Theory to Industry : The Course on Wheels

Introductory view:

The Course on Wheels (CoW) is an innovative learning program introduced by the Department of Chemical Engineering at IIT Bombay to help students connect classroom concepts with real-world industrial applications. Launched in the 2016-17 academic year, CoW has been running successfully for over seven years, offering students first-hand exposure to various sectors of the chemical industry. Unlike traditional industrial visits, CoW is designed to be highly immersive and academically rigorous, with faculty members actively engaging with students through lectures, discussions, and structured coursework during the trip. The program aims to bridge the gap between academia and industry by providing direct insight into large-scale chemical operations.

Over the period of three weeks, students travel nearly 2000 km across India’s Western Chemical Belt, visiting industries in oil and gas, power, fertilizers, pharmaceuticals, agrochemicals, and more. To ensure a structured learning experience, students undergo training sessions before the trip, preparing them to engage effectively during site visits. At each industrial site, students attend expert briefings, observe complex processes and machinery, and interact with practicing engineers. To successfully complete the course, students must submit detailed company reports, take an exam, and work on a simulation project based on their experiences. 

Insight interviewed Prof. Sanjay Mahajani, the professor in charge of the Course on Wheels initiative. Additionally, Insight gathered reviews about the course from students who had taken it in the previous iterations. 

The Idea Behind Course on Wheels

Traditional courses on chemical processes often focused on descriptive content, which might not necessarily delve into the nuances involved in practical implementation. An actual chemical operation extends much more beyond chemical engineering theory, bringing in aspects like shop-floor management, reliability, inspection, safety control among others. On these lines, CoW aims to provide students with a holistic perspective on the technical aspects of chemical engineering, while also offering insight into the exciting challenges faced by professionals in the field. 

Prof. Sanjay Mahajani, sharing his perspective on the origins of this program, said:

“About 15 years ago, I was teaching a course on chemical processes. At that time, I realized that the course was very theoretical and descriptive, lacking a practical aspect. Classroom learning is valuable, but unless students see applications in real life, they don’t fully appreciate the subject. Although industrial tours had been conducted in the past, they only provided a glimpse of the chemical industry and lacked the depth of learning we aimed for. We wanted to focus on both immersion and meaningful engagement, thus we designed the program from scratch and ensured active faculty participation.”

“However, over time, another purpose evolved. Despite the many resources available on campus, students may often find themselves in a closed circle, disconnected from what’s happening outside. Even though they engage in various positions of responsibility (PoRs) and activities, we needed something to ensure their dedicated engagement in core learning.”

Today, the program has successfully integrated  into the department’s academic framework, allowing students to gain a clearer perspective on industry, making their academic journey more meaningful and direction-oriented.

The 2024 Edition:

The 2024-25 edition of Course on Wheels (CoW) kicked off on 2nd December. The trip itinerary included a visit to the following facilities:

• GIPCL thermal power plant, Ankleshwar: Visit and insights into power generation.
• ONGC, Ankleshwar: Exploration of oil and gas operations.
• Birla Copper, Ankleshwar: Understanding copper manufacturing processes.
• UPL (agrochemicals), Jhagadia: Exposure to agrochemical production.
• ATUL, Ankleshwar : Visit to chemical manufacturing facilities.
• GNFC (fertilizers), Bharuch : Learning about fertilizer production.
• Zydus, Ankleshwar: Insights into pharmaceutical manufacturing.
• JB Chemicals, Ankleshwar: Visit to pharmaceutical production units.
• Nirma, Bhavnagar: Exploration of detSrgent and chemical production.
• Reliance Petroleum Refinery, Jamnagar: Multi-day visit to the world’s largest refinery complex.
• Reliance, Dahej: Observing petrochemical operations.
• AMUL, Anand: Understanding large-scale dairy processing.
• L&T-Hazira, Hazira: Insights into heavy equipment fabrication.

