ME HoD and faculty member visit SEFPRO – Saint-Gobain, Palakkad under PALS Industry Engagement Program”

A team from Vidya Academy of Science and Technology, Thrissur visited SEFPRO – Saint-Gobain Sintered and Electrofused Products, Kanjikode, Palakkad, on 25 November 2025, under the PALS Industry Engagement Program. The visit aimed to provide students and faculty with first-hand exposure to a world-class refractory manufacturing facility serving the glass industry. The official team included Dr. Rakesh Hari (Prof & HoD, ME Dept)) and Mr. Vishnu Shaji(Asst. Prof, ME Dept)

The primary objective of the visit was to observe advanced manufacturing processes, technological innovations, and operational practices at SEFPRO, bridging the gap between theoretical knowledge and industrial implementation. Key areas of exposure included refractory material production, world-class manufacturing standards, corporate safety culture, sustainability initiatives, digital transformation strategies, people-development programs, and global research infrastructure.

Overview of SEFPRO and Saint-Gobain

SEFPRO is a global leader in fused-cast, sintered, monolithic, and repair refractories, exclusively serving the glass industry. The Palakkad facility, acquired in 2002, is unique for housing both fused-cast and sintered refractory production on a single campus. Saint-Gobain, with a legacy spanning over 360 years, established SEFPRO’s fused-cast plant in 1929. SEFPRO India operates as SEPR Refractories India Ltd., with branches in Perundurai, Tamil Nadu, and Kanjikode, Kerala. The plant holds multiple certifications including ISO 9001, ISO 14001, ISO 45001, ISO 50001, and ECOVADIS Gold.

Corporate Philosophy and Strategic Vision

SEFPRO’s philosophy is founded on Humanism, Ethics, and Responsibility, emphasizing employee well-being, transparency, integrity, and environmental stewardship. Its vision is to “shape a carbon-neutral glass industry for a brighter future”, while its mission focuses on delivering “future-proof refractory solutions” for glass furnace operations.

Manufacturing Operations and Products

The visit focused on fused-cast refractory technology, which involves melting purified raw materials at temperatures up to 1800°C, followed by controlled casting to produce dense, corrosion-resistant blocks. Key products include AZS 14000 and GrA series, along with the ER series (ER 1600, ER 1681, ER 1711, ER 1851) for furnace sidewalls, bottom blocks, throat blocks, and superstructure parts. Notably, ER 1699 RS, an electro-fused AZS refractory with ~37% zirconia, offers exceptional corrosion resistance for modern hybrid furnaces.

Operational Excellence and Digitalization

The facility follows World Class Manufacturing (WCM) practices, achieving Bronze (2017), Silver (2022), and Gold (2025) levels. Operations are monitored through KPIs, KRIs, OPIs, and OEE, supported by Industry 4.0 digital dashboards and AI-based safety automation.

Safety, Environment and Sustainability

Safety is deeply embedded through PPE compliance, no-mobile-phone zones, and structured frameworks like Safety Diamond and Safety Millionaire Club. SEFPRO targets carbon neutrality by 2050, with 2030 goals of reducing water withdrawal by 50%, CO? emissions by 33%, and overall energy/waste usage by 80%. The Palakkad facility utilizes solar power for 70–80% of its energy needs and practices circular-economy initiatives.

Research, Innovation and People Development

The Saint-Gobain Research Centre at IIT Madras Research Park supports R&D in sustainable refractory design, digital simulation, and advanced materials. The plant promotes workforce autonomy via the “Towards Autonomy” framework, emphasizing decision-making, ownership, teamwork, and diversity (8% women employees).

Learning Outcomes

The visit provided first-hand exposure to world-class manufacturing, precision refractory production, operational excellence, sustainability, digitalization, and global research practices. It successfully bridged the gap between academic theory and industrial practice, offering valuable insights for faculty development, student learning, and future industry-institute collaborations.