SUSTAINABILITY IS GOOD BUSINESS!! MYSORE FACTORY

Transcription

1 SUSTAINABILITY IS GOOD BUSINESS!! MYSORE FACTORY

2 MYSORE FACTORY UNIT

3 AN INSPIRING VISION!

4 WHY GREEN-CO? More focused on actions and results Brings in an standardized and external focus Lets us know how GREEN are we Rating acts as driver for performance Recognizes holistic contribution from the team right from senior level to line operators

5 GREEN-CO JOURNEY TO SILVER! Award of Green-Co Platinum Submission of recommendations July 2013 Preliminary Assessment and Site Visit June 2013 Submission of Green-Co Rating Assessment documents June 2013 Nov 2011 Training Program by CII Godrej GBC April 2011 Registration for rating with Green-Co CII Godrej GBC 1

6 DRIVER AND ENABLERS

7 ALL INLCUSIVE APPROACH!!

8 GOING BEYOND BOUNDARIES!

9 EXECUTION FRAMEWORK Brainstorming discussions Identifying Opportunities Creating action Plan Deciding KPIs Allocating Resources Executing with speed Identify solutions to risk identified Taking CAPA Regular Reviews on progress Identifying bottlenecks/delays Identifying risk to KPIs

10 PERFORMANCE FOR THE LAST 5 YEARS Accumulative Savings of 34.4 Crores

11 ENERGY EFFICIENCY

12 COST STRUCTURE 52.9% Utilities 41.5% Overheads 5.4% Fuel Cost 38% Power 23.6% Steam 38.3% Consumable

13 ENERGY MONITORING SYSTEM SCHEMATIC DIAGRAM power STEAM MONITORING SHEET Emission Monitoring PERFORMANCE MONITORING SHEET ONLINE DIESEL MONITORING KPI MONITORING SHEET

14 METHODOLOGY Pareto Analysis Energy Benchmarking Key Themes identified in Steam Electricity Fuel

15 SEC TREND 15% reduction over last 3 years

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17 WATER CONSERVATION

18 SPECIFIC WATER CONSUMPTION (KL/T)

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20 SPENT WATER RECYCLING Spent Water with sediments Chicory Dumping Chicory Extraction G.B cleaning Roasting Extraction Aroma Stripping Clarification Thermal Concentration De-Canter Filter Press Spray Drying 40 KLD Recycled! Powder Collection Storage Tank

21 EVAPORATOR REJECT WATER RECYCLING Overflow to SCE Extraction Feed tank Condensate tank To Extraction CW IN Chicory Dumping Chicory Extraction G.B cleaning Roasting Extraction CW Out Steam Condenser Vapors Evaporator Aroma Stripping Clarification Coffee 12% Coffee 55% Thermal Concentration Spray Drying 60 KLD Recycled! Powder Collection

22 VACUUM PUMP WATER RECYCLING Before After Cold Water IN Hot Water Out to ETP Cold Water IN PHE with chilled water Vacuum Pump Before Vacuum Pump 20 KLD Recycled! Vaccum Vaccum

23 HOSE DOWN STATION AND TANK DRAIN COLLECTION BEFORE Filter Water Steam AFTER Filter Water Hose Station Steam Mixing Hot 70 Degrees Liquor Tank Liquor Tank To ETP 10 KL Recycled! Divert to Another tank

24 60 KLD Condensate recovered

25 40 KLD Recycled! Ro permeate to Cooling tower, Boiler

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27 Infosys Training center HP Bottling plant PLANT LAYOUT TREATED EFFLUENT USAGE POINTS Utility area ETP IC Processing New Boiler Zero Fresh Water for Gardening CC Processing & packing Area Boiler makeup water cooling tower makeup Coconut gardens Inhouse gardening RO

28 OUR OWN KITCHEN GARDEN Water from ETP Manure from Biogas plant

29 Treated water used for gardening & Vegetable growing in coconut garden

30 LANDSCAPING Identified Fauna species 1. Mouse / Rodents 2. Termites 3. Monkeys 4. Pigeons, Parrots, Crows, Sparrows, Owls, Wood peckers 5. Ants 6. Squirrels 7. Mongoose 8. Snakes 9. Chameleons 10. Snails 11. Lizards 12. Centipedes 13. Millipedes 14. Flies 15. Earth worms 16. Honey bees 17. Butterflies 18. Peacocks 19. Dogs and Cats Witnessed snakes will be relocated to Chamundi / Bandipur forest

31 BEST PRACTICES SHARED WITH LOCAL COLLEGES Water saved for 1000 Urban People!!

32 RENEWABLE ENERGY AND GREENHOUSE GAS MITIGATION

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36 2011 0% Green Energy % Green Energy CLOSER THAN EVER BEFORE!

