CII National Award for Excellence in Energy Management 2018

Transcription

1 CII National Award for Excellence in Energy Management 2018 Presented By:- Vinay Sarode- AM (Green Cell) Ganesh Patil- AM (Maintenance) Saving Energy Everywhere

2 Godrej Interio Product portfolio Godrej Interio - Enriching life by transforming home and work spaces 176 product solutions for home and institution spaces Kal bhi Aaj Bhi 20 Indoor Advantage certified products 9 BIFMA Level certified products Green Products 50 GREENGUA RD certified products 2 GREENPRO certified products

3 Brief introduction on Company/Unit National Benchmark In furniture Manufacturing

4 Process layout for Interio Shirwal Interio Shirwal Maintenance & Utilities Common Resources Administration Quality Supply Chain Lamination Resin preparation Lamination Wood Working Cutting Edge- Banding Drilling Membrane Pressing Lacquering Packing and Dispatch Powder coating Pre treatment Powder coating Metal Working Cutting Bending Notching Punching Welding

5 Renewable energy Briquette Fired Thermic fluid Heater Employee involvement Kaizens Smart sense Monitoring Better capacity utilisation Variable frequency Drives Green chemicals Elements of Energy Conservation Overall Equipment Effectiveness(OEE) Solar energy Blower efficiency improvement Harmonic reduction LED Lighting Compressed air management Automation Technology up-gradation Timers High volume low speed fans(hvls) Motor De-Rating

6 Energy Sources-Godrej Interio, Shirwal 200 MWh units 3490 MWh units 365 kw capacity 3.5% Renewable Energy 40% Grid Electricity 2.5 lacs liters 24.5 % Energy 535 tons Briquettes 32 % Utilization of waste

7 Energy Performance Specific Energy reduction Benchmarking with national and international manufacturers Action plan to become Best in class

8 Energy performance for the plant Specific Energy Consumption trend (MJ/Sqm) Increase Over Last Year due to additional Plant commissioning % reduction 39 % reduction % Reduction Over Energy Baseline 39% Reduction in last 3 years FY Target MJ/SQM 300 KVA Energy capacity surrendered to MSEDCL

9 Reduction in absolute consumption 0.34 Production in million Sqm % Rise Diesel consumption (KLitres) % Rise Briquette consumption (tons) Additional Plant commissioning Electricity consumption million kwh % Drop % Drop

10 Comparing ourself with other industries better better

11 Benchmarking our processes with International Manufacturer Interio Shirwal Wood MJ/sqm % reduction 54.19% 58% Home furnishing Supplier Data FY12 FY14 FY15 FY16 Energy GWh Specific energy kwh/m Initiative taken by our Competitor Building Certification Natural Lighting Lighting sensors Use of Heat Pump Renewable Energy Initiative Godrej Interio Y Y Y Y y Renewab le energy %

12 Our focus for energy conservation List of energy intensive equipments No Name of equipment Units Rated Load % contribution to Total Electrical Energy % contribution to Total Thermal Energy 1 Air Compressor 2 180kW 22.5% NA 2 Thermic fluid heater 1 NA 4.9% 19% 3 Pre Treatment line pumps 14 motors 4 Powder Coating blowers 6 blowers 7.5 kw x kw x 4 15kW x 6 8.8% 20 kw x 2 14 kw x 4 NA NA 5 Dust extractor 4 133kW 16% NA 6 WDO and PCO burner 2 NA NA 80% total diesel 7 Powder Coating oven 1 NA NA consumption

13 Approach for Energy Planning-Priority Matrix Equipment Can this be eliminated? Alternate Process? Increase efficiency? Reduce consumption? New technology Use of Renewable Energy Compressors PT line motors Dust collectors Thermic fluid heater Cooling tower Hydraulic power packs ETP /STP / Water circulation system Press Shop Blowers for ovens Plant Lighting Air Conditioning

14 Zero investment projects done in last 3 years Title of Project Year Annual Electrical Saving, Annual Thermal Saving, Total Annual Savings, (Million Rs) Investment Made (Million kwh) (Million kcal) (Rs million) Resin formulation changed for lamination Elimination of Fume extractor pumps due to change in PT line chemicals Lighting optimization- New kitchen shop Timer circuit for new kitchen shop lighting Optimization of PT line blower frequency vacuum pump elimination Total 25 Lac INR 0 Annual cost saving Investment

15 Projects implemented in last 3 years Title of Project Year Annual Electrical Saving, Million kwh Annual Thermal Saving, Million kcal Total Annual Savings, Million Rs Investment Made (Rs million) Payback Replacement of Lamps in press shop to LED Capacitor panels to compressor and dust collector Replacement of 3 hydraulic press with one Press brake Replacement of Inefficient turret punch with advanced and efficient LVD turret VFD for RO HP pump Savings due to air leakage arresting Sensor based drain valves to Compressed air Led lighting for shop floor Thermic fluid heater briquette drying PT line auto cut off panel thermal paint coating of scl plates Installation of VFD for cyclone PTO..

