Our Customers & Case Studies

Client A – The Ugar Sugar Works Limited (“USWL”)

USWL is a manufacturer of white crystal sugar with current crushing a total of 18,000 TCD. USWL wanted to construct an advanced ethanol plant with a capacity of 800 KLPD on a syrup basis during season and 600 KLPD grain during off season.

Location

Ugar Khurd, Belagavi, Karnataka

Challenges

Constructing an ethanol plant with a capacity of 800 KLPD on a syrup basis during season and 600 KLPD grain during off season.

Low-pressure steam: The proposed ethanol plant was required to operate on low-pressure steam at 1 kg/cm2(g) and therefore, availability of steam at low pressure was a critical requirement to be met.

Strict quality standard: Regreen-Excel EPC India Limited had to meet requisite quality standards to meet oil marketing companies’ requirements.

Solution

Detailed process design: A team of experts conducted detailed process design to identify the configurations for low utility consumption in both cases and with suitable equipment for both syrup and grain modes of operation.

Low pressure steam: Regreen-Excel EPC India Limited developed the plant with a design for low pressure steam of 1 kg/cm2(g).

Measurable Impact

High-capacity plant: Regreen-Excel EPC India Limited supplied an 800 KLPD distillery plant. This plant showcases company’s engineering expertise and commitment to delivering solutions to company’s valued clients.

Client B - Hermes Distillery Private Limited (“HDPL”)

HDPL is an Indian made foreign liquor industry producer. HDPL entered into a contract with Regreen-Excel EPC India Limited to establish a 500 KLPD capacity ethanol plant

Location

Ankali Raibag Road, Yadrav, Dist Belgavi, Karnataka

Challenges

Capacity and feedstock complexity: The client aimed to establish a 500 KLPD capacity ethanol plant, facing challenges due to its multi-feedstock operations.

Steam and utility efficiency: Low steam and utility consumption levels were required by the client at the plant.

Integration of utilities: Ensuring seamless integration of utilities, particularly with company supplied processing plant, was company’s key focus.

Solution

Developing an effective process design: Regreen-Excel EPC India Limited designed for 500 KLPD in Sugar Syrup mode and 425 KLPD in Grain mode operation, with company’s team scrutinizing the process design. The objective was to identify configurations that would minimize utility consumption in both grain and syrup modes while ensuring the selection of suitable equipment for seamless operation in both scenarios.

Implementing E-max 75 technology: Regreen-Excel EPC India Limited implemented the E-max 75 technology, aimed at achieving significantly low steam and utility consumption levels. Through engineering, Regreen-Excel EPC India Limited attained steam consumption rates of 2.0 kg/ lit and 2.5 kg/litre, in case of syrup and grain respectively, demonstrating the use of E-max 75 technology.

Integration of utilities: Company’s team with their proactive approach and clear communication facilitated smooth coordination between various stakeholders, ensuring that the integration of utilities proceeded.

Measurable Impact

Minimal utility consumption, low steam consumption, integrated utilities: Regreen-Excel EPC India Limited supplied a 500 KLPD capacity ethanol plant with minimal utility consumption of grain and syrup, low steam consumption, and integrated utilities within the plant.

Client C - Gulshan Polyols Limited (“Gulshan Polyols”)

Gulshan Polyols is a manufacturer in grain processing, bio-fuel, distillery, and mineral processing operations.

Location

Boregaon, Sausar, Dist Chhindwada, Madhya Pradesh, Madhya Pradesh

Challenges

Grain slurry: Handling grain slurry in the establishment of a 400 KLPD grain-based distillery plant.

Integration of utilities: Regreen-Excel EPC India Limited sought to ensure integration of utilities within the plant.

Solution

Expertise in grain-based distillery industry: Their expertise in the industry helped Regreen-Excel EPC India Limited handle the grain slurry task in setting up the plant. In the grain-based distillery industry, Dried Distillers Grains with Solubles (DDGS), a by-product has gained significant attention which is adding to client’s profitability. The in-house designed rotary steam tube bundle dryer plays a crucial role in ensuring the production of high-quality DDGS without compromising the valuable protein content. This innovative technology allows distilleries to extract the increased value from their operations, making DDGS a sought-after commodity that is readily accepted by all purchasers.

