Process Equipment & Complete Plants
Kerone’s Process Equipment & Complete Plants division delivers turnkey industrial processing solutions that encompass the full spectrum of equipment design, fabrication, integration, and commissioning.
Engineered precision for Process Equipment & Complete Plants.
Kerone’s Process Equipment & Complete Plants division delivers turnkey industrial processing solutions that encompass the full spectrum of equipment design, fabrication, integration, and commissioning. From individual process units such as reactors, heat exchangers, mixers, and separators, to fully integrated processing plants with complete material handling, utilities, and control systems, Kerone serves as a single-source partner for complex industrial projects. With extensive expertise across chemical, pharmaceutical, food, mineral, and energy sectors, Kerone designs plants that are operationally efficient, safe, and compliant with all relevant regulatory and environmental standards.
Our advanced AI, ML, and IoT technologies, this solution delivers smarter automation, real-time insights, and predictive intelligence to enhance efficiency and drive future-ready growth.
Continuous tracking of process parameters with instant adjustments.
Intelligent fault detection to prevent failures before they occur.
Dynamic tuning of operations for maximum output and efficiency.
The thermodynamic architecture of our Process Equipment & Complete Plants incorporates advanced thermal modeling and computational fluid dynamics (CFD) to ensure optimal heat and mass transfer across the entire processing zone. By precisely controlling thermal gradients, air velocity profiles, and direct energy delivery mechanisms, the system achieves uniform treatment while preventing localized overheating, product degradation, or thermal stress. This balance of intensive heat transfer and controlled retention time ensures maximum operational throughput with minimal specific energy consumption.
Built with heavy-duty structural engineering and sanitary metallurgy, each unit is manufactured to withstand continuous 24/7 industrial operating conditions. Contact surfaces are finished in high-grade stainless steel (SS 304, SS 316L, or corrosion-resistant alloys) with sanitary mirror-polish options, CIP/SIP washdown provisions, and hermetic chamber sealing. This guarantees full compliance with stringent international hygiene, CE machinery directives, and cGMP standards across food, pharmaceutical, specialty chemical, and heavy manufacturing applications.
Proprietary control algorithms ensure strict process repeatability, while built-in safety interlocks and electromagnetic shielding comply with international CE and OSHA standards. Full process development support — including material loss tangent testing, moisture sorption isotherms, and pilot trials at our Ambernath R&D facility — ensures the selected technology matches your exact industrial throughput goals.
Product & Systems Gallery
Explore authentic high-resolution photographs of industrial machinery, pilot trial rigs, and continuous turnkey processing installations engineered by Kerone Engineering Solutions for Process Equipment & Complete Plants. Each system is fabricated at our ISO 9001:2015 certified manufacturing facilities with precision laser cutting, robotic welding, and stringent Factory Acceptance Testing (FAT).
Process Equipment & Complete Plants
Click to view high-res
Process Equipment & Complete Plants
Click to view high-res
Process Equipment & Complete Plants
Click to view high-res
Process Equipment & Complete Plants
Click to view high-res
Process Equipment & Complete Plants
Click to view high-res
Process Equipment & Complete Plants
Click to view high-res
Process Equipment & Complete Plants
Click to view high-res
Process Equipment & Complete Plants
Click to view high-res
Process Equipment & Complete Plants
Click to view high-res
Process Equipment & Complete Plants
Click to view high-res50+ Years of Thermal Engineering Leadership.
Since 1976, Kerone Engineering Solutions has delivered over 5,000 custom-engineered thermal and process installations across 50+ countries. In technical collaboration with premier global institutions like CSIR-CEERI and University of Nottingham research partnerships, we design and manufacture high-efficiency machinery that minimizes production downtime and cuts operating expenses.
Unlike standard off-the-shelf equipment suppliers, Kerone operates a complete pilot-scale testing facility at our KRDC Ambernath center. We validate your exact raw material properties — determining moisture sorption isotherms, specific heat capacity, and dielectric behavior — before finalizing equipment sizing, ensuring zero risk during industrial scale-up.
Engineering precision, built into every system.
