6 th November 2015
Company Profile Joint venture Promoted by TATAs & TIDCO. Year of Establishment - 1987 Products - Quartz Analog Wrist Watches, Precious Jewellery, Precision Components & Fashion accessories. Brand Titan, Sonata,Fast Track & Xylus in Watches & Accessories and Tanishq in Jewelry Watch market share - 60 % Exports -More than 39 countries
Carbon Neutral Manufacturing Focus Areas Energy Management Fuel Management Renewable Energy Substitution Supply Chain Management Logistics Travel Phase -I
Energy Management
Policies Green Perspective in all our business Conservation of Resources Elimination of Waste Renewable energy substitution Quality and Environmental Policy Energy Policy TATA Group Climate Change Policy
Group Climate Change Policy
QEMS policy
Energy policy TITAN COMPANY LIMITED WATCHES & ACCESSORIES DIVISION Energy Efficiency ENERGY POLICY We, at TITAN Watch Manufacturing, Hosur are committed to continually improve our energy performance at in-house manufacturing activities so as to make it environmentally sustainable for the future generations. TITAN will demonstrate the above by: Evaluating, reviewing and optimizing the energy requirements at in-house manufacturing activities through energy efficient methods and minimizing energy wastages. Providing appropriate resources to enhance the energy performance of manufacturing activities including utility services. Incorporating the energy performance requirements, while designing the manufacturing processes and procurement of energy products & services. Complying with applicable Legal & Other requirements. Harnessing Renewable Energy Resources wherever feasible, to reduce Carbon / Green House Gas emissions. Communicating the policy and importance of energy management to all personnel in watch manufacturing, Hosur. Head ISCM, Watch Manufacturing Carbon neutral manufacturing
ENCON Our Approach Specific energy target 1:1 In-house expertise Visit to other industries Energy audits & External professional agencies Technology Scanning To Become energy efficient and Carbon Neutral Target 2017-18 1 unit /Watch Carbon neutral Mfg
Manufacturing process Final Assembly Case Manufacturing Services Movement Manufacturing
Energy consumption -Scenario 14.0 Energy - Million kwh 13.47 13.0 12.16 12.17 12.34 12.20 12.48 12.0 11.24 11.29 11.0 10.0 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 Year 44 9 37 Machines Lighting Air conditioning Compressed air Around 63% of total energy consumption was for service load 10
Energy Management
Energy Conservation Key Focus Areas Compressed Air system Air conditioning system Lighting system Fuel Conservation Energy efficiency in Production operations
ENCON Key Initiatives.. V Belt to Flat Belt conversion Intermediate controllers Screw air compressors SYSTEM Refrigerant dryer Transvector nozzle for clean air guns SCADA system for battery of compressors
ENCON Key Initiatives.. Screw air compressor SCADA system - SAM Air gun with transvector nozzle
ENCON Key Initiatives Recip chiller to Screw chiller water cooled AIR CONDITIONING SYSTEM Star delta Star convertors Flat belt conversion for AHU s Energy efficient pumps BMS for air conditioning Aircon savers for smaller A/c units VFD s or AHU s Free cooling system Thermal Energy storage system
ENCON Key Initiatives AIRCO saver Screw chiller Thermal Energy Storage system VFD for AHU
ENCON Key Initiatives Lighting transformer Silver shield reflectors Induction lighting for high bay application LED lighting for shop floors and street lights
Shop floor general lighting - LED Retrofitting Total No of fittings converted -3000 Nos Investment Rs 42 Lakh Energy saving - 2.60 LkWH Cost saving - Rs 26 Lakh Payback - 2 Years