Executing integration of utilities: The team worked diligently to plan and execute the integration of all necessary utilities, including electricity, water, and steam.

Measurable Impact

Plant Specifications: Regreen-Excel EPC India Limited delivered a grain-based distillery plant producing ENA and ethanol, with a capacity of 400 KLPD and operating year-round.

Operational Efficiency: The multi-feedstock ethanol production facility achieved efficiency in both syrup and grain modes, with optimized utility consumption and reduced operational costs.

Flexibility and Availability: The client benefits from a multi-feed plant with swift feedstock changeover capabilities.

Efficient Project Management: Regreen-Excel EPC India Limited provide a single point of coordination for the entire complex, ensuring project management, guaranteed plant uptime, and comprehensive O&M system.

Client A. India Glycols Limited (“India Glycols”)

India Glycols an Indian green chemical industry producing a range of performance chemicals including glycols, glycol ethers, acetates, biopolymers, natural gums, and potable alcohol. [In the past, Regreen-Excel EPC India Limited have completed various projects for India Glycols in Kashipur and Gorakhpur such as a 120 KLPD plant, 180 KLPD grain based RS plant, 110 KLPD ENA plant, 270 KLPD RS to ethanol plant, amongst others.

Location

Kashipur, Uttarakhand

Challenges

Inefficient plant capacity levels: Client faced a significant challenge with its 120 KLPD molasses-based rectified spirit plant, operating at only 50.00% capacity, and struggling to achieve its designed efficiency. Regreen-Excel EPC India Limited conducted a comprehensive assessment of the client’s plant and identified several key areas for improvement.

Inadequate equipment: The plant suffered losses due to equipment that was inadequately sized for the production requirements, leading to inefficiencies and suboptimal performance.

High operational expense: The absence of heat integration systems led to higher OPEX due to increased steam costs, as energy was not efficiently utilized within the production process.

Solution

Equipment optimization: Regreen-Excel EPC India Limited upgraded and resized equipment to align with production needs, minimizing losses and increasing throughput.

Process control and optimization: Implementing advanced control strategies and optimizing fermentation and distillation parameters enhanced overall efficiency and yield, increasing productivity and profitability.

Distillation column redesign: Redesigning distillation columns ensured proper sizing and performance, enhancing separation and purification for improved product quality and purity.

Heat integration systems: Integration of heat systems optimized energy usage in production, reducing steam consumption and lowering OPEX.

Measurable Impact

Regreen-Excel EPC India Limited revamped India Glycol’s 120 KLPD molasses-based plant to a 180 KLPD with 270 KLPD grain-based ethanol facilities.

Operational efficiency: Through modernization and revamping initiatives, the client witnessed significant enhancements in operational efficiency across their old plants.

Conversion from molasses-based to grain-based facility: The transition from molasses-based to grain-based production and the establishment of ethanol plants enabled the client to adapt to evolving market dynamics and consumer preferences. The successful conversion of the plant to a grain-based facility enabled the client to capitalize on the benefits of alternative feedstock, enhancing flexibility, sustainability, and cost -effectiveness.

Full capacity utilisation: With the optimization measures in place, the client successfully achieved full capacity utilization of the plants, maximizing its production potential.

Client A - Muzzaffarpur Biofuels Private Limited (“MBPL”)

MBPL is a firm with diverse product portfolio, enabling Regreen-Excel EPC India Limited to offer full EPC solution project including project management and commissioning as single point responsibility.

Location

Muzzaffarpur, Bihar

Challenges

Interconnected nature of the Company’s projects: Regreen-Excel EPC India Limited were tasked with designing and constructing a new ethanol plant based on the E-max technology. The challenge lay in the interconnected nature of Company’s many projects since the resources working on them are often shared, requiring meticulous planning and seamless execution to ensure that each component is delivered on time and to the highest standards.

