Rajeev Sherry, Exhibition Committee Chairman, PPMAI; and Managing Director – India and BA Europe, Outokumpu India, pens down his thoughts about the importance of stainless steel for the manufacturing sector, ahead of Global Stainless Steel Exhibition 2025 (GSSE).
Indian Process Plant and Machinery (PPM) industry that has estimated capacity of US$ 6 billion per annum has made significant contribution in establishing the Indian Process Industry.
The Process Plant Machinery Association of India (PPMAI) represents a world class pool of talent in engineering and management skills, having proven track record in basic design, multidisciplinary detailed engineering, manufacturing of plant and equipment, transportation, installation, construction at sites, erection and commissioning of process plants.
PPMAI members provide products and services to diverse range of industries in India and abroad such as:
- Oil and gas
- Hydrocarbon refining and processing
- Fertiliser, chemical, paper and pulp, synthetic fibre
- Food and dairy
- Environment control
Importance of Stainless Steel for PPMAI
Stainless steel has long been the foundation of India’s process plant and machinery industry, serving as an essential material across various sectors. From food processing and pharmaceuticals to chemical plants and heavy engineering, stainless steel is indispensable due to its durability, corrosion resistance, and versatility. As India’s manufacturing sector continues to grow, the demand for high-quality stainless steel components in industrial applications is set to rise.
Role of Stainless Steel in Process Plant and Machinery
The process plant and machinery sector rely heavily on stainless steel for its ability to withstand extreme temperatures, aggressive chemicals, and high-pressure environments. Key applications include:
- Pharmaceutical and Food Processing Equipment: Ensuring hygiene and longevity in production lines.
- Chemical and Petrochemical Industry: Corrosion-resistant tanks, pipes and reactors.
- Power Generation and Renewable Energy: Turbine components, heat exchangers and structural elements.
- Water Treatment and Environmental Solutions: Wastewater treatment plants and desalination systems.
Stainless steel stands out as a premium material in process plants and machinery manufacturing, offering a host of advantages that enhance both efficiency and longevity. Here’s why its use can be a game changer for your operations:
1. Exceptional Durability and Strength
Stainless steel offers impressive mechanical strength, ensuring that components in process plants and machinery can withstand high pressures, heavy loads and mechanical wear. Its structural integrity under stress minimises failure risks and helps maintain a safe operating environment, thereby reducing downtime and costly repairs.
2. Superior Corrosion and Chemical Resistance
Unlike other materials, stainless steel remains highly resistant to corrosion even when exposed to aggressive chemicals, moisture, and extreme environments. This property is indispensable for process industries where equipment frequently encounters corrosive substances or where the operating environment can quickly degrade less resilient materials.
3. High Temperature Endurance
Many process plants operate under elevated temperatures. Stainless steel retains its structural properties and chemical stability at high temperatures, preventing deformation and ensuring consistent performance in heat-intensive processes. This reliability is critical in sectors like petrochemicals, power generation and high-temperature manufacturing.
4. Hygienic and Cleanable Surface
Processes in food, beverage, pharmaceuticals, and biotechnology demand immaculate hygiene standards. The smooth, non-porous surface of stainless steel minimises the buildup of contaminants and facilitates easier cleaning and sterilisation. This not only speaks to quality control but also helps in complying with stringent health and safety regulations.
5. Long-Term Economic Benefits
While the initial investment in stainless steel might be higher compared to other materials, its low maintenance needs and extended lifespan often translate into significant cost savings over time. Reduced repair frequency and less operational downtime contribute to a lower total cost of ownership, making it an economically sound choice.
6. Design Versatility and Fabrication Flexibility
Stainless steel can be intricately formed, welded and machined into customised parts that meet the specific demands of any process plant design. This versatility allows engineers to innovate and optimise designs to achieve both aesthetic appeal and functional performance without compromising strength or durability.
7. Sustainability and Environmental Impact
With increasing emphasis on sustainable manufacturing, stainless steel’s recyclability is a significant advantage. It is fully recyclable without a loss in quality, which not only reduces waste but also helps achieve environmental compliance. Leveraging stainless steel aligns well with modern green engineering practices and corporate sustainability targets.
In summary, the use of stainless steel in process plant and machinery manufacturing is a strategic decision driven by its unparalleled strength, resistance to harsh environments, hygiene, and long-term cost-effectiveness. These benefits ensure robust, resilient operations that can adapt to varying industrial demands while also contributing to a sustainable manufacturing ecosystem.
Challenges faced by PPMAI members and other manufacturers
Manufacturers today face a multi-pronged set of challenges when purchasing stainless steel. These challenges stem from global market fluctuations, regulatory changes and heightened international competition—all of which can disrupt supply chains and inflate costs.
1. Raw Material Price Volatility and Supply Chain Uncertainty
Many manufacturers rely on imports for critical raw materials such as nickel and chromium, which are essential for producing high-quality stainless steel. Global economic shifts, geopolitical tensions, and unpredictable tariff regimes cause significant price fluctuations. This volatility makes it difficult to establish stable budgets and plan long-term production, especially when suppliers and manufacturers are forced to navigate sudden cost increases or delays.
2. Stringent Regulatory Compliance and Documentation Requirements
A tightened regulatory environment is increasingly impacting manufacturers. New quality control orders and standards—such as those imposed by the Bureau of Indian Standards (BIS) in sectors like cookware, and by extension other stainless-steel products—demand extensive documentation, testing, and certification. These requirements can overwhelm smaller enterprises, leading to higher administrative overheads, operational delays, and increased production costs. For many manufacturers, this has transformed compliance from a routine procedure into a daunting and costly challenge.
3. Infrastructure and Logistics Obstacles
Logistical inefficiencies—ranging from inadequate transportation networks to congested ports—add another layer of difficulty. These infrastructure challenges can delay shipments and increase transportation costs, affecting the timely availability of stainless steel. For manufacturers, maintaining a steady, high-quality inventory becomes a juggling act as they contend with delays and fluctuating supply chain dynamics.
4. Technology Adoption and Cost Pressures
Keeping pace with rapid technological advances is crucial in today’s competitive environment. However, many small and medium enterprises (SMEs) struggle with the high initial costs and limited access to modern manufacturing and quality control technologies. This difficulty in embracing technological innovation contributes to inefficiencies in production processes and can leave some manufacturers lagging behind those that are quicker to adapt.
In summary, the challenges of buying stainless steel today revolve around unpredictable raw material prices, rigorous regulatory landscapes, infrastructural shortcomings and the hurdles of technological integration. These interconnected issues require manufacturers to adopt strategic, often multifaceted, approaches—ranging from enhanced supply chain management to lobbying for supportive trade policies—to ensure they maintain both competitive cost structures and compliance with quality standards.
India’s Position in the Global Stainless-Steel Market
India has emerged as a leading producer and consumer of stainless steel, with domestic manufacturers expanding their capabilities to meet international standards. With policy support such as the ‘Make in India’ initiative, the industry has witnessed tremendous growth, strengthening its position in global supply chains.
Summary
Despite its growth, the industry faces challenges such as price volatility, fluctuating raw material costs, and increasing competition from international markets. However, opportunities such as sustainable production methods, new alloy innovations, and export expansion provide a promising outlook.
Stainless steel continues to be the backbone of India’s process plant and machinery industry. As manufacturers innovate with advanced technologies and sustainable practices, the sector is poised for continued success in both domestic and international markets.
