Client outcomes
Real results from the field
A selection of engagements across extraction plants, refineries, and sustainable fuel operations.
Optimal yields and energy savings through close monitoring of residual oil in oilcake and DOC
The challenge
Residual oil levels in oilcake and de-oiled cake (DOC) were not being tracked closely enough, leading to suboptimal extraction yields and higher-than-necessary energy consumption. The quality of extracted oil was also being affected as a result.
Our approach
- Established a systematic monitoring protocol for residual oil content in oilcake and DOC at regular intervals
- Analysed the correlation between process parameters and residual oil levels to identify the key control variables
- Adjusted extraction process settings based on real-time monitoring data to minimise oil left behind
- Optimised energy input in line with the improved process parameters, reducing unnecessary consumption
Outcomes
Optimal
Extraction yields achieved through tighter process control
Reduced
Energy bills through process optimisation
Improved
Quality of extracted oil as a direct result of process improvements
Successful commissioning of a newly set up oil processing plant — from troubled start-up to stable operations
The challenge
A newly constructed oil processing plant was struggling to become operational. The team was unable to establish the correct process parameters and the various stages of the plant were not working in synchronisation, preventing the facility from running reliably or producing on-spec output.
Our approach
- Conducted a thorough review of the plant design, equipment specifications, and intended process flow
- Identified the root causes of parameter instability across each processing stage
- Defined the correct operational parameters for each unit and established the sequencing required for inter-stage synchronisation
- Worked alongside the plant team during live commissioning runs to validate settings and make real-time adjustments
- Documented the finalised operating procedures and trained plant personnel for independent ongoing operation
Outcomes
Stable
Plant operations achieved after commissioning support
On-spec
Output quality established across all processing stages
Aligned
Inter-stage synchronisation resolved across the full process line
Design, setup, and commissioning of proprietary oil processing units producing premium finished products
The challenge
The goal was to conceive, design, and bring into production a set of oil processing units capable of delivering premium quality finished products — requiring end-to-end ownership of the process from initial design through to successful commissioning and stable output.
Our approach
- Designed the oil processing units from the ground up, specifying process flow, equipment selection, and quality control parameters
- Oversaw plant setup and installation, ensuring the build matched the design intent at every stage
- Led the commissioning process, establishing and validating all operational parameters for each unit
- Conducted trial production runs to verify output quality against premium product specifications
- Handed over fully operational units with documented procedures and trained operating personnel
Outcomes
Premium
Finished product quality achieved from first production runs
End-to-end
Ownership from design through to commissioned production
Operational
Units handed over fully commissioned and running to specification
"Thanks a lot for your contribution in bringing our business from small operations to huge ones. Your contribution is unforgettable."
— Managing Director, PURTI
Dramatic improvement in finished product quality across multiple struggling oil processing operations
The challenge
A number of oil processing units — both operational and underperforming — were failing to consistently produce finished products that met quality standards. The issues varied across operations but shared a common root: process parameters, equipment settings, and quality control practices that had not been properly established or maintained.
Our approach
- Assessed each operation individually to diagnose the specific quality shortfalls and their underlying process causes
- Identified the critical control points in each processing line that had the greatest impact on finished product quality
- Recalibrated process parameters and equipment settings tailored to each unit's feedstock and output requirements
- Introduced quality monitoring checkpoints at key stages to catch deviations before they affected the final product
- Supported plant teams through the transition, building the in-house capability to sustain the improvements independently
Outcomes
Dramatic
Improvement in finished product quality across all operations assisted
Multiple
Plants brought up to consistent quality standards
Sustained
Quality gains maintained through in-house capability built during the engagement
"Huge thanks for quality improvement, losses control and streamlining production."
— Managing Director, Rajasthan Vanaspati (Mansingka Group), Bhilwara
Resolving deep-rooted operational problems that had kept plants from running
The challenge
Across numerous projects, oil processing plants were being held back by persistent, hard-to-diagnose problems — issues that had resisted previous attempts at resolution and were preventing the facilities from operating at all, or from running with any reliability. These were not surface-level faults but entrenched operational problems requiring systematic investigation.
Our approach
- Conducted in-depth on-site investigations to understand the full history and nature of each plant's recurring problems
- Applied structured root-cause analysis to move beyond symptoms and identify the underlying technical and process failures
- Developed targeted remediation plans addressing the specific combination of equipment, process, and operational factors at play
- Implemented fixes in a controlled sequence, testing at each stage to confirm the problem was resolved before proceeding
- Established safeguards and monitoring practices to prevent recurrence and give plant teams confidence in sustained operation
Outcomes
Resolved
Sticky problems that had blocked plant operation across numerous projects
Running
Plants returned to reliable operation after persistent issues were cleared
Protected
Against recurrence through targeted safeguards and monitoring
From by-product to biodiesel: establishing a validated process for converting Acid Oil into a sustainable fuel
The challenge
Acid Oil — a by-product of the oil processing industry — was being treated as low-value waste rather than a feedstock for sustainable energy. No proven, scalable process existed within the organisation to convert it into biodiesel. The challenge was to establish one from first principles, moving from laboratory hypothesis through to a pilot-scale process that could be confidently taken to commercial production.