Energy Consumption -Scenario 9 37 44 Machines 10 Lighting Air conditioning 6 Compressed air Machine power increased by 46 % 36 54 4 2014-15
Energy Trend Specific Energy Consumption Units in KWh Specific Energy Consumption 5.5 4.9 5.0 4.7 4.5 4.2 4.0 3.7 Better 3.5 3.3 3.1 2.9 3.0 2.6 2.1 2.2 2.4 2.5 1.9 2.0 2.1 2.0 2.1 2.0 1.5 1.0 2.5 2.3 Year Long term objective - Specific energy consumption of 1 kwh / Watch
Fuel Conservation
Fuel Conservation Key Focus Areas Optimizing DG set utilization DG Waste Heat recovery Fuel Additives Solar energy harvesting
Dedicated feeder system ( DFS) Key Challenges Grid Availability Power & Demand restrictions Higher DG set operation Un Utilized Wind Power
Dedicated feeder system ( DFS) Establishment of Dedicated 11 kv Power Feeder System 100.0 80.0 60.0 40.0 20.0 Grid availability 60.1 74.1 99.9 Project objective - Reduce HSD Consumption... Initiated during 2013-14 Investment : Rs 60 Lakh System commissioned during Feb 15 Assured grid availability of 99 % 0.0 13-14 14-15 15-16 (YTM -Aug )
Dedicated Power Feeder System Diesel Consumption In Lakh.Liters Key Deliverables Enable to Maximize the wind power substitution Drastically reduce the DG set operation and diesel consumption 20 18 Key outcome- diesel consumption 18.15 16 14 12 2015-16 April - Sep 2.15 Lakh Liters 11.05 10 8 6 4 39 % Reduction 2014-15 April - Sep 3.50 Lakh Liters 4.55 6.36 2 0 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Plan 15-16 14-15 13-14 12-13 2014-15 1.26 1.21 0.36 0.21 0.24 0.20 0.27 0.16 0.21 0.94 0.62 0.69 4.55 6.36 11.05 18.15 2015-16 0.73 0.81 0.20 0.06 0.10 0.25 2.15
Solar Cooking System No of dishes :15 Solar system capacity : 75 kg/ Hour Steam generation between 11.00 to 3.00 PM Supplementing our Canteen steam requirement about 4 Hrs Diesel savings 3000 Liters /Year Investment - Rs 43 Lakh
MVR Mechanical Vapor Recompressor MVR is the evolving technology to evaporate water at optimal cost. MVR evaporator uses the vapor that has been evaporated from the product, compresses the vapor mechanically using a radial type fan to a higher pressure. Processes is happening under vacuum (200 mm/hg )and hence evaporation ( @ 63 Deg C). faster Compared to MES (Mechanical evaporation system), MVR operates on lower temperature difference but with higher surface area. Higher Surface area of evaporation - in MVR ~ 200 Sq.mtr compared to 20 Sq.mtr in a MES. 28
ETP Process with MES 60 to 70 KLD @ 2000 PPM Four Stage RO system Reject 10 % @ 20000 PPM MES Mechanical evaporator 6 to7 KLD Salt Permeate - back to process @ 90 % recovery rate Effluent KL/day Op. Cost/KL, Rs Op. Cost/day, Rs Total Op. Cost/annum Existing MES 6.0 3500 21000 Rs 63.00 Lakh
ETP Process with MES & MVR 60 to 70 KLD @ 2000 PPM Four Stage RO system Reject 10 % @ 20000 PPM MES Mechanical evaporator Salt Permeate - back to process @ 90 % recovery rate Condensate @ 80 % recovery rate 6 to7 KLD MVR ( Mechanical Vapor Recopmressor ) 25 KLD MVR Reject 1.2 KLD Overall water recovery > 95%
Key highlights Designed for smaller capacity (first of in its kind) - 25 KLD Larger surface area for heat transfer No expensive pre treatment Benefits Comparison MVR @ Rs 1100/KL Effluent/day MES @ Rs 3500/KL Operating cost/day, Rs Operating cost/annum, Rs Cost savings, Rs MES 0 6.0 KL/day 21000 63.00 Lakh MVR + MES 6.0 KL/day 1.2 KL/day 10800 32.4 Lakh 30.60Lakh
Mechanical Vapor Recompressor Pellet reactor MVR vessel
Diesel Consumption / KL Effluent processed in KL Diesel consumption in Lakh Liters Key results Diesel consumption Vs Effluent processed 3000 2500 2000 2,239 2,690 1.36 2,460 2,460 2.00 1.50 1500 1.11 0.94 1.00 1000 500 0.55 911 0.29 0.50 0 2012-13 2013-14 2014-15 Target 2015-16 2015-16 (Ytm YEAR Sep) Effluent processed in KL Diesel Consumption in Lakh Litres 0.00 60 50 40 30 50 51 38 30 34 20 10 0 Year Specific fuel consumption /KL
