HERITAGE FOODS LIMITED

Transcription

1 First Prize Dairy HERITAGE FOODS LIMITED Hyderabad (Telangana) Unit Profile Heritage Foods Limited founded in the Year 1992,is one of the fastest growing enterprises in Dairy Industry in South India. Uppal Dairy Plant Commissioned in the Year 2006 with a rated capacity of 0.6 LLPD and was subsequently expanded to 0.74 LLPD in 2007, 1.1 LLPD in 2010, 2.0 LLPD (1.5 Milk and 0.5 products) in Heritage Milk and Milk Products have market Presence in Andhra Pradesh, Telangana, Karnataka, Tamilnadu, Kerala, Maharashtra, Odisha, Haryana and Delhi with 14 Packing Stations, 142 Bulk Coolers, Chilling Centers, Ice Plants giving utmost care to preserve the Freshness of the Milk By adopting higher level of operational and QA standards. In the Year 2015 the plant was certified for Energy Management System ISO 50001:2011 towards its commitment to improve Energy Efficiency in all levels. 106

2 Energy Consumption Energy is the biggest component of the operational costs in the Dairy Industry. Hence the unit had taken this as a challenge to reduce our Energy Costs by involving all the staff to dedicate themselves to avoid any wastage and to save energy at every point. The Energy Conservation Drive started by us in 2012 is in continuous progress. Description Unit % Reduction Specific Electrical energy kwh / Ton Specific Thermal Energy Million Kcal / Ton Solar Power Generation: In , % of Electrical Energy consumed at Uppal Plant, was procured from 2.34 MW Solar Power Plant, connected under the Open access system, situated at Mulugu (Village), 70 KM from Hyderabad. 107

3 Total Electrical Power utilized at Uppal : 56, 99, 429 Units Solar Units adjusted by TS Electrical Board : 32, 79,823 Units % share of Solar Power is : % Major Energy Conservation Measures Implemented in the year Complete Renovation of Plant lighting with LED tubes & fittings All the Conventional Light fittings were completely replaced with energy efficient LED fittings (Tubes, Fittings, down lights, Panel type fittings) to conserve the electrical energy as well as to improve the illumination levels in the plant. It leads to saving of electrical energy 316 kwh per day. Electrical Units savings/year : 1.16 Lakh kwh Total cost savings : Rs.8.27 Lakhs 2 Replacement of air handling units of cold rooms & interlocking arranged for auto cut off w.r.t to temperature Air Handling Units of Curd Cold rooms were running continuously, irrespective of required Cold room temperature of 5 0 C. As a part of energy conservation, we have replaced Units equipped with energy efficient blowers. Interlocking arrangement was done for Air handling Units, to cut off ammonia feeding followed by blowers against the preset temperature. With this measure reduction of running hrs of blowers achieved which in turn we have saved electrical energy per day is KWh Electrical Units savings/year : 1.55 Lakh kwh Total cost savings : Rs Lakhs 3. Installation of new fully automated CIP system in place of Old CIP system The old CIP system was replaced with fully automatic CIP system aligned with PLC & SCADA system. The new CIP system is equipped with energy efficient Pumps and reduction in operating hours due to auto operation which leads to saving in electrical energy. Thermal energy savings also 108

4 achieved through reduction in hot water utilization during the CIP process with close monitoring of flush outs by SCADA system and automation. Electrical Units savings/year : Lakh kwh Furnace oil savings/year : 47.2 KL Total cost savings : Rs Lakh 4. IBT Pumps replaced with energy efficient pumps 2Nos. of IBT chilled water pumps of 7.5 KW rated, were replaced with energy efficient Grundfoes Pumps of 4.0 KW, to conserve electrical energy without affecting the process parameters. ( Saving 132 kwh per day ) Electrical Units savings/year : 0.48 Lakh kwh Total cost savings : Rs.3.45 Lakhs 5. Downsizing of Bore well pump with energy efficient pump The existing 15KW Bore well submersible pump, which consumes more energy was replaced by energy efficient 11.2 KW pump with the same output. The Electrical Energy saved with this measure was 88 KWH per day. Electrical Units savings/year : 0.32 Lakh kwh Total cost savings : Rs.2.30 Lakhs 6. Install ation o f Hig h Speed p acking machines in place of old packing machines in curd section We have replaced the normal speed curd packing machines with high speed packing machines. (80 pouches per minute to 160 pouches per minute).by this measure, we had saved electrical energy and as well as man-hours. Electrical Units savings/year : 0.25 Lakh kwh Total cost savings : Rs Lakhs 109