Turnkey Project Delivery From
Turnkey project delivery from concept design to plant commissioning and operator training
ASME, PED, and IS Code
ASME, PED, and IS code compliant pressure vessel and equipment fabrication
Complete 3D Plant Layout Design
Complete 3D plant layout design with clash detection and constructability review
Integrated DCS/PLC/SCADA Automation
Integrated DCS/PLC/SCADA automation for full plant process control
Hazardous Processes
HAZOP studies and SIL-rated safety system design for hazardous processes
Fast Installation and Portability
Skid-mounted modular plant configurations for fast installation and portability
Full Utilities Design
Full utilities design including steam, compressed air, cooling water, and effluent treatment
Comprehensive Documentation
Comprehensive documentation including P&IDs, equipment datasheets, O&M manuals, and as-built drawings
Powered by AI, Machine Learning & Smart IoT Integration
Modern industrial processing requires unprecedented thermal precision, energy efficiency, and operational agility. Kerone equips each system with high-speed industrial edge computing controllers, multi-spectral non-contact infrared pyrometry, and proprietary closed-loop machine learning algorithms that continuously analyze process parameters in real time.
The intelligent automation stack monitors dynamic changes in incoming material load, bed thickness, moisture content, and environmental factors. In response, our algorithms dynamically adjust heater power arrays, generator frequency, conveyor drive velocities, and exhaust dampers within milliseconds — entirely eliminating product burn, under-processing, or thermal hotspotting.
Seamlessly integrated with factory-wide SCADA and enterprise ERP architectures via native MQTT, OPC-UA, and Modbus TCP protocols, our systems deliver complete digital recipe control, remote diagnostics, predictive maintenance alerting, and tamper-evident batch logs compliant with global FDA 21 CFR Part 11 and cGMP standards.
Adaptive Heat Modulation
Neural algorithms detect material thermal variations in real time (<50ms response) and tune generator frequency and power arrays automatically.
IoT Cloud Telemetry
Continuous bidirectional telemetry stream via MQTT/OPC-UA protocols directly to centralized plant SCADA, MES, or mobile engineer dashboards.
Predictive Maintenance
Monitors magnetron cathode current, vibration frequency signatures, and differential filter pressure to schedule AMC maintenance before failures occur.
Quality & Batch Traceability
Automated digital recipe execution, multi-stage temperature ramp/soak curves, and cryptographically signed electronic batch logs compliant with 21 CFR Part 11.
Engineered for High-Value Industrial Sectors
Tailored thermal and process configurations across continuous manufacturing lines.
Specialty chemical and bulk chemica...
Specialty chemical and bulk chemical manufacturing plant design and supply
Pharmaceutical API production facil...
Pharmaceutical API production facilities with GMP-compliant equipment and clean utilities
Food and beverage processing plants...
Food and beverage processing plants including extraction, concentration, and packaging lines
Mineral processing plants for ore b...
Mineral processing plants for ore beneficiation, leaching, and product recovery
Biomass to energy conversion plants...
Biomass to energy conversion plants including pyrolysis and gasification systems
Effluent treatment and zero liquid ...
Effluent treatment and zero liquid discharge plants for industrial wastewater management
Configured to Your Process Window
Technical parameter envelopes across industrial manufacturing and engineering architectures.
Frequently Asked Questions
Engineering answers regarding equipment sizing, integration, and process performance.
Kerone serves chemical, pharmaceutical, food and beverage, mining and mineral processing, energy, and environmental engineering industries with complete process plant solutions.
Yes, Kerone provides full EPC (Engineering, Procurement, and Construction) services including process design, equipment procurement, fabrication, installation, commissioning, and training.
Kerone fabricates pressure vessels and process equipment in compliance with ASME Section VIII, PED (European Pressure Equipment Directive), IS 2825, and other applicable international codes.
Yes, Kerone's safety engineering team conducts HAZOP (Hazard and Operability) studies and designs SIL-rated safety instrumented systems to ensure process safety.
Yes, Kerone specializes in skid-mounted modular plant designs that offer faster installation, easy transportation, and reduced civil work compared to stick-built plants.
Kerone integrates DCS, PLC, and SCADA systems from leading vendors including Siemens, ABB, Rockwell, and Honeywell, providing full process visibility and control.
Kerone maintains an ISO-certified quality management system with in-process inspection, non-destructive testing (NDT), hydrostatic testing, and third-party inspection as required.
Yes, Kerone provides comprehensive operator and maintenance training covering equipment operation, safety procedures, troubleshooting, and emergency response protocols.
Let’s Engineer the Right Process.
From application trials to full-scale production systems, our engineering team works with you to develop the right thermal processing solution for your material, throughput, and production requirements.