16 Projects implemented in last 3 years Title of Project Year Annual Electrical Saving, Million kwh Annual Thermal Saving, Million kcal Total Annual Savings, Million Rs Investment Made (Rs million) vacuum pump elimination Replacement of thermic fluid motor Lighting generator Installation of VFD for HKL dust collector Installation of VFD for STP compressor Reduction of PT line blower frequency VFD for 500 cfm air compressor Motion sensors for ground floor lighting TFH door thermal insulation painting Ligting optimization Kitchen shop Online diesel monitoring Online motor monitoring Timer circuits for kitchen shop lighting % investment over turnover Total Saving - INR 55 lacs/annum Investment INR 80lacs

17 Action plan to achieve Targets S = Short term (17-18) M = Medium term (18-19) L = Long term(19-20) Plan Plan S M L Contribution to total energy Reduction 1 Minimising air leakages through continuous arresting 3% kwh 2 VFD s for air compressors 2% kwh 3 Led lighting optimization in new kitchen shop 2% kwh 4 Timer Circuits for new kitchen shop lighting 1% 8000 kwh 5 Replacement of fans with larger capacity HVLS fans on shop floor 1% kwh 6 VFD for HKL dust collector 2% kwh 7 VFD for STP compressor 1% kwh 8 Heat pipe heat recovery system 2% 55 ton briquettes/annum 9 Heat pump for paint curing process 1% lit diesel /yr 10 Reduction in fixed energy consumption 4% 2,70,000 kwh 11 Purchase of energy efficient machines 1% kwh 12 Capability training of employees 1% Through kaizens 13 Automation of thermic fluid fuel intake 1% 26 ton briquettes 14 OEE and productivity improvement 1% kbtu

18 We have taken initiative to eliminate Diesel utilization by lit Annual diesel saving Powder coating- hot water generator eliminated Electric Forklifts lit Annual diesel saving Total no of forklifts-6 Replaced-2 Paint Curing- Heat pump instead of hot water generator Heat pump lit Annual diesel saving Diesel Elimination By 2022 PNG burners Future PNG fired burners-new Khalapur facility

19 Heat pump- For paint curing Raw water Hot water generator(diesel) lit Annual diesel saving 28 kw heat pump Old process New process 4.25 lac Annual cost saving 21.7 Kg/day CO2 reduction Hot water to heat exchanger

20 Basic Learning.. Fluke- Power analyzer Fluke -Thermal imaging camera Testo-Moisture meter Testo- Lux meter The more you measure, the more you save Online energy monitoring

21 Instrument :- Thermal Imaging Camera Instrument Cost INR 2,00,000 Make Fluke Saving Potential - 5 Lac

22 Heat Pipe- Heat recovery system Thermic fluid heater Chimney Hot gases at 120 C Unique heat pipe recovery T achieved= 40 C Pre heated air at 80 C Improved combustion efficiency To chimney Old process New process 55 Ton Annual briquette saving 5 lac Annual cost saving Heat Pipe

23 Instrument :- Compressed air flow meter Instrument Cost 50,000/- INR to 2,00,000 INR Make VP, Vortex,SMC Saving Potential - 25 Lac

24 New plant-500 CFM compressor VFD Flow meter Installed for Air measurement Cloud based Air monitoring system Establishment of pressure flow diagram KWh Annual saving Machine wise Flow measurements VFD installed for compressors Air leakage tags implemented lac Annual cost saving Replacement of guns with Ventury effect air guns KWh/CFM Best in class efficiency Installation of auto drain valves

25 Instrument :- Power Analyzer and Logger Instrument Cost 50,000/- INR to 10,00,000 INR Make Fluke, Krykard Saving Potential - 50 lac INR

26 Installation of VFDs Power logging Title- VFD for HKL Dust collector Initiative- - Installed VFD to HKL dust collector motor(22kw) - Reduced RPM of Motor to 45Hz Title- VFD for STP roots blower Initiative- - Installed VFD to STP roots blower (7.5kW) - Reduced RPM of Motor to 45Hz 45600KWh Annual saving 3.4 lac Annual cost saving 23000KWh Annual saving 1.72 lac Annual cost saving

