India’s petrochemical economy: Opportunities for manufacturing industry growth

  • Articles
  • Oct 10,25
With supportive government policies and robust market demand, the Indian petrochemical industry has the potential to emerge as a pillar of industrial self-reliance, write R Jayaraman and T C R Amon.
India’s petrochemical economy: Opportunities for manufacturing industry growth

The global petrochemicals (PC) industry is one of the most critical for the manufacture of goods of various types. Being used in finished products like polyester, LPG, plastics and such, it has formed the backbone of industry in many countries. India is among the top 5 countries in the world in PC production, with a projected capacity of 45 mtpa by 2023. 25 to 30 mtpa, the others being China, USA, South Korea and KSA. India's niche-petrochemical industry is poised for accelerated growth, driven by rising domestic demand and national initiatives promoting import substitution and local manufacturing. Currently valued at $ 50–60 billion, the Indian petrochemical market is projected to reach $ 84.4 billion by 2033, according to IMARC Group.

High value niche segments such as acrylic acid, polyols, and acrylates, represent promising opportunities. Scaling local production not only reduces dependence on imports but also advances national priorities such as Make in India. These products in B2B ecosystem caters to diverse downstream industries including speciality chemicals, coatings, plasticizers, paints and adhesives, cosmetics, automotive paints, detergents, and pharmaceuticals. With the right policy support and strategic market deployment, this sector can evolve into a source of long-term competitive advantage.




Historically, India's niche petrochemical supply chain has been import-dependent due to limited indigenous production capacities. Although recent capital investments in manufacturing facilities have begun reshaping this landscape, the sector continues to face challenges and volatility which constrain the competitiveness and market footprint. The intricate production processes, specialized storage requirements, and highly variable demand make the supply chain management of niche petrochemicals unique from conventional petroleum products. Easy international availability, coupled with extended lead times, unpredictable pull pull-marketing demand and fragmented domestic logistics generate the classical 'bullwhip effect'—a phenomenon where small demand variations cause increasing fluctuations up the supply chain. This phenomenon inflates operational costs through overproduction or stockouts, destabilizes operations, reduces profitability and hampers customer confidence.



Key challenges
A deeper analysis of the Indian petrochemical supply chain reveals several challenges:
  • Intermediate inventory constraints: Limited buffer and intermediate storage capacity disturbs smooth production and distribution continuity amidst demand volatility. The infrastructural complexity for maintaining such inventories adds operational overhead
  • Fluctuating plant utilization: Variability in plant loading disrupts operational consistency, leading to underutilization of installed capacities. Production plants, particularly those dealing with sensitive chemical processes, require steady load regimes to maintain process integrity and reliability.
  • Geographically dislocated storage and logistics: Unlike other petroleum products, presently there is no comprehensive network of tankages facilitating seamless transfer and storage of niche petrochemical products which weakens supply resilience. Dedicated storage infrastructure tailored to product-specific needs is essential and must evolve alongside shifting industrial demand clusters, leading to higher logistics costs. 
  • Limited number of domestic manufacturers: The relatively small number of domestic producers—for instance, only select companies manufacturing acrylic acid—poses supply risk during production disruptions. Consequently, customers often revert to imports, contrasting with more diversified and resilient petroleum product supply chains existing now in market.
  • Distinct strategic requirements compared to petroleum products: Supply chain and marketing strategies for petrochemicals demand higher responsiveness due to the product characteristics, demand unpredictability, and stringent quality requirements, following responsive supply chain differing significantly from conventional petroleum supply chains.

Overcoming the challenges
In summary, addressing these challenges involves establishing new storage facilities, enhancing supply  chain connectivity through logistics optimization, managing volatile demand with responsive supply chains, and implementing sophisticated storage and handling infrastructure. Indian manufacturers, those who want to take advantage of the opportunities in the PC segment can examine the given below suggestions to enter the market. 
  • Expansion of storage and warehouse facilities: It is imperative to establish additional tank farms and warehouses in strategic geographic locations beyond manufacturing hubs, at key consumption hubs. Such infrastructure will reduce lead times, improve market responsiveness, and support phased market expansion. A phased rollout of warehouse aligned with industrial clusters will strengthen supply resilience. A cost–demand analysis should guide investments in a nationwide chain of product-specific storage assets.
  • Implementation of advanced production planning tools: Leveraging digital transformation by investing in digital infrastructure, demand simulators, and predictive analytics to align production schedules with market signals, thus reducing variability, ensuring optimized asset utilization and enhancing operational stability. 
  • Adoption of a ‘Hybrid Push-Pull Marketing’ model: Combining proactive inventory build-up (push marketing) to anticipate demand spikes with reactive supply fulfilment (pull marketing) mitigates the bullwhip effect. For petrochemicals, this hybrid model typically incorporates a higher push inventory ratio—initial ratio of ~30–40% push to 60–70% pull, refined in future via trend and time-series analysis, can improve customer responsiveness while optimizing carrying costs. This approach curbs the bullwhip effect and improves customer responsiveness.

Conclusion
The Indian petrochemical industry stands at a strategic inflection point, presents robust growth opportunities aligned with national economic priorities. With supportive government policies and robust market demand, the sector has the potential to emerge as a pillar of industrial self-reliance. Enhancing supply chain agility through strategic inventory management, advanced planning, and marketing integration is vital for expanding market share and profitability. Such an integrated operational model not only mitigates the risks of volatile demand but also positions domestic producers to leverage expanding market demand sustainably. As domestic production capabilities mature, investments in value-added product development and strategic capacity expansions will be critical in positioning India as a global leader in the niche petrochemicals space.

About the authors:
R Jayaraman is the Head, Capstone Projects, at Bhavan's S P Jain Institute of Management & Research (SPJIMR). He has worked in several capacities, including Tata Steel, for over 30 years. He has authored over 60 papers in academic and techno economic journals in India and abroad. Jayaraman is a qualified and trained Malcolm Baldrige and EFQM Business Model Lead Assessor.

T C R Amon is the Chief Manager at BPCL, Kochi.

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