Pranay Ikkurthy

Process engineer · Industry 4.0 · IT/OT integration

Digital process optimization for real plant constraints.

Process Engineer focused on improving how manufacturing systems actually run, not just how they look on a dashboard.

My work sits at the intersection of process engineering and Industry 4.0. The biggest bottleneck in industrial digitalization is not the algorithm; it is the gap between Information Technology (IT) and the physical realities of Operational Technology (OT).

Connect on LinkedIn View focus areas

Approach

Physics first, digital second.

I start from the physics of the process and the architecture of the plant. I build hybrid models and digital tools that respect DCS boundaries and strengthen decision-making, rather than trying to replace engineering judgment.

Leverage industrial data, control systems, and physical engineering to make manufacturing systems more reliable, efficient, and transparent.

Actively expanding my professional network within the DACH manufacturing and automation sectors. German: B1 Level

Core focus areas

Industrial digitalization with engineering constraints in view.

Process Engineering & MSAT

Scale-up, tech transfer, debottlenecking, and resolving process-facility mismatches in complex CDMO and chemical manufacturing.

Control Systems & Automation (OT)

Working alongside DCS environments to implement APC, MPC, and RTO safely within physical and operational constraints.

Industrial Data & OT/IT Bridge

Contextualizing historian and DCS tags into actionable operational improvements without disrupting GMP operations.

Hybrid Modeling & Digital Twins

Grounding data-driven analytics in first-principles physical realities, including mass and energy balances.

Technical stack

Tools and systems

Control & data infrastructure

DCS architectures
OSIsoft PI System
Seeq
ABB 800xA

Process simulation

Aspen Plus
Aspen
PRO/II

Digital workflows

Python
Streamlit
n8n
Power BI

Optimization themes

APC
MPC
RTO
Digital Twins
AI Process Automation

Top skills

Profile skill highlights

Process Engineering

Good Manufacturing Practice (GMP)

AI Agents

Process Design

Pharmaceutical Process Scale-Up

Experience

Detailed work history

Quest Global

Full-time

Bangalore Urban, Karnataka, India · On-site

Process Engineer

Jun 2025 - Present · 1 yr

Conducted data collection, trend analysis, and performance monitoring using historian tools such as PI System and Seeq, supporting data-driven decision-making and continuous improvement.
Interpreted P&IDs, PFDs, and equipment datasheets, ensuring accurate documentation for design, operations, and scale-up activities.
Applied process monitoring and optimization expertise across complex production facilities, improving efficiency, reliability, and safety under regulated operating standards.

Process SimulationPro II+2 skills

Deccan Fine Chemicals Pvt. Limited

Full-time · 2 yrs 10 mos

Tuni, Andhra Pradesh, India · On-site

Process Engineer

May 2024 - May 2025 · 1 yr 1 mo

Performed process design and technology transfer for complex agrochemical manufacturing processes for a global client base under GMP and EHS guidelines.
Implemented process improvement initiatives in agrochemical manufacturing, achieving approximately 8–10% reduction in cycle time through optimized batch operations.
Supported scale-up of pilot plant operations to commercial scale, ensuring reproducibility and compliance with GMP.
Collaborated with cross-functional teams across QC, QA, and R&D to resolve process deviations, improving first-pass yield reliability through Kaizen initiatives.
Contributed to cost-saving initiatives such as solvent recovery optimization, lowering input costs by approximately 5%.
Participated in global client reviews, presenting process performance and improvement actions for ongoing projects.

Process EngineeringMaterial Balance+6 skills

Junior Process Engineer

Sep 2023 - May 2024 · 9 mos

Assisted in technology transfer projects, translating lab parameters into stable plant-scale processes.
Prepared operating procedures and process diagrams, improving operator understanding and reducing errors.
Monitored critical process parameters (CPPs), contributing to an approximately 5% reduction in batch variability.
Contributed to Root Cause Analysis, cutting recurrence of deviations.
Collaborated with production, QA, and R&D teams to enhance process robustness and efficiency.
Participated in pilot-scale trials, refining parameters for smoother commercial production.

Process EngineeringProcess Optimization (Manufacturing)

Graduate Engineering Trainee

Aug 2022 - Sep 2023 · 1 yr 2 mos

Rotated through production and process engineering functions, gaining comprehensive plant exposure.
Conducted mass and energy balance studies that guided senior engineers in yield improvement efforts.
Documented pilot trials and process observations, accelerating decision-making for scale-up.
Assisted in new equipment commissioning and process safety checks, ensuring compliance and operational efficiency.
Participated in cost tracking and process efficiency reviews, providing inputs for small Kaizen initiatives.

Data AnalysisCost Reduction+1 skill

Chegg India

Full-time

Remote

Subject Matter Expert

May 2022 - Mar 2023 · 11 mos

Solved advanced chemical engineering problems, strengthening core technical knowledge and applied problem-solving skills.
Delivered clear, structured solutions to a global learner base, refining technical communication and analytical presentation.
Maintained high accuracy and response quality under tight timelines, building discipline and consistency in professional output.

Subject Matter ExpertsProblem Solving+1 skill

Education & certifications

Credentials

Oct 2025

AI Automation certification

Udemy

AI Automation: Build LLM apps and AI agents using n8n.

2018–2022

Engineering education

Sri Venkateswara University

Engineering foundation supporting process improvement, scale-up, and systems thinking.

Contact

Connect within the DACH manufacturing and automation network.