27 Thermal Insulation painting Optimization of PT line blowers frequency Before Temperature = 212 C After Temperature = 48 C Title- Thermal insulation painting of TFH doors Initiative- - Thermal imaging of heat losses - Application of thermal insulation painting Title- Optimization of PT line blowers frequency Initiative- - Energy logging of 4 PCO blowers (25 HP) and 2 WDO blowers(40hp) - VFD frequency tuning with the help of quality department ( 40Hz) 12MKcal Annual thermal energy saving 3Ton Briquette saving kwh Annual energy saving 2.75 lac Annual cost saving

28 Installation of bladeless Before- Almonard fans Root cause High energy consumption of fans 750 Watt/fan After-Bladeless fans Unsafe condition while fan cleaning & turning Saving & benefits- 1.No of fans replaced-5 2.Saving kwh 3. Safe and easy operation

29 Innovation-01 Cycle time reduction for lamination with the help of benchmarking Initiative :- 1. Initiative to increase productivity by Resin formulation change. 2. Initiative to reduce number of chemicals used in Resin preparation. Description- Formaldehyde to Melamine ratio modified Before Ratio- 1:6.5 After Ratio- 1:6 Benefits- -Reduction in Formaldehyde consumption by 3% -Reduction in cycle time by 5 sec 18 % Productivity improvement 15 % cycle time reduction Resin Kettle Impregnation line KWh Annual saving 27 Ton Annual briquette saving 5 Lac Annual cost saving Short cycle lamination m/c

30 Innovation 02-Inhouse development of Routing tool Before- Turn blade routers Feed rate- 8m/min Root cause Increased energy consumption After- Diamond routers Feed rate m/min High cycle time 2 pass operation KWh Annual saving 50% Productivity improvement Improper designtool wear 57 % Cycle time reduction 33% Scrap Reduction Tool geometry changed to 7

31 Innovation 03- Cloud based diesel monitoring system RS485 compatible diesel flow meters 450 liters Diesel saving INR 30,000 Annual saving Accurate Monitoring Before-Manual data entry Cloud based monitoring Air-Fuel ratio adjusted

32 Roadmap for renewal energy in plant 35.5% RE share in total MJ energy Short Term Target ( ) -Power purchase agreement -100 kw solar Mid term Targets 50% RE ( ) Wind power Long term Targets 60% RE (2020) Solar concentrators to be used in plant Heating application

33 Solar power plant 365KW 365 KW Installed capacity 720 Kg/day CO2 reduction 100 KW Additional capacity this year

34 Briquette Fired Thermic Fluid Heater In-house briquette fired thermic fluid heater used for lamination process Fuel Used - Briquettes made from peanut shells and agro waste Energy generated by this heater accounts to about 42 % of total thermal load of the plant briquettes Utilisation of waste material as fuel

35 Energy awareness activity programs Kaizens, suggestion boxes Trainings given to employees Competitions organized Poster, slogans, quiz etc Celebration of days Encon week, Earth Day, Energy Hour etc Energy Score cards and stickers Mailers and Handouts to employees for EnCon Poster and Slogan Competition themed Save Energy Save Future Energy Conservation stickers

36 Monitoring Mechanisms Energy monitoring Project monitoring Reporting formats ISO methodologies

37 Energy Monitoring system-smartsense New Addition- Features of EMS Cloud based system with storage space up to 3 years of data Data provided by EMS- kwh Department wise consumption Machine wise consumption Daily reports to all Members. Diesel monitoring Motor Insights

38 Monitoring and measurement:- Gantt Chart for monitoring of Projects planned and implementation

39 DIVISIONAL ABP -Target Planning & Review Area UOM Base Year Reduction Target (16-17) Achievement Budget Spend Savings Progress Specific Value % Specific Value Energy kwh/mva Water KL/MVA % (In Lacs) (In Lakh) In Lakh Q 1 Q 2 Q 3 Q 4 Waste(Haz.) * MT/MVA Renewable Energy GHG Waste ( Non-Haz.) * Absolute value in kwh Absolute Value in MtCO2-e * MT / SVOP % Recycled Positive On Track Behind Schedule

40 STRENGTHENING ENERGY MANAGEMENT SYSTEM ISO TOOLS Energy Management Cell Energy Use Register and significant energy use Plant-I Green-co Platinum rated Plant-II IGBC Platinum Rated Performance Indicators at Plant and Dept level Setting Baseline and target Register of Opportunities and Energy Management Programs Internal ISO audits and External Energy Audits Energy Review

