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Prashant Arun Bhatwadekar

Dubai

Summary

Results-driven chemical engineer with 27 years of operational excellence specializing in a broad spectrum of chemicals, including hazardous/non-hazardous, flammable, toxic, corrosive, and food-grade chemicals. Demonstrated expertise in chemical manufacturing and operations, with a strong focus on managing complex reactions such as endothermic reactions for aromatic and aliphatic polyester polyols and exothermic reactions for polyether polyols, prepolymers, and blended polyols used in rigid and flexible foams, including spray foam and polyurea. Skilled in process engineering, troubleshooting, production planning and scheduling, with a proven ability to coordinate cross-functional teams and drive plant operations. Experienced in scaling up products from lab scale to commercial production through lab-scale trials, pilot plant trials, and full-scale plant trials. Proficient in applying industry-leading safety and process optimization methodologies such as JSA, MOC, PHA, PSSR, 5S, and LSSGB to improve operational efficiency while maintaining the highest safety standards. Successfully managed projects, commissioned plant machinery, and led initiatives to enhance production performance and cost-efficiency.

Insightful Manager with experience directing and improving operations through effective employee motivational strategies and strong policy enforcement. Proficient in best practices, market trends and regulatory requirements of industry operations. Talented leader with analytical approach to business planning and day-to-day problem-solving.

Overview

27
27
years of professional experience

Work History

Manager operations & Mfg and maint.

HUNTSMAN UAE FZE
07.2019 - Current
  • Company Overview: Leading Manufacturer of polyurethane chemicals i.e Aromatic & Aliphatic polyester polyols & Blended polyols - Rigid, Flexible, Polyurea, Spray polyols
  • Production Oversight: Plan, organize, & manage daily production activities to ensure products are manufactured in a timely and cost-efficient manner with higher OEE
  • Process Improvement: Continuously evaluate and improve production processes, identify bottlenecks, and recommend solutions to improve efficiency and reduce costs with LEAN
  • Team Leadership: Lead, train, and develop production staff, ensuring adherence to health, safety, and quality standards along with JSA
  • Inventory Management: Monitor RM / PM, equipment & FG inventory to ensure there are no disruptions in production
  • Quality Control: Ensure all products meet quality standards & regulatory requirements, addressing any NCM
  • Scheduling & Coordination: Develop and manage production schedules, ensure resources are allocated effectively, and liaise with other departments to ensure smooth operations
  • Cost Control: Monitor and report on production costs and work with finance to ensure profitability targets are met with min waste management
  • Safety Management: Ensure a safe working environment by enforcing safety protocols and conducting regular audits and training
  • Leading Manufacturer of polyurethane chemicals i.e Aromatic & Aliphatic polyester polyols & Blended polyols - Rigid, Flexible, Polyurea, Spray polyols
  • Achievements :- - Rx timing reduction by 37 % (from 26 hrs to 19 hrs) for Aromatic polyester polyol
  • Rx timing reduction by 63 % (from 36 hrs to 22 hrs) for PTA based Aromatic polyol
  • Production of New polyester polyols and developing the market
  • Cost saving of USD 165K per annum through LEAN & process improvement
  • EHS goal of ZERO Harm & ZERO LTI, NCM – Zero % & FPQ -Above 93 %
  • Handling Plant audits with FM Global and internal PHA / FRA team
  • Reduction in transport cost / kg by 10% & reduction of CO2 footprints by 10 %

Production Manager

IFFCO CHEMICALS
05.2018 - 06.2019
  • Company Overview: Leading Manufacturer of Alkyd resins and polyurethane chemicals (Group company of ALLANA Chemicals An ISO 9001 : 2015,ISO 14000 : 2015, OHSAS 18001 : 2007 Certified organization.)
  • Successful Modification of the existing system and making it suitable for proposed Aromatic & Aliphatic polyester polyol production at Tarapur Plant and UAE – Sharajah Plant (IFFCO Chemicals)
  • Successful Modification of the existing system and making it suitable for prepolymer production as well as MDI handling system at UAE – Sharajah Plant (IFFCO Chemicals)
  • Conducting lab trials for the development of PU chemicals i.e polyester polyols and prepolymers
  • Training & commercial scale up + product stabilization of polyester polyols as well as prepolymer plant
  • Achieving the sales target by on time delivery - export as well domestic
  • Leading Manufacturer of Alkyd resins and polyurethane chemicals (Group company of ALLANA Chemicals An ISO 9001 : 2015,ISO 14000 : 2015, OHSAS 18001 : 2007 Certified organization.)

