Neuland

Facilities

Manufacturing Facilities

Unit I – Bonthapally | Unit II – Pashamylaram

Manufacturing

Overview | Services | Production Blocks | Special Reaction Blocks

Bonthapally

In keeping with its commitment to provide assured quality, the manufacturing facility at Bonthapally (Unit I) adheres to stringent guidelines & requirements of Good Manufacturing Practices (GMP) and is approved by international health and regulatory agencies such as US FDA, TGA (Australia), PMDA (Japan) and WHO.

A key feature of the manufacturing process is the supervision and the involvement of a committed team which with the help of latest production techniques and calibrated planning guarantees on-time delivery of products.

Unit-1 is situated at Bonthapally Village in Medak District which is approximately 65 kilometers from the Hyderabad Airport. It is developed on a total area of 11.2 acres and has seven production blocks including the kilo labs and other supporting departments such as quality assurance & quality control (QA&QC) and Regulatory Affairs (RA).

The facility was inspected by the US FDA 5 times march 1997, May 2004, March 2008, Nov. 2010, April 2014. EDQM in 2005. PMDA (Japan) in October 2008 has also audited and approved the facility. The facility is certified by the following management systems:

  • ISO 9001 certified for its quality systems
  • ISO 14001 certified for its environment management
  • OHSAS 18001 certification for occupational health systems

Highlights of Unit-1

  • Consists of small volume high value production facility with vessels ranging between 20 liters to 3000 liters.
  • Seven production blocks covering 3,875 square meters of production area, kilo lab and 4 ware houses (including explosive warehouse).
  • Built up area of the plant is approximately 45,325 sq mts.
  • Total reactor volume of 175.47 KL.
  • Capable of handling broad spectrum of reactions and a wide range of process parameters.
  • Products manufactured include:
    Anti-Asthmatics, Cardiovasculars, Anti-Fungal, Anti convulsants, Anti emetic, Central Nervous System (CNS), Fluoroquinolones, Corticosteroids, Anti Psychotic, Anti bacterial and Anti-parkinson.

Services

Following is an illustrative list of reactions that are handled at Neuland’s facilities on a continuous basis:

  • Bromination
  • Diazotization
  • Friedel Craft Reactions
  • Hydrogenations
  • Mannich Reactions
  • Grignard Reactions
  • Metal Hydride Reactions
  • Oxidation
  • Cryogenic Reactions
  • Hydrofluorination
  • Methylation
  • Resolution of Racemic mixtures
  • Stereo-specific synthesis
  • Micheal Addition Reaction
  • Silylation Reaction