Route of the course in 2016

Credits: Course on Wheels archive

The above planned itinerary was designed to cover various aspects spanning the chemical industry landscape. The program covered equipment and operations, including mass transfer (distillation, absorption, extraction), heat transfer (heat exchangers, evaporators), process control via DCS (distributed control systems), power plants (turbines, generators, boilers), and diverse reactor types (catalytic, fluidized beds, stirred tanks). The course aimed to cover different sub-fields of chemical engineering such as petrochemicals (e.g., ethylene oxide, polyethylene), fertilizers (e.g., ammonia, urea), agrochemicals (e.g., mancozeb), inorganics (e.g., soda ash, chlorine), and specialty products (e.g., dyes, APIs). The experience also included techno-commercial discussions with practicing engineers and managers, and a session with first-generation entrepreneurs in the chemical sector.

Implementation and Logistics

The successful execution of the Course on Wheels (CoW) program relies on meticulous planning, dedicated faculty involvement, and sustainable funding strategies. Prof. Sanjay Mahajani outlined the key logistical and financial aspects that ensure CoW’s continued success:

Faculty and TA Involvement

Implementing a month-long intensive program like CoW demands significant commitment from faculty members and teaching assistants (TAs). 

“Faculty commitment for a month is very tough. Many of my colleagues have their own teaching and research responsibilities, making it challenging to dedicate the necessary time..” – said Prof Mahajani.

Dedicated faculty members such as Prof. Madhu Vinjamur, Prof. Rahul Nabar, and Prof. Vinay Juvekar have consistently supported the program over the years. PhD students working as TA’s for this course have also played a crucial role, offering flexibility and direct involvement. Both the TAs and technical staff are required to be proficient, enthusiastic, and capable of managing the program’s dynamic nature.

Funding and Financial Management

Financial sustainability has been the primary challenge for CoW. Offering more perspective on this, Prof. Mahajani said:

“In the first year, CoW was entirely free, funded by the institute. However, as the program grew, it became necessary to introduce fees to cover expenses like accommodation, travel, and food. To alleviate the financial burden on students, we started seeking industry sponsorships, which significantly reduced the costs.”

Over the past few years, securing sponsorships through strong industry contacts has allowed students to pay minimal fees, around 10-15k INR, compared to the initial years when the institute bore most expenses. Industry partners view their support as part of their Corporate Social Responsibility (CSR) initiatives, benefiting both the industry and the students.

Students’ Perspectives on CoW: Motivation, Learning, and Challenges

Insight conducted a survey among students who took part in the programme in the last 2 years, which was filled by 14 students. Following are some of the key insights derived from these responses.

Motivation to Participate

Practical exposure and exploring chemical opportunities in chemical engineering emerged as the most significant reason for students to join CoW. Other popular motivating factors included traveling with friends or batchmates and building a profile/resume.

One responder shared, “I wanted to understand how theoretical principles translate into real-world applications, and CoW seemed like the perfect platform for that.”

Learning and Academic Experience

Students liked the academic structure of CoW, finding the industry visits and preparatory theory sessions particularly useful. While most found the lectures and quizzes to be helpful, some believed the assessment methods and workload could be improved.

The students widely appreciated the affordability and logistical arrangements of the course. They also highly praised the travel, accommodation, and food services for ensuring their comfort and making the intense schedule manageable. 

Most Rewarding Experiences

When asked about the most rewarding aspects of the course, students highlighted the exposure to cutting-edge industrial processes and the opportunity to visit world-class facilities. Many found the visit to Reliance’s Jamnagar Refinery particularly impactful, with one participant describing it as “an eye-opener to the scale and sophistication of operations in the chemical industry.” Another student noted, “The multi-day visit to Reliance Petroleum helped me truly appreciate the scale of petrochemical manufacturing and its global significance.”

In addition to technical learning, several respondents cherished the bonds they formed with peers during the trip. Traveling together and engaging in discussions after each visit helped foster a sense of camaraderie, making the experience both professionally and personally enriching.

Pitfalls and Challenges

The demanding schedule of CoW presented significant challenges for participants. Many described the course as physically and mentally exhausting, with little time to rest or recover. A responder remarked, “The workload can be hectic with tight deadlines.” Another noted, “It’s busy from the start to the end of the day, and it doesn’t let you rest.”

