~Capability enhancement by building Capacity
~The company is strengthening its presence in sectors of Hydrogen and Power for delivery of
specialized and large equipment with an investment of Rs. 300 Cr towards an expansion of its Dahej plant
Mumbai, 25th July 2022 (GNI): Godrej & Boyce, the flagship company of the Godrej Group,
announced that its business Godrej Process Equipment will be expanding its state-of-the-art
facility in Dahej, Gujarat. They plan to double their revenue by 2025 and this expansion will
significantly contribute towards this plan by doubling their capacity and enhancing
capability. This ongoing expansion will increase their manufacturing area by approx. 25,000
sq. m. They are presently investing an additional Rs. 300 Cr towards this expansion.
This state-of-the-art manufacturing facility by Godrej & Boyce was established in 2016. This
facility is well-equipped for manufacturing & delivering critical and over-dimensional
consignments (ODC) for global projects. This ongoing expansion is being constructed with a
focus on sustainability principles along with improved and efficient utilization of resources.
Green initiatives like Solar Power and various installations for recycling, water conservation,
and reducing fuel consumption will be incorporated. The expansion is focused on catering to the growing needs of the industry and leading to opportunities for local employment in the region.
This strategic expansion will involve a dedicated bay for nuclear equipment, and another
bay dedicated for heavy equipment manufacturing. This will house a state-of-the-art Clean Room facility for manufacturing critical process equipment with exotic metallurgy like
Titanium, Zirconium etc. Also, having a higher crane height will facilitate the manufacturing
of Large and over-dimensional equipment as large as 16 m in diameter. This expansion also
will include 2 extended manufacturing yards for large & ODC equipment. The extended
fabrication yard houses a crane with an under-the-hook height of 20 metres with a prime
focus on manufacturing Large and over-dimensional static equipment. In the future, this
extended yard will also be used for Modular fabrication.
This ongoing expansion, both in terms of capacity and capability will help Godrej Process
Equipment strengthen its presence in sectors of Hydrogen and Power for specialized and
large equipment in addition to their existing portfolios in the Oil & Gas, Chemicals &
Fertilizers, and Power Sector.
Godrej Process Equipment is also focusing on improving its manufacturing efficiency and
productivity. The process flow (Workcentre) Concept is being gradually implemented to
transform Dahej into an ultra-modern facility. Workcentre is a designated area of
production that is designed to perform specific tasks and by implementing this the flexibility within the manufacturing system is improved. Lead time is reduced by an increase in productivity and reduced errors thereby resulting in an improved specialization.
Dedicated Training Centre is being modernized to take care of the in-house capability
training of the highly skilled employees and workmen. There are plans to implement VR/AR-
based Welding Simulating systems to provide an immersive experience to welders and thus
making the simulation close to reality.
In their continuous journey toward excellence, they have recently set up a World class
Testing Laboratory in Dahej which is accredited as per NABL.
The business is also digitally transforming its operations at this facility. IoT revolution will be
a game changer in manufacturing, and they plan to implement Industry 4.0. Increased focus
on Automation, Digital data capturing as part of Digitalization and implementation of the
Manufacturing Execution System on the shop floor are the various initiatives that are under
implementation at the Dahej Manufacturing facility.
The emphasis on Automation starts with the journey of every piece of equipment with the
Automated Plate Marking and Cutting process, followed by Under-water Plasma Cutting,
Waterjet Cutting, Hotwire TIG processes, Submerged Arc Strip Cladding (SASC), and
advanced Non-Destructive Testing (NDT) techniques. Additionally, technologies including
the Orbital welding, Narrow groove tandem wire Submerged Arc Welding (SAW), and Inner
bore Internal Diameter overlay streamline the manufacturing of equipment. In addition,
Robotics in key manufacturing activities like Nozzle Cutting, Nozzle Welding, Tube-to-tube
sheet Welding, etc has already been deployed. It is worthwhile to note that more than 80%
of their Welding activities are automated and the main focus of this automation is to
improve productivity, quality & safety.
Hussain Shariyarr, Senior Vice President & Business Head, Godrej Process Equipment said, “The Dahej manufacturing facility has enabled us to achieve several milestones due to its
well-equipped capacity & capability to deliver critical projects. The Dahej facility was
developed with the intent of building specialized equipment not just in dimension but also in complexity. It uniquely provides us with ease of access to International Seaports for
transportation of such equipment. We have embarked on our journey to make this facility a
smart factory and enhance the productivity and quality of products delivered to enrich
customer delight. Also, we aim to make this facility one of the greenest manufacturing
facilities in the industry,” stated in the press release.
About Godrej Process Equipment
Godrej Process Equipment is one of the fourteen businesses of Godrej & Boyce, with the
largest global footprint in the G&B group. Godrej Process Equipment is a leader in
manufacturing custom-built process equipment such as Heavy walled Reactors, Pressure
Vessels, High-Pressure Heat Exchangers, Columns, Trays, and Reactor Internals for various critical applications in the Oil and Gas, Petrochemical, Hydrogen Fertilizer and Power sector across the globe, with over 80% of their products being exported
About Godrej & Boyce Mfg. Co. Ltd
Godrej & Boyce (‘G&B’), a Godrej Group Company, was founded in 1897 and has
contributed to India’s journey of self-reliance through manufacturing. G&B patented the
world’s first springless lock and since then, has diversified into 14 businesses across various
sectors from Security, Furniture, and Aerospace to Infrastructure and Defence. Godrej is one
of India’s most trusted brands serving over 1.1bn customers worldwide daily.
To learn more visit: www.godrej.com
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