Chemicals
Why Chemicals Must Transform Now
The chemicals sector is under intense pressure as companies face rising regulatory demands, energy volatility, workforce shortages, and global competition. Plants must balance high safety standards with the need for operational continuity, product quality, and environmental responsibility.
Highly hazardous materials require strict safety and compliance controls.
Unplanned downtime causes major financial losses due to continuous-process operations.
Aging assets increase equipment failure risk and maintenance cost.
Energy price fluctuations affect production economics and profitability.
Quality variation impacts downstream customers and multi-step chemical reactions.
Environmental expectations and ESG requirements continue to tighten globally.
Skilled technical workforce shortages affect plant stability and operational excellence.
Chemical organizations must improve plant reliability, safety, and process efficiency — while accelerating digital transformation to remain globally competitive.
BGMC’s Transformation Approach for Chemicals & Process Industries
Assess Critical Processes & Operational Risks
We perform a comprehensive evaluation of your chemical plant’s production units, utility systems, quality processes, maintenance practices, supply chain, and workforce capability.
We identify:
Process bottlenecks & reaction delays
Safety & compliance gaps (PSM, QHSE, ISO)
High-risk equipment failure modes
Energy inefficiencies & waste
Workforce and skills capability gaps
Redesign for Safe, Stable & Efficient Chemical Operations
We redesign processes to ensure continuous, stable, and safe operations across batch and continuous-production systems.
Includes:
Lean chemical process mapping & optimization
Control limit standardization & error-proofing
SOP development for hazardous operations
Inventory & materials flow optimization
Reaction, mixing & filtration efficiency improvements
Deploy Predictive Tools, Safety Systems & Digital Technologies
We enhance performance and reduce risk with digital tools and advanced analytics.
Includes:
Digital twins for chemical processes and utility systems
Predictive maintenance for rotating & static equipment
Advanced process control (APC) enhancements
IoT sensors for temperature, pressure, vibration, and leak detection
Real-time dashboards for production, energy & compliance
Standardize & Expand Across Sites
We build enterprise-level governance that scales improvements across multiple plants, warehouses, and laboratories.
Includes:
EHS governance & compliance structure
Standardized QA/QC practices
Cross-site benchmarking
Global SOP alignment
MES/ERP integration for chemical workflows
Build Capability for Long-Term Safety & Performance
We strengthen technical and operational capability across chemical organizations.
Includes:
PSM compliance training
QHSE leadership programs
Maintenance & reliability training
Lean & Six Sigma capability building
Emergency response readiness programs
Our Chemicals, Refining & Process Manufacturing Operational Offerings
Operational Excellence & Lean Transformation for Chemical Processing
We help chemical manufacturers stabilize batch and continuous production, reduce variation, improve equipment utilization, and optimize process flow across reactors, mixers, distillation units, packaging lines, utilities, and storage systems. Our approach enhances throughput, minimizes losses, and ensures consistent, repeatable performance.
Services include:
Lean process redesign for batch & continuous operations
Value stream mapping from raw material intake to finished goods
Cycle time optimization & bottleneck elimination
SMED for grade changes, tank changeovers & cleaning cycles
Process standardization & operator discipline systems
Daily performance management & control-room routines
Waste reduction for off-spec batches, rework & material loss
Example outcomes:
Higher production stability, fewer process deviations, and improved yield performance.
Procurement Optimization for Raw Materials, Additives, Catalysts & Packaging
We strengthen sourcing systems for feedstock, chemicals, solvents, resins, additives, catalysts, and specialized equipment essential to chemical manufacturing.
Services include:
Supplier qualification, audits & performance scoring
Inventory planning for hazardous chemicals & bulk materials
Cost optimization across chemical categories
Warehouse layout for chemical segregation & safe storage
Risk assessment for supply disruptions & lead-time variability
Example outcomes:
Reduced procurement cost, stronger supply continuity, improved material availability.
Compliance Systems for Quality, Safety, Environment & Chemical Handling
We support chemical manufacturers in implementing globally recognized standards to ensure safe and quality-controlled processing.
Services include:
ISO 9001 (Quality Management)
ISO 14001 (Environmental Management)
ISO 45001 (Occupational Health & Safety)
Responsible Care® systems & chemical compliance frameworks
Documentation & SOP development
Audit readiness & CAPA systems
Example outcomes:
Stronger regulatory compliance, lower operational risk, improved audit performance.
Quality Excellence for Batch Consistency, Purity Control & Specification Compliance
Chemical processes require precise control over formulation, reaction conditions, and purity. We improve consistency and reduce defects.
Services include:
SPC for batch and continuous production
Root-cause analysis for off-spec batches
Quality checkpoints across blending, mixing & packaging
Calibration, metrology & lab-quality systems
Control plans for critical formulations
Waste & rework reduction in chemical processing
Example outcomes:
Lower rejection rates, fewer off-spec batches, better customer satisfaction.
