When tragedy struck Zavenir Daubert India in October 2022, a devastating fire consumed their old manufacturing plant, presenting the company with an immense challenge. For Saket Bhartia, the Managing Director of Zavenir Daubert India, the immediate priority was clear: ensuring uninterrupted product availability for their customers. Remarkably, through the relentless efforts of the team, operations resumed within a few weeks. However, this incident became a catalyst for something much greater—a complete reimagining of their manufacturing capabilities.
Journey from setback to comeback
"We had two choices," Bhartia says. "We could rebuild quickly using existing technologies, or we could align the new plant with our long-term vision and values of innovation, growth mindset, sustainability, and well-being. We chose the latter." This decision led to the creation of a cutting-edge, futureproof facility in Binola, Haryana, which sets a new benchmark for the specialty chemical industry. With an investment of approximately USD 10 million (Rs 85 crores), the new plant doubles the production capacity of the old one and features advanced technologies such as haptic technology, automation, and a 10,000-square-foot ‘Technology and Experience Centre' for research and innovation.
Smart state-of-the-art facility
The Binola facility is not just a to Zavenir Daubert's commitment to blending global technologies with the "Make in India" initiative. "Our plant is a first in many ways—not just in India but globally in the specialty chemicals sector," Bhartia explains. The facility integrates advanced robotics, autonomous mobile robots (AMRs), and automated storage and retrieval systems (ASRS) to manage every step, from raw material handling to finished goods dispatch. This seamless process ensures precision, efficiency, and workplace safety, setting new standards for smart manufacturing.
Zavenir Daubert specialises in corrosion prevention and metalworking solutions, and the new facility is equipped with state-of-the-art R&D labs for corrosion testing, tribology, microscopy, and chemical analysis. Bhartia emphasises the importance of these innovations: "India has some of the most challenging conditions for corrosion management due to its climate. Our advanced labs enable us to adapt global products for the Indian market and develop new ones that deliver superior performance."
The company's focus, however, extends beyond the domestic market. With products compliant with international regulations such as REACH (Europe) and EPA (USA), Zavenir Daubert is well-positioned to support export oriented customers. Bhartia notes, "While our primary focus remains on the Indian manufacturing industry, we are expanding into sectors like steel, construction, defence, and railways, while also growing our export capabilities. We are also targeting upcoming segments like electronic parts manufacturing."
An eco-conscious approach
Sustainability is a cornerstone of the Binola plant. From solar power generation to a zero-water-discharge unit, every aspect of the facility is designed to minimise environmental impact. Bhartia elaborates, "Our plant embodies our vision of achieving a carbon-neutral footprint. It's not just about the products we make but how we make them. Our processes align with global benchmarks in green manufacturing."
The plant is meticulously designed with the vision of minimising environmental impact, striving to create a balance between industrial operations and nature. This vision is exemplified by Zavenir Daubert's reliance on 100 per cent solar power generation, ensuring that clean, renewable energy powers all its processes. Furthermore, their zero effluent discharge policy and advanced water conservation systems reflect an unwavering commitment to preserving precious natural resources. Even the power backup systems align with this ethos, operating without causing pollution—a holistic approach that encapsulates their dedication to environmental stewardship. These concerted efforts move Zavenir Daubert closer to its goal of achieving sustainable industrial practices while protecting the planet for future generations.
In addition to these measures, Bhartia highlighted the company's innovative Light Management System (LMS), designed to optimise energy consumption while enhancing safety. By employing low-voltage DC lighting, the system not only reduces energy usage but also eliminates fire hazards, ensuring efficient and secure illumination across operations. This initiative serves the dual purpose of advancing workplace safety and supporting Zavenir Daubert's pursuit of LEED certification, reinforcing its commitment to environmentally conscious practices.
Zavenir Daubert's products further exemplify their dedication to sustainability. Compliant with global chemical regulations, their solutions are built on environmentally friendly chemistry. Bhartia pointed to the Metalworking Fluid X-Series as a prime example product free from Boron, Chlorine, and other restricted chemicals, setting a new standard for eco-friendly industrial solutions. Looking ahead, the company has ambitious plans to introduce a revolutionary biodegradable VCI film to the Indian market. Developed using novel technology, this product is poised to transform the component packaging segment, offering a sustainable alternative that aligns with the growing demand for green solutions.
Growth anticipation
Zavenir Daubert's ambitious goals facility. Currently generating annual revenues of Rs 150 crores, the company is targeting an impressive Rs 1,000 crores by 2030. This growth is underpinned by their technical collaboration with Germany's ZET-CHEMIE GMBH, which will strengthen their portfolio in metalworking fluids and component cleaning.
Innovation remains at the heart of Zavenir Daubert's strategy. Their "Cut-Clean-Protect-Pack" approach harmonises chemistry to reduce the total cost of ownership (TCO) for customers, helping them achieve compliance with evolving chemical regulations and sustainability goals. "The industry is moving toward reducing carbon footprints and enhancing productivity," Bhartia observes. "Our products, formulated with high-performance additives and free from harmful chemicals, address these priorities while enabling our customers to compete globally."
The Binola plant also supports India's "Make in India" initiative by advancing local manufacturing capabilities and creating employment opportunities. Bhartia emphasises, "Our manufacturing facility provides Indian customers with access to globally benchmarked technologies while supporting the domestic supply chain. This is how we contribute to India's growth story."
Future plans
Looking ahead, Zavenir Daubert has ambitious plans to expand its footprint. "This is just the first of many manufacturing plants," Bhartia shares, hinting at future projects aligned with the company's vision of innovation and sustainability.
As the manufacturing sector evolves, Bhartia believes Zavenir Daubert is well-equipped to tackle emerging challenges. "Our products not only meet stringent global chemical regulations but also address critical issues like sustainability and productivity. This allows us to deliver cost-effective, high-quality solutions to our customers, enabling them to thrive in competitive markets."
In an era where sustainability and innovation are paramount, Zavenir Daubert's Binola facility stands as a beacon of progress—a symbol of resilience, vision, and the drive to redefine industry standards. "We are not just making in India," Bhartia concludes with conviction. "We are innovating in India, for India, and the world."