Challenges in a turnkey approach: Implementing a turnkey manufacturing project is fraught with several critical factors to consider which need to be carefully monitored, managed, and executed for the project to succeed. Turnkey execution of a project including the process plant, grain handling, storage silos, milling, boiler, turbine, and other utilities come with challenges in its execution. This integrated approach demands a level of expertise that sets it apart from traditional project management.

Additionally, in a turnkey project, the supplier bears all the responsibility from concept to commissioning. Design, engineering, supply, erection, testing and commissioning of the entire project including training of operators and meeting regulatory guidelines is single point responsibility of the supplier.

Solution

Company’s expertise: Company’s team of experts provided end-to-end project management and ensuring the seamless execution of this critical project. Regreen-Excel EPC India Limited have an in-depth knowledge of the industry landscape and the ability to navigate the complexities of each project. Company’s seasoned professionals leverage their expertise and technologies to identify challenges in advance, allowing us to develop solutions that keep projects on track and construct an ethanol plant. Regreen-Excel EPC India Limited have delivered high-quality, sustainable EPC plant to enable MBPL to produce high quality ethanol as per client’s requirement.

Measurable Impact

Plant commissioning and operating: Regreen-Excel EPC India Limited met the client’s requirements. Regreen-Excel EPC India Limited achieved the following results on plant commissioning and operating consistently.

This turnkey project with end to end solutions, is a testament to company’s ability to provide comprehensive solutions that cater to the unique needs of its clients.

Client A - Baramati Agro Limited (“Baramati Agro”)

Baramati Agro partnered with us to enhance their production efficiency and sustainability. By upgrading from earlier versions of E-max technology to E-max 75, Baramati Agro achieved reductions in steam and water consumption, further improving their operations and reinforcing their commitment to sustainability.

Location

Shetphalgade, Taluka Indapur, Pune

Challenges

Resource Utilization: Increasing resource utilization and efficiency related challenges, particularly in the 60 KLPD Molasses with integrated evaporation project.

Water Content Management: Managing high water content in wash for increased ethanol yield presented a significant challenge in the 100 KLPD wash to ethanol with 60.00% concentration spent integrated evaporation project.

Solution

Projects developed: (1) 100 KLPD Molasses based ENA plant - revamping project; (2) 60 KLPD molasses with integrated evaporation; (3) 100 KLPD wash to ethanol with 60.00% concentration spent wash evaporation; (4) 150 KLPD wash to ethanol with 60.00% concentration evaporation; (5) 150 KLPD wash to ethanol with integrated evaporation; (6) 1320 TPD evaporation on MVR (Steam saving -5 TPH or 0.8kg/ litres steam saving); (7) 1800 TPD evaporation project with MVR.

Measurable Impact

Reduced steam and water consumption: By upgrading from earlier versions of E-Max Technology to E-Max75, Baramati Agro Limited has achieved reductions in steam and water consumption, further optimizing their operations and reinforcing their commitment to environmental stewardship.

Type 5 : DDGS Dryers (Make in India)

Regreen-Excel EPC India Limited assisted its customers in the import of these DDGS Dryers, between 2012 to 2021. DDGS Dryers were imported mainly from one country prior to the COVID-19. A total of 13 DDGS Dryers of sizes ranging from 500m2 to 1500 m2 were imported in this period.

Challenges

In January 2021, Regreen-Excel EPC India Limited had 15 Ongoing Projects which required import of DDGS Dryers. However, due to restrictions imposed on account of COVID-19. These Projects had a risk of delay on account of COVID-19 and other geopolitical reasons, which could have adversely impacted its business.

Solution

With inhouse technical expertise in design and engineering of large sized equipment, Regreen-Excel EPC India Limited ventured into manufacturing of DDGS Dryer inhouse using a technique called “Reverse Engineering” and utilizing technical knowhow of operating personnel from various distillation plants where DDGS Dryers have been in use.

Measurable Impact

In-house manufacturing of DDGS Dryers has led to reduction in costs and has reduced dependence on one country for import of DDGS Dryers.

The table below illustrates the key players we cater to in End User Industries.