Process Safety, Chemical Handling & Environmental Compliance
Chemical manufacturing presents unique hazards ranging from flammable materials to toxic emissions and high-pressure systems.
Services include:
Process safety reviews & HAZOP
Chemical storage, segregation & handling protocols
LOTO for reactors, boilers & high-pressure systems
Fire, explosion & toxic gas hazard controls
PPE programs & emergency response planning
Environmental compliance for effluents, emissions & waste
Example outcomes:
Fewer incidents, safer handling of hazardous materials, stronger environmental compliance.
Chemical Plant Project Management, Turnarounds & Expansion Programs
We support chemical companies in managing complex engineering, expansion, shutdown, and modernization projects with strong governance and execution discipline.
Services include:
PMO setup for expansion & capital projects
Project scheduling, budgeting & contractor management
Process-equipment installation oversight
Turnaround/shutdown planning & execution support
Safety and environmental risk assessment for projects
Commissioning readiness & performance validation
Stakeholder updates & digital project reporting
Example outcomes:
On-time project delivery, reduced overruns, and smoother plant commissioning.
Chemical Supply Chain, Procurement & Material Handling Optimization
We help chemical producers stabilize material availability, reduce delays, manage supplier risks, and improve overall logistics across hazardous materials, bulk chemicals, and finished goods.
Services include:
Supplier evaluation, risk analysis & performance monitoring
Inventory optimization for raw chemicals & packaging
Bulk storage & tank-farm material flow improvements
Logistics optimization for hazardous materials
Warehouse layout & compliance improvements
Demand planning & forecasting for batch operations
Import/export & regulatory documentation support
Example outcomes:
Reduced lead times, lower material shortages, and improved supply reliability.
Smart Chemical Manufacturing Using IoT, Automation, AI & Digital Twins
We apply digital tools to improve consistency, traceability, and safety across chemical operations.
Services include:
IoT for monitoring temperature, pressure, flow, vibration & energy
Digital twins for reactors & process plants
Predictive maintenance for pumps, compressors & rotating equipment
AI models for formulation optimization & off-spec prediction
Digital dashboards for production & safety monitoring
ERP integration for traceability & compliance
Example outcomes:
Improved reliability, fewer process deviations, smarter decision-making.
Technology Stack for Chemical Excellence
Example Use Cases & Outcomes
Petrochemical Plant Yield & Reaction Optimization
A large petrochemical operation struggled with inconsistent reaction times and lower-than-target yields.
Challenge:Â Variability in reaction control and energy inefficiencies.
Solution:Â Advanced process control tuning, digital twin simulation, and Lean reaction mapping.
Outcome: 12–18% yield improvement and reduced energy consumption.
Specialty Chemicals Predictive Maintenance Deployment
A specialty chemicals facility faced recurring pump and compressor failures.
Challenge:Â Frequent equipment breakdowns causing production delays.
Solution:Â IoT sensors, predictive models, and RCM methodology.
Outcome:Â 30% reduction in equipment failures and improved uptime reliability.
Industrial Chemicals Safety & Compliance Enhancement
A chemicals producer needed stronger QHSE systems to meet global regulatory expectations.
Challenge:Â Gaps in process safety, environmental controls, and documentation.
Solution:Â Full PSM system, updated SOPs, HAZOP reviews, and digital QHSE dashboards.
Outcome:Â Higher compliance scores and reduced incident frequency.
Chemical Supply Chain ERP/MES Integration
A multi-site chemical company struggled with fragmented data and slow coordination across production and logistics.
Challenge:Â Poor visibility of inventory, batches, and material flow.
Solution:Â SAP-integrated workflows, digital batch records, and automated reporting.
Outcome:Â Streamlined planning and improved traceability.
Who We Serve
Industries
- Petrochemicals
- Specialty chemicals
- Industrial chemicals
- Paints, coatings & adhesives
- Fertilizers & agrochemicals
- Pharmaceuticals (API & chemical processes)
- Water treatment & chemical utilities
- Packaging chemicals & intermediates
Functions
- Operations & Production
- Process Engineering
- Quality & Laboratory Management
- HSE / QHSE / PSM
- Maintenance & Reliability
- Supply Chain & Logistics
- IT & Digital
- Leadership
Regions
Frequently Asked Questions
1. How do we begin improving safety and operations in a chemical plant?
2. Can BGMC support PSM and global chemical compliance?
3. Do you support turnaround/shutdown planning?
4. Can digital tools improve safety and reliability in chemicals?
5. Can you help optimize energy consumption?
6. Do you support multi-site chemical transformation?
Ready to Transform Your Manufacturing Operations?
Let’s discuss how BGMC Group can help transform your operations and drive measurable results.
Connect with our experts today to explore customized industrial and business solutions designed for your success.
We work with ambitious leaders who want to define the future, not hide from it. Together, we achieve extraordinary outcomes.