,000–10,000 crore EPCC contract from BPCL for India’s largest LLDPE/HDPE swing unit at Bina, Madhya Pradesh, supporting BPCL’s refinery expansion, boosting domestic polymer capacity, strengthening supply chains, and advancing Aatmanirbhar Bharat.
Dr. Raghunath Mashelkar launched his book “More from Less for More,” highlighting frugal, inclusive, science-led innovation for sustainable growth. The event drew eminent industry leaders, underscoring innovation’s role in shaping India’s future and embedding purpose-driven development strategies.
VA Tech WABAG will serve as EPC partner for Saudi Arabia’s Hadda ISTP under a consortium led by Metito Utilities. The 25-year BOOT project includes a 100,000 m³/day sewage plant, expandable to 250,000 m³/day, with reuse and transmission infrastructure.
IFFCO inaugurated a nano fertiliser plant in Devanahalli, Bengaluru, producing 200,000 bottles of Nano Urea Plus daily. The facility promotes precision farming, reduces conventional urea dependence and imports, and reinforces IFFCO’s science-driven, farmer-centric approach aligned with Atmanirbhar Bharat.