Utilities services at Unit-1

  • Cooling Water Tower: 1540 TR
  • Chilled Water: 247 TR
  • Chilled Brine: 244 TR
  • Purified water system: 2000LPH
  • Hot Water: up to 90°C
  • Steam: 8 TPH
  • Vacuum System: up to 1 Torr
  • Compressed Air: 1170 cfm
  • Captive Power Generators: 2000 KVA
  • Boiler: 8 tons
Description Capacity Operating Conditions
Steam Boiler (Coal Fired)   11 Tons/hr Up to 175°C
Brine Chilling Units 403 TR/ hr  +5°C to -20°C
Liquid N2 storage  5 KL Up to 0.3 % o2and  99.7% Purity
Diesel Power Generators 2325 KVA -------
Air Compressor 744 CFM Up to 9.0 kg/cm²
Cooling Towers 2140 TR/hr Room water temp. 28°C to 32°C
Vacuum Pumps 9745 M3/hr Up to 700 mm of Hg
RT water pumps 715 M3/hr Running
  815 M3/hr Stand by
Air Handling Unit (Clean Air System) 1,14,000 CFM With ISO 8 (100000 class) filtered air supply
High Vacuum Ejectors (TORR) 29600 LPM Up to 0.5 to 10 Torr
DM Water 10 M3/OBR Conductivity up to 1.3 µS/Cm 
Softener Water 240 M3/hr Below 5 PPM Hardness
Purified Water 2 M3/hr USP grade
R.O. Water (plant) 10 M3/hr Boiler
R.O. Water (for effluent system) 80KL/Day  
Evaporator 11 KL/ Day  
3 HCL gas generators    
  • CFM : Cubic feet per minute
  • LPM : Liters per minute
S. No. Blocks Stainless Steel Glass Lined Decomposer PP/FRP Separation Drying Finishing Condensers Centrifuges
1 Block- I 7 x 5000 L
4 x 3000 L 
2 x 5000 L      -------- 3x 2500L(NF)
3x100L(PF)
3x200L(LF)
3x96 Trays(AO)
2x48 Trays(AO);
2x48 Trays(VD);
2x300kg(FBD);
2Micronisers;
1Pulaviser;
2x2500L (Blender);
2 Multi millers;
3 Sifters
26 Heat transfer Condensers in multi quantities 6x48" ;
Speed 800 RPM
2 Block-II 1 x 5000 L
4 x 3000 L
1 x 2500 L
1 x 2000 L
2 x 1600 L
1x1000 L
1x 250 L
1 x 3000 L
2 x 630 L
1 x 250 L
--------  1x150L(PF);
2 x300L(NF);
2x125L; 1x50L(LF)
1 X 75 L
1 x 60 kg( FBD )
3x48 Trays(AO);
1 VD with 6 Trays;
1 VD with 48 Trays;
1x100 kg/h (miller)
1 Microniser;;
1x200L Blender;
1x400L Blender
19 Heat transfer Condensers in multi quantities 4x36”
3 Block- III 1 x 3000 L
1 x 2000 L
3 x 1500 L
3x1000 L
1 x 2000 L
1 x 1000 L
-------- -------- 1VD with 48 trays
3 AO s with 48 trays;
1with 6 trays
-------- 20 Heat transfer Condensers in multi quantities --------
4 Block- IV 1 x 3000 L
2 x 1500 L
1x1000 L
1x 250 L
1 x 3000 L
1 x 2000 L
4x1000 L
-------- 2x100L,1x250L (PF);
1x200L,1x100L, 1x50L (NF)
2x50L (LF)
2 AO s with 48 trays
1x100 kg (FBD)
1VD with 48 trays
50-200 kg/h ( Miller )
1x1200L (OB)
1 Sifters 30”
1 Microniser
15 Heat transfer Condensers in multi quantities --------
5 Block- H 1 x 3000 L
2 x 2000 L
1 x 1600 L
1 x 1500 L
3 x 1000 L
1 x   500 L
3 x 2000 L
1 x 1600 L
1 x 1000 L
4 x 630 L
2 x 250 L
 -------- 1x 150L ( PF);1x175L (PF)
1x2000L(NF); 1x300L (NF);
1x200L (NF); 1x100L(NF)
2x125L(LF)
1 x 60 kg( FBD ) -------- 33 Heat transfer Condensers in multi quantities --------
6 ETP 3x5000L
1x2000L
1x1200L
-------- 1x2500 L -------- -------- -------- 5 Heat transfer Condensers in multi quantities --------
7 Kilo Lab  -------- 1x250L  -------- 1 cGMP (PF) 3x 3 Trays (VD) 1x100L cGMP (OB);
1cGMP Microniser;
1x8 Blades Miller;
8 Heat transfer Condensers in multi quantities 3x12” 
8 Inter-
mediate Kilo Lab
-------- -------- -------- -------- -------- 1x 24" vibro sifter
1 Multi mill
1 Microniser
1x3000L (OB)
1x1200L(OB)
-------- --------
S. No. Block RBFs Rotary Evaporators Separation Drying Columns
9 Block-S 5x10 L 4 Neck RBF s;
1x5 L 4 Neck RBF;
1x2 L 4 Neck RBF
3x20 L ;
1x2 L
1x10L Filtration flask;
3x5L Separating funnels;
1x500 g Buckner Funnel
2 Vacuum Dryer
(3 Trays)
1x 150mm ;
1x120mm;
1x 80mm

