MADHUKAR N. TAKBIDE

To lead & develop an operation team by Budget-Supply Chain-Project-Risk Management, Performance Optimization, Quality Assurance, Compliance, Resource Allocation, Lean Manufacturing, Continuous Improvement, Collaboration & continues development of professional skills.

• 4.5x capacity enhancement at toll site with ~3% yield improvement.
• Solvent savings of ₹6–8 Cr/year through optimized recovery systems.
• Patented process development generating ₹3 Cr/year savings.
• Distillation capacity enhanced using ASPENTECH-based optimization.
• Multi-product plant modernization, safety upgrades, and advanced equipment deployment (ATFE, FFE, LLE, MEE, FCE).

• Attained 4th International Workshop on Crystallization, Filtration and Drying at UDCT Mumbai-2010.
• Attained Micro-Reactor Technology Seminar at NCL Pune-2009.
• Attained CHEMSPEC exhibition at Mumbai.

• Chemical Engineer with 23 years of experience in plant operations, process engineering, projects, and flow chemistry within the pharmaceutical and chemical industries.
• Strong expertise in production operations, process optimization, process control, resource utilization, and achieving efficient consumption norms and quality standards.
• Experienced in commercial-scale product development, including PFD/P&ID preparation, process scale-up, equipment design, equipment datasheets, and layout engineering.
• Skilled in training and handling plant unit operations.
• Effective in analytical problem-solving, technical coordination, and operational planning.
• Proficient in process intensification, new technology integration, capacity enhancement, cost reduction, and energy optimization.
• Experienced in basic engineering for greenfield projects.
• Coordinated with technical institutes and consultants (ICT, CSIR) for advanced process and technology support.

• Led end-to-end process scale-up, validation, technology transfer and commercialization for APIs, intermediates, CRAMS/NCE products, and sterile operations.
• Established critical process parameters (CPPs), material attributes (CMAs) and safe operating windows using DOE, risk assessment and engineering studies.
• Developed cost-competitive, robust and scalable processes with optimized mass balance, cycle time, solvent use, productivity and yield.
• Supported customer audits, technical discussions, feasibility studies (RFPs), and regulatory documentation.

• Prepared and reviewed PFDs, P&IDs, equipment data sheets, layouts, mass & energy balances, and engineering packages for new and existing facilities.
• Designed and optimized reactors, heat exchangers, MEE/FCE, CFBD, condensers, pumps, solvent recovery systems, and utility integration.
• Conducted equipment philosophy development for mixing, filtration, extraction, drying, crystallization, and distillation operations.
• Executed design, installation, commissioning of new process equipment for campaign-based and continuous operations.

• Interpreted Process Safety Studies (PSM, HAZOP, PSR) and implemented engineering controls for safe operation across hazardous reactions.
• Designed process modifications aligned with GEP, risk mitigation practices, thermal hazard studies, and regulatory safety requirements.
• Built a strong process safety culture by reviewing legacy processes and identifying gaps in safety interlocks, containment, and operation windows.

• Executed process intensification projects including loop reactor design, continuous hydrogenation systems, and automated reactor experimentation.
• Implemented flow chemistry, electrochemical synthesis, sono-crystallization, microwave drying, and other novel technologies to improve throughput and safety.
• Led continuous process trials, resulting in cycle time reduction, energy savings, and enhanced solvent recovery efficiency.

• Performed root-cause analysis, CAPA implementation, and engineering-based corrective improvements for process robustness.
• Optimized process parameters to minimize deviations, improve consistency, reduce surprises at scale, and enhance reliability.
• Led in-plant troubleshooting for reaction execution, filtration bottlenecks, crystallization control, distillation efficiency, drying behaviour, and solvent losses.
• Achieved significant improvements including 4.5x capacity enhancement, 3% yield improvement, and multi-core savings at various sites.

• Developed eco-friendly and sustainable operations through effluent load reduction, COD minimization, and recycle/reuse of streams.
• Improved solvent recovery by redesigning columns, optimizing operating parameters, and applying simulation tools such as ASPENTECH.
• Implemented waste-minimizing engineering solutions to meet environmental norms and reduce operational costs.

• Led multi-disciplinary teams (Manufacturing Excellence, Scale-up, Process Safety, Technology Transfer).
• Coordinated with R&D, QA, QC, EHS, Engineering, Procurement, and external agencies/technical institutes (ICT, NCL, UDCT, CSIR).
• Managed toll manufacturing operations, vendor development and technical evaluations of third-party sites.

• Led production operations in multi-product API/intermediate plants, ensuring throughput, quality compliance and safety.
• Executed basic and detailed engineering, erection, commissioning of greenfield/brownfield reactors, utilities and multipurpose API facilities.
• Oversaw pilot plant trials, data generation, and scale-up runs for technology development.