Chitchat with Chethan R Sundar, Engineer at Flownetics
During the interaction with RashmiKumari of Neo Science Hub, the engineer at Flownetics Engineering, Chethan R Sundar, explored the company’s first-time participation at India Lab Expo and its innovative approach to flow chemistry. Flownetics, based in Bangalore, specializes in providing customized flow chemistry solutions for industries like pharmaceuticals and fine chemicals. Chethan introduces their continuous manufacturing technology, built entirely in India, and shares details about their unique Factory as a Service model, which allows clients to adopt cutting-edge technology without heavy capital investment. Here are the excerpts:
Chethan, could you start by telling us a little about Flownetics Engineering and your role here at India Lab Expo?
I’m Chethan R Sundar, an engineer at Flownetics Engineering. This is actually our first time exhibiting at India Lab Expo, and we’re excited to be here, especially since Hyderabad is a major hub for pharmaceuticals and manufacturing. We’re showcasing our flow chemistry platform, a completely engineered and assembled product made in India. We’re proud to be OEMs (Original Equipment Manufacturers) based in Bangalore, and our technology is designed, engineered, and built by us.
Please explain a bit more about flow chemistry and why it’s an important technology in the industry?
Flow chemistry is a type of continuous manufacturing that offers an alternative to traditional batch processing. Normally, in batch chemistry, raw materials are mixed in tanks, heated, and the reaction takes time to complete, which can be inefficient, especially in cases where hazardous chemicals are involved or safety is a concern.
With flow chemistry, we continuously feed the raw materials through reactors, and the product is formed in a continuous stream. This method is particularly useful in the API (Active Pharmaceutical Ingredient) and intermediate manufacturing industries. The technology is gaining traction because it’s more economically beneficial, and we can tackle inefficiencies in hazardous processes or when companies need to improve cost-effectiveness.
So, flow chemistry sounds like a game-changer. Can you tell us about the benefits it offers compared to traditional batch processes?
Definitely! One of the major advantages is that with flow chemistry, the process becomes much faster and safer. For example, in batch processing, scaling up from lab to plant can be a major challenge. However, with our technology, scaling up is seamless—what works in the lab can be easily transferred to the plant without facing significant hurdles.
Another benefit is that flow chemistry can significantly reduce effluent generation and costs. We’ve had case studies where we’ve helped clients reduce their effluent by up to 70% and manufacturing costs by up to 40%. This makes it an attractive solution for companies looking to optimize their processes and make them more environmentally friendly.
That’s impressive! You mentioned you work closely with clients to offer customized solutions. Could you elaborate on how you do that?
At Flownetics, we offer turnkey solutions tailored to the specific needs of our clients. We start by understanding their problem statement, and then we build a customized piece of equipment that suits their process. This includes selecting materials that are compatible with the chemicals they’re working with and offering customization in terms of the design and handling of the equipment.
We offer a wide range of choices for materials, whether they need stainless steel, glass, or other chemical-resistant materials. Our goal is to deliver equipment that not only meets their current needs but is also scalable and future-proof.
It sounds like you’re very focused on providing client-specific solutions. You also mentioned a new business model you’ve developed—Factory as a Service. Could you explain how that works?
Yes, Factory as a Service is an innovative business model we’ve introduced to help make it easier for companies to adopt flow chemistry technology. One of the barriers we’ve noticed is the initial capital investment required to implement this new technology. So, we’ve developed a model where we engage with clients from R&D to commercial production without requiring a large upfront capital investment.
The way it works is that we take on the cost of developing the technology for them, and in return, the client pays based on OPEX (Operating Expenses). This eliminates the need for heavy capital expenditure and allows companies to gradually adopt the technology without financial strain. Essentially, we work together to ensure their process is enabled, and they can start using the technology efficiently without worrying about the initial costs.
How has the industry responded to this new model and to flow chemistry in general?
The response has been positive, but adoption has been slow. Flow chemistry is still relatively new in some sectors, and companies tend to be cautious when adopting new technologies. However, with models like Factory as a Service, we’re seeing a shift in attitude. More companies are now open to trying it, especially as they recognize the cost savings and efficiency gains.
Additionally, our clients appreciate that we stay involved throughout the entire process—from R&D to commercial implementation—ensuring that the technology fits seamlessly into their operations. This ongoing partnership builds confidence, and we’re optimistic about the future.
It sounds like Flownetics is offering both technology and partnership. How do you see flow chemistry and Flownetics evolving in the future?
Flow chemistry is definitely the future of continuous manufacturing, especially in sectors like pharmaceuticals and fine chemicals. As safety regulations become stricter and companies push for efficiency and sustainability, I believe more companies will adopt this technology.
At Flownetics, we’ll continue to focus on innovation and customization. Our goal is to become the go-to provider of flow chemistry solutions in India and globally. We’re committed to developing technologies that help clients not only optimize their processes but also make them more environmentally friendly and cost-efficient. We’re excited about what lies ahead!