Our approach
- Reviewed the chemistry and existing literature on Acid Oil composition and its suitability as a biodiesel feedstock
- Designed and conducted detailed lab-scale experiments to identify the optimal reaction conditions, catalysts, and process parameters for transesterification
- Iteratively refined the lab process based on yield and quality data, resolving the technical challenges specific to high free fatty acid feedstocks
- Scaled the validated lab process to pilot scale, adapting parameters for larger equipment and continuous operation
- Confirmed biodiesel quality against relevant specifications and documented the full process for commercial scale-up
Outcomes
70%
Of stipulated project time — delivered well ahead of schedule
Sustainable
Fuel produced from an industry by-product that was previously treated as waste
Scalable
Process documented and ready for commercial production scale-up
"Helped us complete the project on biodiesel in about 70% of stipulated time. Thanks for technical and analytical support."
— Technical Head, Simon Carves India
Developing a conversion pathway for used oils and Acid Oil into Sustainable Aviation Fuel (SAF)
The challenge
Aviation is one of the hardest sectors to decarbonise, and Sustainable Aviation Fuel represents a critical part of the solution. The project set out to establish a viable technical pathway for converting used cooking oils and Acid Oil — both waste-stream feedstocks — into SAF, a fuel that must meet stringent aviation specifications while delivering meaningful lifecycle carbon reductions.
Our approach
- Assessed the composition and variability of used oil and Acid Oil feedstocks to understand the pre-treatment requirements for SAF production
- Evaluated applicable conversion pathways — including hydroprocessed esters and fatty acids (HEFA) — for their suitability with these feedstock types
- Defined the process design basis, identifying the key unit operations and quality control requirements to meet aviation fuel specifications
- Conducted research and process development work to validate the conversion approach with the target feedstocks
- Mapped the route to scale-up and commercial production, including feedstock sourcing, process integration, and certification considerations
Outcomes
In progress
Active project developing a waste-oil-to-SAF conversion pathway
Dual feedstock
Process designed to handle both used cooking oils and Acid Oil
Aviation-grade
Target output meeting SAF specifications for commercial aviation use
End-to-end quality management for two major soap and surfactant producers — from raw material inputs to finished product
The challenge
Two large-scale soap and surfactant manufacturers were facing challenges in maintaining consistent quality across their operations — both in the raw materials and intermediates coming into the plant, and in the finished products leaving it. Without a structured QC framework covering the full input-to-output chain, quality variability was difficult to diagnose and harder to control.
Our approach
- Established systematic input quality monitoring protocols to assess and approve raw materials and intermediates before they entered the production process
- Defined quality benchmarks and testing schedules for each key input category, aligned with the specifications required for the finished product
- Introduced in-process quality checkpoints at critical stages of the soap and surfactant manufacturing lines
- Implemented finished product quality assessment protocols to ensure output consistently met brand and market standards
- Worked closely with plant teams at both facilities to embed quality discipline into day-to-day operations and build in-house QC capability
Outcomes
Consistent
Finished product quality achieved across both manufacturing facilities
Controlled
Input quality managed systematically, reducing variability entering the process
End-to-end
QC framework covering raw material intake through to finished product dispatch
"Thanks a lot for your contribution in bringing our business from small operations to huge ones. Your contribution is unforgettable."
— Managing Director, Rajhans Soap Mills
"The insight of quality parameters given by you is extremely important for us. Your 40 years and continuing association with us has given us remarkable strength."
— Managing Director, Dharam Chand Ladha Mal
Multi-discipline consultancy for one of India's largest oils and fats groups — oils processing, continuous soap manufacture, and specialised formulations
The challenge
Ruchi Soya Products Group, operating at significant scale across the oils and fats value chain, required specialist advisory support across three distinct but interconnected areas: optimising oils processing operations, improving the efficiency and output of continuous soap manufacturing lines, and developing specialised soap formulations to meet specific product and market requirements.
Our approach
- Assessed existing oils processing operations to identify inefficiencies, quality gaps, and opportunities for process improvement
- Provided technical guidance on continuous soap manufacturing processes, addressing parameter settings, line stability, and output consistency
- Developed specialised soap formulations tailored to specific product requirements, working through lab-scale development and scale-up to production
- Delivered recommendations across all three areas in an integrated manner, recognising the interdependencies between oils quality, soap feedstock, and finished product performance
- Supported implementation of recommendations on-site, working alongside the group's technical and production teams
Outcomes
Multi-discipline
Advisory spanning oils processing, continuous soap manufacture, and specialised formulations
Group-scale
Consultancy delivered across one of India's largest oils and fats operations
Integrated
Recommendations aligned across the full oils-to-soap value chain
"Your vision and clarity of technical knowledge with huge data helped our group immensely."
— Technical Director, Ruchi Soya Products Group
Establishing robust raw material quality control procedures for a major vanaspati producer
The challenge
Amrit Banaspati Company needed a structured, reliable procedure for checking the quality parameters of incoming raw materials. Without a systematic intake QC framework, variability in raw material quality was difficult to detect early — creating downstream risk to finished product consistency and process efficiency.
Our approach
- Assessed the existing raw material intake process to identify gaps in quality checking and documentation
- Defined the critical quality parameters for each key raw material category relevant to vanaspati production
- Designed a structured intake QC procedure specifying testing methods, acceptance criteria, and rejection protocols
- Worked with plant and procurement teams to implement the procedure and ensure it was practical for day-to-day operations
- Provided guidance on record-keeping and trend monitoring to enable ongoing quality assurance of incoming materials
Outcomes
Structured
Raw material intake QC procedure established from the ground up
Systematic
Quality parameters defined and tested consistently at point of intake
Preventive
Quality issues identified at intake before entering the production process
"Thanks for putting in place the right procedure to check quality parameters of raw material. That will help us a lot."
— Managing Director, Amrit Banaspati Company, Ghaziabad
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