BAVLA - Main Manufacturing Site
Bavla site is a 800,000 m² (300,000 m² presently developed) campus style works with a specific purpose for developing several cGMP intermediates and several US FDA inspected API facilities. Primarily this site is being developed for pharmaceutical intermediates and actives.
The production units are located at different locations in the campus - steam, water, brine, nitrogen, thermic fluid, vacuum etc. are provided by central units.
This site has potential to become India's largest site for drug substance. There is continuous expansion work going on this site.
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The site presently has eight production units for production of intermediates and APIs, research and development laboratories, quality assurance and control block, various utilities block, warehouses, mechanical workshops and an administrative block.
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Features
- Total area developed 300,000 m²
- 8 production units
- Aggregate area of these production units 10,000 m²
- 76 reactors in these 8 manufacturing units
- 26 glass lined reactors
- 48 SS 326 reactors
- 2 Hastalloy reactors
- Temperature capabilities minus 60° to 260° Celsius
- Vacuum in the plant in general 1 mm Hg
- Specific vacuum for distillation 0.02 mm Hg
- Pressure capabilities up to 15 bar in the some of the hydrogenators and the SS + GL reactors
- Solvent storage and explosive yard for storing 25 m³ in 20 tanks.
- Additionally 20 vertical storage tanks for different solvents and liquid raw materials
- 1500 KV Diesel Generating Sets for alternate standby power.
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Chemistry performed at this site
- Grignard Chemistry(1 MT batch size)
- O-C N Alkylations
- Reduction by Hydrogenation (3 MT batch size)
- Fluorination using HF gas, BF3 gas, Heterocyclics
- Chemistry mainly on substituted Pyridines, Tripyridines and Imidazoles
- Dedicated facility for 2-R Phenothiazines
- Dedicated pilot plants for scale up operations
- Reactions such as oxidations, condensations, reductions, nitrations, alkylations
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Additional facilities will be made available in the near future
- Hydrogenation at 100 bar pressure, 300° Celsius temperature
- Large Hastalloy reactors for large batches of fluorinated molecules
- Dedicated facility in a special zone for hazardous chemistry such as Butyl Lithium, Metal Hydrides, Butoxides, HCN gas and Cyanides, Carbon Monoxide.
- 2 cGMP multi purpose intermediate plants with 200 m³ reaction capacity
- 3 API facilities for US FDA approved API production
- High Potency/Cytotoxic Unit
- cGMP pilot facility with more than 50 reactors ranging from 5 ltrs to 1500 ltrs combined with a dedicated R&D Center where 80 batch chemists per shift x 3 shifts equivalent to 240 chemists will work.
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Infrastructure to support long term expansion
- 800,000 m² of green field site of which 300,000 m² are presently developed.
- More than 30000 m² constructed area
- Two large central utility blocks having utilities such as Boilers, Chillers, Power generators, DM & USP water systems, Liquid Nitrogen, VAC Pumps, Thermic Fluid Boilers etc. supplying these service to all plants by Header Systems.
- Container loading/unloading ports
- More than 5,000 m² warehousing area. Separate building for different raw materials.
- Easy and overnight access to main Seaports and Airports
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