5 Energy Policy Heritage Foods Limited are committed to excel in Energy Performance in Process and Manufacture of Milk and Milk products on a continual basis for sustainable growth through, Continual improvement through up gradation of Technology, Systems and Services for improving Energy Efficiency to optimize the Energy Cost. Monitor and Control the Energy Consumption effectively by innovative designing and cost effective methods including procurement of Energy efficient products and services Providing resources to achieve measurable objectives and targets whenever necessary Complying with all applicable legal and other requirements related Energy use, consumption and efficiency. Integrating the energy policy in to our business planning, decision making and reviewing as and when necessary. To establish Bench marking standards in Dairy Industry in Energy Management We commit to communicate this policy to all our employees, persons working for and on our behalf and make it available to the interested parties on request. Date: GENERAL MANAGER (O) Energy Conservation Commitment, Policy and Set up Heritage Foods Limited, Uppal visualized the importance of Energy Conservation and taken measures accordingly in forming the core team, implementation team and monitoring teams. Unit had conducted several brain-storming sessions section wise to create awareness and motivate employees to identify the opportunities and establish action plans to conserve the same. The unit had inoculated the truth every unit of energy saved is equivalent to production of 3 units of energy in each employee so that he is attentive everywhere. 110

6 Second Prize Dairy MOTHER DAIRY FRUIT & VEGETABLE PRIVATE LIMITED Patparganj (Delhi) Unit Profile Mother Dairy, Delhi a subsidiary unit of National Dairy Development Board was set up under the Operation Flood Project. The Dairy was commissioned on 4th December Overview Products Handled lacs Liters of Milk & Liters of Ice-cream Turnover Rs Crores Technology Fully Automated State of the Art Dairy Plant Mother Dairy is the foremost liquid milk brand in the country. It started its operations in 1974 under the Operation Flood Programme of the National Dairy Development Board. Today, Mother Dairy sells more than 30 lakh litres of milk everyday of which 9 lakh litres is sold through bulk vended machines installed at their Milk Shops across Delhi/NCR, Lucknow, Kanpur, Mumbai, Hyderabad, and Chennai. Mother Dairy today has over 1500 exclusive Milk Shops across Delhi/NCR. Apart from milk, Mother Dairy also has a range of other dairy products like Ice Creams, Dahi, Lassi, Mishti Dhoi, Yogurt, Ghee, Cheese & Butter. Mother Dairy also sells Edible Oils under the brand name Dhara and Frozen vegetables under the brand name Safal. All these products are sold through Mother Dairy Milk Shops and Safal stores in Delhi/NCR, & are also available at retail stores across India. 111

7 Innovation in product and packaging development has been in the DNA of the Company and has helped Mother Dairy to set new benchmarks for the industry. Towards this end a world class Innovation Centre with top of the shelf Research & Development facilities was set up at the Patparganj manufacturing unit of Mother Dairy in This facility is certified by national accreditation board for testing and calibration laboratory (NABL)-department of science and technology, Government of India. Mother Dairy was the first brand to introduce pro biotic drinks for the masses and it continues to nurture the culture of innovation in bringing flavorsome range of products for consumers to satisfy their taste buds. Mother Dairy has also been an early technology adopter by implementing SAP for all critical business processes and reporting in It was the first dairy company in India to do so and provided Mother Dairy a robust, scalable and standard technology framework to become a truly national entity. It has continued the technology innovation journey by adopting trends like social media, mobility and cloud to empower the business. Deployment of SAP HR/payroll, e-procurement, RAMCO for outsourced vendor process and quality management, and consolidation of all response management like consumer feedback, equipment maintenance, farmer feedback on cloud platforms have been landmark initiatives. Specific Energy Consumption: Specific Energy Consumption (SEC) Reduction during the period Year Product Specific Electrical % Reduction Specific Thermal % Reduction over Energy Consump. over Energy Consumption kwh/lac litres Million kcal/lac litres Milk Milk

8 Energy Conservation Measures: 1 Installation of 100 KWp Solar Power Generation Plant at Mother Dairy premises. Installation of 100 KWp grid connected Solar Power Generation plant at roof top of administrative block building in Dairy premises. Energy generation Cost Saving Investment = kwh/yr = Rs.10.45/- lacs/yr = Rs.65.00/-lacs 2 Installation of New Energy Efficient refrigeration Package Unit Installation of additional new energy efficient refrigeration package units fully automatic screw compressors, consisting of PHEs,De-superheaters, automatic capacity slides. By doing this, the connected load is also reduced apart from reduction of quantity of ammonia. Elect. Energy saving = kwh/yr Cost saving = Rs.60/- lacs/yr Investment = Rs.600/- lacs 3 Insulation of steam pipe lines and condensate pipe lines and replacement of ineffective insulation. The condensate recovery pipe lines, steam pipe lines and hot water lines are insulated and ineffective insulation was replaced with new energy efficient insulation. Total PNG saved/yr Cost saving Investment = SCM/yr = Rs.25/- lacs/yr = Rs.1.21/- lacs 113

9 4 Optimization of capacity of hydro flow pumps by installation of VFD Replacement of old Hydro flow pumps (conventional centrifugal pumps) with energy efficient vertical pumps and VFDs for optimized capacity utilization in the process plant. Electricity Saving Cost saving Investment = kwh/yr = Rs Lacs/yr = Rs1.53/- Lacs 5 Installation of Energy efficient LED Lights Installation of energy efficient LED lights in place of conventional Metal Halide type 400 Watts and HPSV/HPMV lamps.also replaced the T8 type conventional tube lights with LED tube lights. Energy saving Cost Saving Investment = 1,31,728 kwh/yr = Rs lacs/yr = Rs.10.05/-lacs 114