A commodity manufacturing company was facing continuous yield losses, which were impacting overall profitability and increasing raw material costs.
While the immediate assumption was that the issue was only within the manufacturing process, Patham India believed the problem needed a broader investigation.
Instead of focusing only on production, we analysed the entire value chain — from raw material sourcing to transportation, storage, processing, and finished goods management.
We conducted a detailed review across:
The raw material supplier had a broad purity range, which caused inconsistency in production performance. We worked towards standardising specifications and improving raw material quality. Result: A minimum saving of 0.75% in raw material efficiency was achieved.
Evaporation and washing losses during transportation were contributing to material wastage. We recommended the use of insulated and dedicated tankers, reducing avoidable losses during transit. Result: An additional 0.2% reduction in losses.
Storage systems for raw materials and finished goods were redesigned with: ● Insulation systems ● Cooling mechanisms ● Recycling condensers This reduced material losses during storage. Result: Up to 0.5% monthly reduction in losses.
We improved process efficiency by: ● Installing efficient condensers to recover unreacted materials ● Controlling cooling parameters for better condensation ● Tightening process controls for consistency Result: An average 0.5% improvement in yield.
An additional finished product tank was installed to better manage varying product specifications and avoid unnecessary oversupply to customers. This improved inventory control and reduced product giveaway losses.
The combined improvements delivered significant results:
The required investments included: ● A few condensers ● One finished goods tank ● Transportation contract improvements ● Advisory support