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5 API Finishing areas with ISO 8 (Class 1,00,000 ) Filtered Air

  • VD : Vacuum Dryer
  • AO : Air Oven
  • OB : Octagonal Blender
  • PF : Pressure Filter
  • LF : Leaf Filter
  • FBD : Fluid Bed Dryer
  • NF : Nutsch Filter
  • HPR : High Pressure Reactor
  • ETP : Effluent Treatment Plant
  • RBF : Round Bottom Flask
S. No Blocks Stainless Steel Glass Lined HPR's Decomposer PP/FRP Separation Drying Finishing
1 Corrosive / Friedel Crafts Block -------- 1 x 1600 L
1 x 630 L
1 x 250 L
-------- -------- 1x 150L ( PF) ;1x175L (PF)
1x2000L(NF); 1x300L (NF);
1x200L (NF); 1x100L(NF)
2x125L(LF)
1 x 60 kg( FBD ) --------
2 Hydrogenation 1 x 3000 L
1 x 2500 L
2 x 1600 L
1 x 1500 L
1 x  250 L
-------- -------- --------  1x150L(PF);
2 x300L(NF);
2x125L;     1x50L(LF)
1 X 75 L
1 x 60 kg( FBD )
3x48 Trays(AO);
1 VD with 6 Trays;
1 VD with 48 Trays
1x100 kg/h (miller)
1 Microniser;;
1x200L Blender;
1x400L Blender
3 Chlorination -------- 1 x 2000 L
1 x 630 L
1 x 250 L
-------- -------- 1x 150L ( PF);1x175L (PF)
1x2000L(NF); 1x300L (NF);
1x200L (NF); 1x100L(NF)
2x125L(LF)
1 x 60 kg( FBD ) --------
4 Bromination -------- 1 x 2000 L
1 x 630 L
-------- -------- 1x 150L ( PF);1x175L(PF)
1x2000L(NF); 1x300L (NF);
1x200L (NF); 1x100L(NF)
2x125L(LF)
1 x 60 kg( FBD ) --------
5 Sodium Hydride, Grignard reaction & Lithium aluminum Hydride   1x1600 L -------- -------- 1x 150L ( PF);1x175L(PF)
1x2000L(NF); 1x300L (NF);
1x200L (NF); 1x100L(NF)
2x125L(LF)
1 x 60 kg( FBD ) --------
6 Hivaccum Distillation   20 L & 50 L           

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Vitamin D2

S. No RBFs Rotary Evaporators Separation Drying Columns
7 5x10 L 4 Neck RBF s;
1x5 L 4 Neck RBF;
1x2 L 4 Neck RBF
3x20 L ;
1x2 L
1x10L Filtration flask;
3x5L Separating funnels;
1x500 g Buckner Funnel
2 Vacuum Dryer
(3 Trays)
1x 150mm ;
1x120mm;
1x 80mm

Production blocks & Special reaction blocks:

Unit II overview

Unit-II situated at Pashamylaram is about 45 kilometers from Hyderabad airport. The facilities are built in a total area of 36,800 sq.mts and consist of three main production blocks, engineering workshop and four warehouses.

