Process Engineer Chemical Manufacturing Scale-Up

NILAY BHARUCHA Lawrenceville, GA • +1-404-***-**** • *************@*****.*** U.S. Permanent Resident (Green Card)

PROCESS ENGINEER CHEMICAL MANUFACTURING

Process Engineering professional with 24+ years of experience optimizing chemical processes, scaling up new molecules, improving yields, and driving PSMcompliant operations. Strong background in continuous and batch processing, technology transfer, rootcause analysis, and Lean/Six Sigma methodologies. Proven success supporting Fortune 500 clients and improving plant reliability, throughput, and cost efficiency.

CORE COMPETENCIES

Process Design & Optimization

Technology Transfer & ScaleUp

Root Cause Analysis (RCA)

PSM & EHS Compliance

Batch & Continuous Operations

Lean Manufacturing / Six Sigma

Process Hazard Analysis (PHA/HAZOP)

Yield Improvement & Cycle Time Reduction

Equipment Troubleshooting

SOP Development & Process Documentation

PROFESSIONAL EXPERIENCE

UPL Limited – Kingstree, SC, USA

Process Engineer / Operations Excellence (Present)

Leading process design, scaleup, and technology transfer for a new chemical molecule.

Conducting mass balance, heat balance, and process capability studies to optimize production.

Improving cycle time, yield, and equipment reliability using Lean and Six Sigma tools.

Supporting PSM elements including MOC, PHA, SOP updates, and operator training.

Collaborating with production, engineering, and EHS teams to ensure safe and stable operations.

UPL Limited – India

Unit Head / Plant Head / Production Head (2014–2025)

Directed endtoend chemical manufacturing processes for herbicides, insecticides, and specialty chemicals.

Led process improvements that increased throughput, reduced variability, and improved product quality.

Executed multiple debottlenecking and capacityexpansion projects.

Ensured 100% compliance with PSM, ISO, and regulatory requirements.

Launched 6 specialty oil additive products through successful process development and scaleup.

Gharda Chemicals – India

Manager – Operations (2010–2014)

Improved process stability and reduced batch cycle time through structured problemsolving.

Implemented process modifications that reduced cost and increased throughput.

Coordinated with R&D and QC for process validation and optimization.

Perstorp Chemicals – India

Senior Executive – Production (2007–2010)

Prime Health Care Products – India

Oral Care InCharge (2004–2007)

Jaysynth Dyestuff – India

Production Officer (2001–2004)

EDUCATION

B.E. Chemical Engineering South Gujarat University, 2001 (First Class with Distinction)

CERTIFICATIONS

Six Sigma Green Belt

ISO Internal Auditor (9001, 14001, 45001, 50001)

HAZOP & Bowtie Risk Analysis

PSM Training

Energy Management Systems Auditor

KEY ACHIEVEMENTS

Led PSM implementation across 14 manufacturing sites.

Converted hazardous byproducts into revenuegenerating streams.

Maintained zeroincident safety record across largescale operations.

Successfully scaled up 6 global specialty oil additive products.

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