Open to conversations around GMP/CDMO manufacturing, Industry 4.0, IT/OT integration, digital twins, APC/MPC/RTO, and AI process automation.

Open LinkedIn

Pranay Ikkurthy

Preparing modern profile experience

Process engineer · Industry 4.0 · IT/OT integration

Digital process optimization for real plant constraints.

Process Engineer focused on improving how manufacturing systems actually run, not just how they look on a dashboard.

Connect on LinkedIn View focus areas

Approach

Physics first, digital second.

Leverage industrial data, control systems, and physical engineering to make manufacturing systems more reliable, efficient, and transparent.

Actively expanding my professional network within the DACH manufacturing and automation sectors. German: B1 Level

Core focus areas

Industrial digitalization with engineering constraints in view.

Process Engineering & MSAT

Scale-up, tech transfer, debottlenecking, and resolving process-facility mismatches in complex CDMO and chemical manufacturing.

Control Systems & Automation (OT)

Working alongside DCS environments to implement APC, MPC, and RTO safely within physical and operational constraints.

Industrial Data & OT/IT Bridge

Contextualizing historian and DCS tags into actionable operational improvements without disrupting GMP operations.

Hybrid Modeling & Digital Twins

Grounding data-driven analytics in first-principles physical realities, including mass and energy balances.

Technical stack

Tools and systems

Control & data infrastructure

DCS architectures
OSIsoft PI System
Seeq
ABB 800xA

Process simulation

Aspen Plus
Aspen
PRO/II

Digital workflows

Python
Streamlit
n8n
Power BI

Optimization themes

APC
MPC
RTO
Digital Twins
AI Process Automation

Top skills

Profile skill highlights

Process Engineering

Good Manufacturing Practice (GMP)

AI Agents

Process Design

Pharmaceutical Process Scale-Up

Experience

Detailed work history

Quest Global

Full-time

Bangalore Urban, Karnataka, India · On-site

Process Engineer

Jun 2025 - Present · 1 yr

Conducted data collection, trend analysis, and performance monitoring using historian tools such as PI System and Seeq, supporting data-driven decision-making and continuous improvement.
Interpreted P&IDs, PFDs, and equipment datasheets, ensuring accurate documentation for design, operations, and scale-up activities.
Applied process monitoring and optimization expertise across complex production facilities, improving efficiency, reliability, and safety under regulated operating standards.

Process SimulationPro II+2 skills

Deccan Fine Chemicals Pvt. Limited

Full-time · 2 yrs 10 mos

Tuni, Andhra Pradesh, India · On-site

Process Engineer

May 2024 - May 2025 · 1 yr 1 mo

Performed process design and technology transfer for complex agrochemical manufacturing processes for a global client base under GMP and EHS guidelines.
Implemented process improvement initiatives in agrochemical manufacturing, achieving approximately 8–10% reduction in cycle time through optimized batch operations.
Supported scale-up of pilot plant operations to commercial scale, ensuring reproducibility and compliance with GMP.
Collaborated with cross-functional teams across QC, QA, and R&D to resolve process deviations, improving first-pass yield reliability through Kaizen initiatives.
Contributed to cost-saving initiatives such as solvent recovery optimization, lowering input costs by approximately 5%.
Participated in global client reviews, presenting process performance and improvement actions for ongoing projects.

Process EngineeringMaterial Balance+6 skills

Junior Process Engineer

Sep 2023 - May 2024 · 9 mos

Assisted in technology transfer projects, translating lab parameters into stable plant-scale processes.
Prepared operating procedures and process diagrams, improving operator understanding and reducing errors.
Monitored critical process parameters (CPPs), contributing to an approximately 5% reduction in batch variability.
Contributed to Root Cause Analysis, cutting recurrence of deviations.
Collaborated with production, QA, and R&D teams to enhance process robustness and efficiency.
Participated in pilot-scale trials, refining parameters for smoother commercial production.

Process EngineeringProcess Optimization (Manufacturing)

Graduate Engineering Trainee

Aug 2022 - Sep 2023 · 1 yr 2 mos

Rotated through production and process engineering functions, gaining comprehensive plant exposure.
Conducted mass and energy balance studies that guided senior engineers in yield improvement efforts.
Documented pilot trials and process observations, accelerating decision-making for scale-up.
Assisted in new equipment commissioning and process safety checks, ensuring compliance and operational efficiency.
Participated in cost tracking and process efficiency reviews, providing inputs for small Kaizen initiatives.

Data AnalysisCost Reduction+1 skill

Chegg India

Full-time

Remote

Subject Matter Expert

May 2022 - Mar 2023 · 11 mos

Solved advanced chemical engineering problems, strengthening core technical knowledge and applied problem-solving skills.
Delivered clear, structured solutions to a global learner base, refining technical communication and analytical presentation.
Maintained high accuracy and response quality under tight timelines, building discipline and consistency in professional output.

Subject Matter ExpertsProblem Solving+1 skill

Education & certifications

Credentials

Oct 2025

AI Automation certification

Udemy

AI Automation: Build LLM apps and AI agents using n8n.

2018–2022

Engineering education

Sri Venkateswara University

Engineering foundation supporting process improvement, scale-up, and systems thinking.

Contact

Connect within the DACH manufacturing and automation network.

Open to conversations around GMP/CDMO manufacturing, Industry 4.0, IT/OT integration, digital twins, APC/MPC/RTO, and AI process automation.

Open LinkedIn