Highlights of Unit-II

  • Inspected by US FDA in 1999, 2002 and 2005.
  • Inspected by BGS Hamburg (German Health Authority) in 2007.
  • TGA cGMP and WHO GMP approved.
  • High volume facility with dedicated production blocks for range of products.
  • Six production blocks covering 3250 sq. mts of production area.
  • Total Reactors Volume of 300.10 KL.
  • Product line includes Fluoroquinlones, Anti-Ulcerants, and Prostaglandins.
  • State -of-the-art Pilot Plant in compliance with GMP with two production lines.
  • Certified in May 2010 by TUV Nord for ISO 14001 : 2004 Environment Management System and for OHSAS 18001 : 2007 Occupational Health & Safety Management System
Description Capacity Operating Conditions
Steam Boiler (Coal Fired)   11 Tons/hr Up to 165°C
Brine Chilling Units 144 TR/ hr Up to -15°C
Chilled water Unit   200 TR/ hr Up to +6°C
Nitrogen Generation Unit 10 NM3/hr Up to 0.5 % o2and  99.5% Purity
Diesel Power Generators 2180 KVA -------
Air Compressor 635 CFM Up to 7.5 kg/cm²
Cooling Towers 2340 TR/hr Room water temp. 28°C
Vacuum Pumps 6545 M3/hr Up to 650 mm of Hg
RT water pumps 330000 Lts/hr Up to 3.0 Kg/cm²
Air Handling Unit (Clean Air System) 121050 CFM With ISO 8 (100000 class) filtered air supply
High Vacuum Ejectors (TORR) 450 M3/hr Up to 0.5 to 10 Torr
DM Water 10 M3/hr Regeneration Conductivity up to 1.3 µS/Cm 
Softener Water 200 M3/hr Regeneration Below 5 PPM Hardness
Purified Water 1.5 M3/hr USP grade
MEE(Multiple effect evaporators) 100KL/Day -------
Incinerator 40Kgs /Hr For Gas Capacity 
Multiple incinerators 400Kgs /day For Solid   Capacity 
  300L /Hr For Liquid  Capacity 
  70Kgs /Hr For Gas  Capacity 
  • CFM : Cubic feet per minute
  • LPM : Liters per minute
S. No. Blocks Stainless Steel  reactors Glass Lined reactors MS Reactors Decomposer PP/FRP Drying Finishing Roll Compactors Condensers Centrifuges
1 Block- I &  FC Block 13 x 5000 L
7 x 3000 L        7x 2000L
1x1000L
2x630L
1X500L, 4 x 6000 L
5 x 5000 L
5 x 3000 L   1 x 1600 L
2x5000L 6x5000L 1x250Kg(FBD);
1x150kg(FBD);  1x300Kg(FBD)
4x100 KG
Sifter;
1x1500L (Blender);
4x100 Kg/h,
1x250kgs/hr
Multi millers;
1x5000L (Blender)
2 24 upto 5KL Capacity 22x48" ;
1X40”,
5x60”
2 Block-II 11x3000L
6x2000L
3x1600L
3x1000L
1x3000L
2x2000L: 1x1600L 1x1000L
------- -------- 1 Double cone rotary VD
3 VD with 48 Trays;
2 dryers with 48 Trays;
3x100 KG
Sifter;
1x1500L (Blender);
2x100 Kg/h
Multi millers;
-------- 35 upto 5KL Capacity 4x48”
2x36"
3 Mini plant
Block-A
1x1600L 
2x630L 1x250L
1x1000L
2x630L
2x250L
--- -------- 3xVD with 24 trays
1x300L rotary cone vacuum dryer
1x60 kg(FBD)
1x100 Kg
Sifter;
1x400L (Blender);
1x100 Kg/h
Multi millers;
1x15 kg/h 12 upto 5KL Capacity 2x36”
2x24"
4 Mini plant
Block-B
1x1000L
1x630L
1x250L
1x1000L
1x630L
2x250L
3x100L
-- -------- 1x VD with 24 trays
2x VD with 12 trays
1x20kg (FBD)
1 AO with 48 trays

1x 60kg/h
Sifter
1x100L
(Blender) 1x5kg/h (Microniser)
            ------- 10 upto 5KL Capacity 1x36”
2x24"
1x12"
S. No Block Reactors Rotary Evaporators Instruments Separation Exhausters Glassware Miscellaneous
5 Prostaglandin block 1x 5L;
1x20L
1x 5L;
1x20L;
1 Vacuum pump
3 Deep freezer
6KVA UPS system;
1 Hot air gun;
2 Temperature Indicators
(-500c to +9000c);
3 kg electronic Balance;
2 Chillers ;
1 Preparative HPLC
1 Flash Column
1 Flash pump
1x 250 CFM (Fume Cupboard)
1x 500 CFM (Environmental Chamber)
1x5000 CFM
1x5000 CFM clean air fan 
4x20L; 4x2L;4x500ml;
Amber Evaporation Flask ;
1x20L Clear Evaporation Flask ;
2x10L Receiving tanks ;
2x1L Clear receiving tank;
4x2L Measuring Jars
2 Breathing apparatus
1 Hydraulic Pellet Trolley
( 1 Ton)

