— SELECTED WORK

Case Studies

Real engineering problems solved for real industry customers.

CASE 01Power

Reverse-engineered impellers for a thermal power utility

Thermal Power Utility, Western India

Reverse-engineered closed impellers replacing obsolete OEM at 1/3 the lead time.

Challenge

OEM impellers were obsolete; lead time on replacements had stretched to 22 weeks, putting plant availability at risk.

Solution

Reverse-engineered the hydraulic profile, validated against duty curve, manufactured in SS 17-4PH with G1.0 balancing.

Outcome

Delivered in 7 weeks. Field performance matched OEM within 1.5 % efficiency. Now standard supply.

CASE 02Paper

Paper Converter, Gujarat

Servo tension-controlled winding line scaled production from 22 to 58 tonnes/day.

Challenge

Existing winder ran without closed-loop tension control. Reject rate at 4.2 %.

Solution

Engineered a servo-driven winder with load-cell tension control, auto cut & glue, and HMI recipe management.

Outcome

Production capacity scaled 2.6×. Reject rate dropped to 0.6 %. Payback in under 11 months.

CASE 03Pharmaceutical

Pharmaceutical Formulations, Pune

Validated batch-type curing oven with FAT-documented temperature uniformity ±2°C.

Challenge

Customer needed a GMP-aligned curing oven with documented temperature uniformity and PLC traceability — within 10 weeks.

Solution

Designed an electric batch oven with PID + PLC control, multiple thermocouple zones, recipe storage and audit trail.

Outcome

Achieved uniformity of ±1.6°C at 180°C across 9 measurement points. Delivered & commissioned in 9 weeks.

CASE 04Chemical

Speciality Chemicals Manufacturer, Maharashtra

Six PVDF magnetic-drive pumps engineered and commissioned for 32% HCl transfer.

Challenge

Existing imported pumps were failing within 4 months due to seal degradation in HCl service. Lead time on imported spares was 14 weeks.

Solution

PT designed PVDF-bodied magnetic-drive pumps with PTFE wetted parts, eliminating dynamic seal. Skid-mounted with VFD and dry-run protection.

Outcome

Zero leakage in 18 months of continuous service. Local spare availability inside 2 weeks. 38 % lower TCO vs imported alternative.