37 CURRENT GREEN QUOTIENT PROCESS STEPS GREEN COFFEE BEANS ETP/ Admin 0% GB Cleaning 0% CHICORY CUBES 55% Energy is Green Utilities GQ 87% 0% Roasting Granulisation 0% 0% CHICORY EXTRACTIO N 55% 0% Extraction Clarification Evaporation SPRAY DRYING 70% 0% 80% 5%

38 2016 GREEN QUOTIENT PROCESS STEPS GREEN COFFEE BEANS ETP/ Admin 90% GB Cleaning 90% CHICORY CUBES 85% Energy will be Green by 2016 Utilities GQ 94% 90% Roasting 0% Granulisation 90% CHICORY EXTRACTIO N 92% 35% Extraction Clarification Evaporation SPRAY DRYING 92% 90% 91% 80%

39 TODAY S SCENARIO 55% as Green Energy Online third Pass installation for MMB Uptime Improvement MMB Installation to Avoid FO Boiler Bio-gas generation through canteen waste Replace Electrical Heating with steam heating

40 2016 ACTION PLAN!!! 65% as Green Energy ESP in MMB Exhaust Full In-house spent burning Electricity Generation through Steam Turbine 8.62 Crores Ann Sav

41 2016 ACTION PLAN!!! Off-Site Solar Power purchase 83% as Green Energy ESP in MMB Exhaust In-house spent burning Electricity Generation through Steam Turbine 8.86 Crores Ann Sav

42 2016 ACTION PLAN!!! Off-Site Solar Power purchase 85% as Green Energy * Extraction Yield Improvement * Elimination of Packing DHU through AC ESP in MMB Exhaust In-house spent burning Electricity Generation through Steam Turbine * 4 Seal EGA Improvement * IC Dumping Powder collection * Rework Tank Installation 9.41 Crores Ann Sav

43 2017 ACTION PLAN!!! Thermic Fluid heater 100% as Green Energy * Extraction Yield Improvement * Elimination of Packing DHU through AC Off-Site Solar Power purchase ESP in MMB Exhaust In-house spent burning Electricity Generation through Steam Turbine * 4 Seal EGA Improvement * IC Dumping Powder collection * Rework Tank Installation Crores Ann Sav In-house Solar Generation

44 GOING Electricity generation through Bio-gas Planting Additional Trees to sequester Carbon Generation of excess Electrical Energy through Solar panels in 33 acres Steam Turbine Installations to generate excess Power

45 WASTE MANAGEMENT

46 Waste Categories Gas Liquid Solid 1. Total 13 stacks 2. SOx 1. Lubricant Oil 2. Effluent ZERO LAND FILL 1. Coffee spent 2. Chicory spent 3. Drybed & filter press 4. Boiler ash 5. Battery 6. Plastics waste 7. Woven sacks 8. Gunny bags 9. Garbage 10. Metal scrap 11. Waste wood 12. Steel scrap 13. Waste paper

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48 SCRAP YARD WITH DESIGNATED AREA FOR DIFFERENT TYPES OF WASTE

49 TREND 13% Reduction

50 Liquid Waste 17.8% Waste Contribution Mysore Factory Other Solid Waste 8.3% Spent Waste 73.8%

51 WASTE REDUCTION 254 KLD ETP LOAD ELIMINATED THROUGH WATER RECYCLING De-Canter Filter Press IN-HOUSE SPENT BURNING 70% REDUCTION Storage Tank

52 Air Waste reduction

53 MATERIAL CONSERVATION

54 MATERIALS GREEN COFFEE ROASTED CHICORY CUBES LIQUID CHICORY NITROGEN(DECOLOURISING AGENT) POLY-ETHELENE LAMIANTE CORRUGATED FIBRE CARTONS

55 MONITORING SYSTEM CROSS FUNCTIONAL TEAM Daily/weekly/monthly yield Monitoring TRAINING

56 TRAINING PARTICIPATION & FEEDBACK Training on roasting loss and yield improvement Training Evaluation

57 MATERIAL RECYCLING LIST OF MATERIAL CONSERVATION PROJECTS Optimized the roasted Beans moisture to 6% Optimized the roasted Beans curing time to 6hrs Recycling of westfalia Desludge Uninterrupted steam supply from MMB Planned cleaning procedure in SCE and Extraction line Changed the raw material spec. in Chicory. Collection of leakages and recirculation.

58 MATERIAL RECYCLING PROJECT-1: WESTFALIA SLUDGE RECYCLING SYSTEM COLLECTION OF SOLUBLE SOLIDS FILTER PRESS FOR SEPRATION 40% OF DESLUDGE MATERIAL RECOVARABLE WITH TSS 13-15%

59 MATERIAL RECYCLING Daily Sludge recovery monitoring With Flow meter Avg 13 kl consumption/day

60 MATERIAL RECYCLING 100 % Usage of Roasted beans chaffs as a Boiler fuel.

61 MINIMISING PACKAGING MATERIAL USAGE. PROJECT-1 Pneumatic sealer system Pneumatic Brake system Vertical sealer modification

62 PM SAVINGS RM SAVINGS Target UOM 2015 Target Actual Improvement over 2010 Improve RM loss against BOM by improving GB & chicory yield % 0% 0.33% 76% Reduce priamry & secondarypm loss % -1% 0% 78%

63 BEST WISHES FOR YOUR OWN GREEN-CO JOURNEY!