41 Environmental project & Projects related to reduction in Carbon emissions

42 Carbon Neutral Plan Inventorization of Emission in absolute MT of CO2e MT.Co2 Scope 1 Scope 2 Scope 3 GHG Offset in FY % MTCO2/SQ MT Consumpti on Equivalent in Fossil fuel Emission saved in MTCO2e 2.34 Briquettes used in Thermic Fluid Heater(kg) Solar Roof Top Electricity (kwh) 5,70, KL of HSD Total MTCO2e saved Utilisation of waste material as fuel Scope 1+2 MTCO2e % reduction

43 Environmental Projects Palashi village waste water project Construction activity of tank Treatment Structure Final Inspection Treatment Structure for Processing Water 5Lac liter/day Recycling potential

44 Use of Waste as Fuel- sawdust to briquettes conversion We are converting sawdust waste generated in the plant of about 90T per month, into briquettes with help of supplier. This has helped reduced the waste that is going outside the plant. Total sawdust generated per annum 1080 tons/annum

45 SCRAP UTILIZATION PROJECT Saving of 1,24,704 Sq.Ft of particle boards Segment of 8 Multifunction Furniture Products introduced in Chocolate Shade - 5 % board area utilized (FY ) Use of large Size offcuts as Partition panels size in bed introduced in 18mm thickness in (FY ) 10,600 units manufactured in FY 17-18

46 Tree Plantation drive

47 Encon by Vendors

48 Approach for Energy conservation at vendors Highlights Sharing of feedback and knowledge Cluster Formation for Facilitation 7 major suppliers are undergoing Greenco Rating Incentives and rewards Training programs for Vendors 13GreenCo certified vendors 2 major Suppliers Green-co Platinum Rated 27% SEC Reduction through 57 energy projects Audits and Reviews Hand Holding 100% supply chain involvement

49 Green Initiatives by our vendor - Khutale Engg Before After Before After LPG Rs.1.80/SF t. 15 Min BT. Wt114 Kgs. LPG Rs.1.50/S Ft. 10 Min BT Wt.40 Kgs Use of CFL Use of LED High LPG consumption due to MS trolleys Low LPG consumption due to Aluminium trolleys 30 Frames loaded for baking 40 Frames loaded for baking No provision for Waste powder Tray for waste powder collection Improper utilization of space in baking oven Optimum space utilization after trolley modification

50 Green Initiative by our Vendor - P M Electro-auto Pvt Ltd Optimized compressed air thru centralized unit Polycarbonate Transparent Sheets & Turbo Ventilators Organizing PUC camp for employees vehicles 15 Tanks Pretreatment Process Optimized Gas Fired Burner For Hot Water Generator To Run Pretreatment Line. Green Initiative : - More than 300 Nos. plantation done in 3 Acres land.

51 Carbon Sequestration Initiative in Supply Chain Tree Plantation Initiative by GreenCo Cluster 1 Members 3622 Trees planted 60+ Farmers Involved 200+ Students Involved 825 MTCO2 saving

52 Certifications and recognitions Name of the Award Year of Receipt Given by Management system as per ISO 14001: TUV NORD Management system as per ISO 9001: TUV NORD Management system as per BS OHSAS 18001: TUV NORD GreenCo Best Practices Award for Design For Environment 2015 CII GBC Green Company Rating System- Gold Rating 2015 CII GBC Green Company Rating System- Platinum Rating 2016 CII GBC B.G. Deshmukh Award for Excellence in CSR 2015 Maratha chamber of commerce and agriculture Home Retailer of the Year Award 2016 Indian retail congress 2016 by Franchise India Marketer of the year Award 2015 DMAi (DirectMarketingAssociation, India) Special Award for energy saving 2016 PDPC pune Winners in excellence in Associate group 2016 PDPC pune Winner in Associate General Engineering 2016 PDPC pune Runner- up in Management General Engineering 2016 PDPC pune Excellent energy efficient Unit CII Energy Summit CII GBC Most Useful Presentation CII energy Summit CII GBC First Prize 11 th State Level award for energy Conservation 2017 MEDA Pune Management System as per ISO 50001: TUV nord Green Factory Rating Platinum Rating 2017 CII First Runner Up CII Energy Circle 2017&2018 CII GBC

53 From us..

54 To our suppliers SME GREENCO CLUSTER 1 SME GREENCO CLUSTER 2

55 Its all about Teamwork Thank you