Factory Manager – works

Joseph Leslie Dynamik’s MFG Pvt. Ltd.
01.2017 - 03.2018
  • Company Overview: An ISO 9001 : 2008 Certified organization
  • Handling & overseeing Purchase, Stores, Tool Room, QA & QC, and Production
  • Ensuring overall operations and manufacturing activities comply with BIS and EN standards for CABA / SCBA with 300-200 bar press
  • As per IS 12021, Breathing Air Line Trolley, Twin Filter Half Masks
  • Liaising with MPCB, DISH, BARC, BIS, SGS, 3rd-party inspections for Indian Armed Forces as well as the Indian Coast Guards through CQAE NS / DQAE / NBCD, as per the QAP
  • Product design and improvement & increasing performance and stability
  • Ensuring implementation and operations adhere to ISO 9001:2008 standards
  • An ISO 9001 : 2008 Certified organization

General Manager – Operations

OceanGlobe Container services (I) PVT Ltd.
04.2013 - 12.2016
  • Company Overview: An ISO 9001, ISO 14001 & ISO 18001 Certified
  • Handling techno commercial aspects along with overall operations as per QMS policy & EHS policy
  • Responsible for Safe operation of plant with Zero Accident, Safe handling as well as disposal of chemicals, Implementation of CAPA
  • Carry out technical audits Joint inspections / insurance Survey, Inspection, Cleaning and handling of approx
  • 700 types of Haz / Non Haz / flammable / Toxic / Corrosive & Food grade chemicals
  • Repairs / Re-furbishment of ISO Tanks (unfired pressure vessels as per ASME SEC
  • VIII) as per ITCO & under class surveyor like BV / DNV
  • Handling capex / RM purchase
  • Handling of labour unions, govt
  • Authorities like CETP / MPCB, DISH / Labour officer and Customers
  • An ISO 9001, ISO 14001 & ISO 18001 Certified

Plant Head

Expanded Polymer systems Pvt Ltd
02.2002 - 04.2013
  • Company Overview: An ISO 9000 certified Industry
  • Production planning & execution, Handling Ethoxylation, Propaxylation, Esterification of Aromatic & Aliphatic Polyester polyols (flexible & rigid foam), footwear industry, coating & flooring fields, Pilot plant, Blending Plant for & TDI / MDI based Pre-polymer plant
  • Expansion project for capacity upgradation from 8KT to 24KT for production of Polyols, vendor development, planning and execution, automation including Preparation of facility layout, P&ID
  • Erection and commissioning, startup activities & plant commissioning for Polyether Polyol plant, Polyester Plant
  • Monitoring & maintaining ISO / EHS procedures, PTW & CAPA
  • An ISO 9000 certified Industry
  • Achievements - Batch timing reduction from 36 hrs to 23 hrs – Aliphatic Polyester polyol
  • Reduction in utility cost by Rs 48000/- per month
  • Yield improvement from 83 % to 86.2 %
  • Handling loss of Propylene Oxide reduction from 0.6% to 0.1% during ship unloading to 3000 kl ST

Project Engineer

Furnace Fabrica India Ltd.
01.2001 - 01.2002
  • Worked on a refinery tank farm project (Tank ɸ 8 mtr to ɸ 47 mtr & including fixed & floating roof type) for Refinery Terminal of Tamtave, South Africa through PII
  • Project planning & scheduling, progress monitoring, monitoring project cost, communication with client and site
  • Coordinating the project of Zinc Smelter capacity up-gradation for M/s HZL at Debari & Vizag

Techno commercial Officer

Vasundhara Rasayans Ltd.
09.1999 - 01.2001
  • Company Overview: A Bulk Drug Mfg
  • Spray Drier fuel system modified to switch over from LDO to Furnace Oil
  • Major change in piping layout & reaction process, Preparation of impurity profile and Drug Master File
  • (DMF)
  • Handling vendor development & purchase of spares, RM / PM lab
  • Equipment’s and chemicals
  • A Bulk Drug Mfg

Project Engineer

Project Consultants.
01.1999 - 08.1999
  • Costing & Designing, Decaffeination project for IIT Mumbai (SCFE process)

Sales & marketing

M/s Unicom Skytech Ltd.
12.1997 - 01.1999
  • Sales & marketing of Filtration systems with UV technology for industrial use

Education

B E - Chemical Engineering

Mumbai University

Skills

  • Plant Operations Management

  • Strategic Planning & Execution

  • Production & Process Optimization

  • Cost Control & Budget Management

  • Project Management & Plant Commissioning

  • Team Leadership & Development

  • EHS Compliance & Safety Management

  • Inventory & Resource Management

  • QA & Regulatory Compliance

  • Vendor development & Management

Phone

  • +91, 9702552019
  • +971, 562690591

Languages

Hindi
Bilingual or Proficient (C2)
English
Bilingual or Proficient (C2)
Marathi
Bilingual or Proficient (C2)

Software

Autocad

SAP S4 HANA

Timeline

Manager operations & Mfg and maint.

HUNTSMAN UAE FZE
07.2019 - Current

Production Manager

IFFCO CHEMICALS
05.2018 - 06.2019

Factory Manager – works

Joseph Leslie Dynamik’s MFG Pvt. Ltd.
01.2017 - 03.2018

General Manager – Operations

OceanGlobe Container services (I) PVT Ltd.
04.2013 - 12.2016

Plant Head

Expanded Polymer systems Pvt Ltd
02.2002 - 04.2013

Project Engineer

Furnace Fabrica India Ltd.
01.2001 - 01.2002

Techno commercial Officer

Vasundhara Rasayans Ltd.
09.1999 - 01.2001

Project Engineer

Project Consultants.
01.1999 - 08.1999

Sales & marketing

M/s Unicom Skytech Ltd.
12.1997 - 01.1999

B E - Chemical Engineering

Mumbai University
Prashant Arun Bhatwadekar