Some students recommended including weekly rest days to address the issue of fatigue, as the packed schedule often led to burnout. Despite these challenges, others reflected positively on the experience, noting how the intensity pushed them out of their comfort zones and helped them grow. One student shared, “Getting used to the packed schedule was difficult at first, but later we amazed ourselves by how hard we worked. It got us out of our comfort zones.”

The Core Connection

For many, CoW strengthened their interest in core chemical engineering by providing a clearer understanding of industrial practices and career possibilities. Several participants shared how the course clarified the scope and challenges of working in the chemical industry. However, some students felt the course did not drastically change their career outlook, though they still valued the exposure and experience it provided.

(1 being strongly demotivated, 5 being strongly motivated)

Adding to this, one participant reflected, “The course didn’t just teach me about industry—it made me think differently about what I want from my career and the skills I need to develop.”

Professor’s Perspective:

Insight asked Prof. Mahajani to share the common feedback received and how it influenced students’ career choices. 

“Learning new technical aspects is not the primary takeaway. Students describe the experience as eye-opening, helping them gain a broader perspective that benefits them in other courses as well. The course is designed to shift perspectives, and many students find that it clears up confusion they previously had.
In terms of career choices, the overall landscape is increasingly interdisciplinary. While I don’t believe CoW alone determines their career paths, it certainly plays a role. If we want more students to get interested in core chemical engineering, we need to do more than what is currently happening, to spark their interest.”

Furthermore, while reviewing the responses to the survey floated among students who had previously taken the course, we found that some students felt overwhelmed by the course’s workload and travelling component. We asked Prof. Mahajani for his thoughts on this, to which he responded:

“As the duration of the journey is only one month, we are bound to keep it slightly hectic. For students, a lot depends on their mindset. I am glad that, physically, they manage well. However, I do agree that, mentally, it can be challenging. Students are not used to such an intense influx of information—industry visits, reports, and quizzes—all within a month. To deal with this, earlier, we used to allocate one free day every week, but it turned out to be economically infeasible.”

Even though the trips were extensive and some days became tiring, students gave a largely positive feedback to the overall experience, through the survey. Sharing his observations on how the program has impacted students, Prof. Mahajani said:

“The same student in a classroom and the Course on Wheels (CoW) program shows a significant difference in their enthusiasm for learning and overall engagement. I see that as a success. Initially, when I started, I thought it would be the first and last time, but every year, students keep coming back. Even if the benefits are not immediately apparent, in the long run, it has proven to be a successful initiative.”

CoW has been a rewarding experience for professors as well. It has also brought recognition to the department, with officials from other universities reaching out to Prof. Mahajani after being inspired by the initiative. Elaborating on this perspective, he said:

“From the teachers’ point of view, they say they enjoy interacting with students. The questions students ask and their responses make the experience fulfilling for teachers as well. Even for me, every time I visit the same company, I learn something new. Even faculty members do not get frequent opportunities to visit industries, and I did not expect how valuable this exposure would be. This experience has also enriched my teaching.

When I shared details with the University of Stuttgart in Germany, a professor was interested enough to visit and understand the program firsthand. Similarly, BITS Dubai Campus approached me, and I gave them an online presentation on how we run the course. Overall, it is gratifying to see the initiative gaining recognition.”

Conclusion

The Course on Wheels (CoW) program has emerged as a revitalizing force for aspiring chemical engineers, bridging the gap between theoretical learning and real-world industrial applications. By immersing students in large-scale operations, CoW enhances their technical understanding and fosters a renewed appreciation for core engineering disciplines. While the program presents challenges such as an intense schedule, extensive travel, and logistical hurdles, its impact is undeniable. The first hand exposure to industry processes, coupled with faculty guidance and structured coursework, equips students with valuable insights that extend beyond academics. Despite the demanding nature of the program, the overwhelmingly positive feedback highlights its success in inspiring students and strengthening their connection to core chemical engineering, ensuring the discipline remains vibrant and relevant.

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