An audit of an intermediates plant should confirm three things: that the plant really makes your product, that it can make it consistently, and that it can keep operating. That means looking at licences, process equipment, the lab, effluent treatment, safety and records.
Plan the audit around your product. Ask to see it being made, or at least the reactors and batch records used for it. Our general guide on what a factory audit should contain sets out the basic structure.
Licences and consents
Start with the paperwork that lets the plant operate. These are the key items:
- The Consent to Operate from the Gujarat Pollution Control Board, checked for your product name, permitted capacity and validity date.
- Environmental clearance where the product or capacity requires it.
- The factory licence and fire safety approvals.
- Hazardous waste authorisation and the records of where waste goes.
- Licences for any controlled or explosive raw materials the process uses.
Process, lab and quality
Walk the process from raw material store to finished goods. Check that the reactors, filters and dryers match the route the plant described and the volume you need. Look at the materials of construction, since corrosive steps need suitable linings or alloys.
In the lab, check that it can run your test methods, such as nitrite titration and HPLC. Look at calibration records, reference standards and retained samples. Ask to see the COA and raw data for a recent batch of your product.
Look at batch records for several lots. Consistent yields and test results are a good sign. Large unexplained swings suggest weak process control or bought-in material.
Effluent, safety and capacity
Look at effluent treatment in operation, not just on a drawing. Ask whether waste goes to a common effluent treatment plant and whether the plant has had closure directions. Our article on how environmental rules affect intermediate supply explains why this matters.
Check process safety: relief valves, temperature control on exothermic reactions, personal protective equipment and emergency drills. Poor safety predicts poor reliability.
Finally, compare the plant's real capacity with its order book. A plant running at full stretch may not have room for your orders when demand rises.
Signs it is not the real maker
Be careful if you are shown only a warehouse, if the reactors are idle and clean on every visit, or if the lab cannot show raw data for your product. These suggest a trader. Our guide on telling a chemical trader from a manufacturer lists more signs.
Next step
We audit intermediates plants in Gujarat on your behalf and report what we find in writing. To arrange one, book a free sourcing review.