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5 API Finishing areas with ISO 8 (Class 1,00,000 ) Filtered Air

  • VD : Vacuum Dryer
  • AO : Air Oven
  • OB : Octagonal Blender
  • PF : Pressure Filter
  • LF : Leaf Filter
  • FBD : Fluid Bed Dryer
  • NF : Nutsch Filter
  • HPR : High Pressure Reactor
  • ETP : Effluent Treatment Plant
  • RBF : Round Bottom Flask
S. No Blocks Stainless Steel Glass Lined HPR's Decomposer PP/FRP Separation Drying Finishing Centrifuges
1 Corrosive / Friedel
Crafts Block
   -------- 1 x 5000 L
1X 3000 L
1 x 1600 L
   --------    --------    -------- 1x250Kg(FBD);
1x150kg(FBD);  1x300Kg(FBD)
4x100 KG Sifter;
1x1500L (Blender);
4x100 Kg/h,1x250kgs/hr Multi millers;
1x5000L (Blender)
4x48"
2 Sodium Hydride  1 x 5000 L
2 x 3000 L
2 x 2000 L
   --------    -------- 1x5000 L    -------- 1x250Kg(FBD);
1x150kg(FBD);  1x300Kg(FBD)
4x100 KG Sifter;
1x1500L (Blender);
4x100 Kg/h,1x250kgs/hr Multi millers;
1x5000L (Blender)
   --------
3 Hydrogenation 1x1000L     --------    --------          

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Prostaglandin Block

S. No Reactors Rotary Evaporators Instruments Separation Exhausters Glassware Miscellaneous
4 1x 5L;
1x20L
1x 5L;
1x20L;
1 Vacuum pump
3 Deep freezer
6KVA UPS system;
1 Hot air gun;
2 Temperature Indicators
(-500c to +9000c);
3 kg electronic Balance;
2 Chillers ;
1 Preparative HPLC
1 Flash Column
1 Flash pump
1x 250 CFM (Fume Cupboard)
1x 500 CFM (Environmental Chamber)
1x5000 CFM
1x5000 CFM clean air fan 
4x20L; 4x2L;4x500ml;
Amber Evaporation Flask ;
1x20L Clear Evaporation Flask ;
2x10L Receiving tanks ;
2x1L Clear receiving tank;
4x2L Measuring Jars
2 Breathing apparatus
1 Hydraulic Pellet Trolley
( 1 Ton)

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Ciprofloxacin Block

S. No Stainless Steel reactors Glass Lined reactors MS Reactors Decomposer PP/FRP Drying Finishing Roll Compactors Condensers Centrifuges
5 13 x 5000 L
7 x 3000 L        7x 2000L
1x1000L
2x630L
1X500L,             4 x 6000 L
5 x 5000 L
5 x 3000 L   1 x 1600 L
2x5000L 6x5000L 1x250Kg(FBD);
1x150kg(FBD);  1x300Kg(FBD)
4x100 KG Sifter;
1x1500L (Blender);
4x100 Kg/h,1x250kgs/hr Multi millers;
1x5000L (Blender)
2 24 upto 5KL Capacity 22x48";
1X40”,      5x60”

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Ranitidine Block

S. No Stainless Steel reactors Glass Lined reactors MS Reactors Decomposer PP/FRP Drying Finishing Roll Compactors Condensers Centrifuges
6 11x3000L
6x2000L
3x1600L
3x1000L
1x3000L
2x2000L: 1x1600L 1x1000L
-------     -------- 1 Double cone rotary VD
3 VD with 48 Trays;
2 dryers with 48 Trays;
3x100 KG Sifter;
1x1500L (Blender);
2x100 Kg/h Multi millers;
    -------- 35 upto 5KL Capacity 4x48”
2x36"

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