Fuel additive Adding fuel additives in boilers fuel (HSD) improves fuel efficiency by 12 % Additive ratio 1:5000 Application Canteen boilers Fuel reduction/ Annum 12KL Investment Rs 3 Lakh Carbon emission reduction 33 Tons
DG waste Heat Recovery System Exhaust heat from 2X 750 kva DG sets used to generate steam. Steam generation - 500 Kg/Hr Used for ETP effluent evaporation Application Effluent processing Fuel reduction/ Annum 20 KL Cost benefit Rs 10 Lakh Carbon emission reduction 55 Tons WHR Boiler
Renewable Energy Substitution
Renewable Energy substitution Wind Energy Solar light pipes Solar cooking system Solar lighting
Renewable Energy substitution- Wind energy Captive Wind Power Plant Installed Capacity : 5.5 MW Energy generation Capacity (kwh) : 10.5 Million /Year We are supplementing our energy requirement through Wind Mills since 2007-08
Energy in Million Units Renewable Energy substitution- Wind energy 16 Total Energy Vs Wind energy 14 13.5 12.2 12.2 12.3 12.2 12.5 12 11.2 11.3 10 13.5 11.0 8 6 4 3.4 4.0 3.1 5.9 5.9 6.5 6.6 2 1.1 0 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 Plan -15-16 Total Energy Wind Energy Year Wind energy contribution 2007-08 9 2014-15 91 50 50 2015-16 19 Other power 81 Wind energy
Renewable Energy substitution- Rooftop solar system
Renewable Energy substitution- Rooftop solar system ON line monitoring Daily generation Carbon emission reduction Unit wise production Solar radiation
Solar Light Pipes Application Shop floor General lighting Area covered 50000 Sq ft No of light pipes installed 60 Energy saving/annum 35000 kwh Cost benefit Rs 3.15 lakh Investment Rs 24 Lakh Payback 8 Years
Green Road Way Wind power substitution -35% Water cooled screw chillers BMS Screw air compressors Flat belts for AHU s ENCON projects with Honeywell Wind power substitution 30 % Solvent recycling 2008-2009 2010-2011 2009-2010 EE lighting V belt to Flat belt Lighting transformer Refrigerant dryer 2004-2007 2011-2012 Wind power substitution -26% WHR, TES Free cooling 2000-2003 2012-2013 Wind power substitution-48 % TES Phase II LED lighting Induction lamps 2013-2015 Wind power contribution > 80% Dedicated Feeder Rooftop Solar MVR, LED lighting, VFD s Wind power substitution-48 % LED lighting Solar cooking RO up gradation
Carbon Emission Scenario Kgs / watch 1000 Tons /annum 2.5 2 56% reduction 15 13 11 1.5 1 9 7 5 0.5 0 CO2 Emission - Kgs/ watch CO2 Emission in 1000Tons 04-05 05-06 06-07 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 15-16 Plan 2.36 2.08 1.94 1.79 1.61 1.61 1.08 0.97 1.07 1.32 1.29 0.65 11.90 10.80 11.30 10.90 8.20 7.70 6.36 5.37 5.50 5.45 5.28 2.50 Year 3 1-1P l a n Want to become Carbon Neutral in our Manufacturing operations by 2017-18
Process Scrap Recycling Tons / Yr % Recycling 450 94 96 90 90 97 93 100 99 100 99 100 90 350 80 70 250 60 150 50 40 50 05-06 06-07 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 Generated - Tons /Yr 222 316 336 376 372 449 424 397 377 500 Recycled - Tons /Yr 210 301 303 336 362 418 422 394 377 496 % Recycled 94 96 90 90 97 93 100 99 100 99 Year 30 99% of the manufacturing process scrap ( Brass material) is recycled
STP Upgradition - Anaerobic Treatment System Installed Anaerobic treatment System prior to existing Sewage Treatment Plant Reduction in COD load to the plant by 64% ( from 1400 ppm to 500 ppm) Treated water output Quality is fairly stable ( BOD between 5 and 10 ppm) Input output Anaerobic System Treated water quality
Cost Savings ENCON Initiatives Savings - Rs Lacs 600 500 400 300 Saving- Combination of a. Energy saving 1 Million kwh /Year b. Optimal wind power sourcing strategy 200 100 0 06-04-05 05-06 07 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 Plan 44.63 70.50 55.00 33.50 36.00 24.85 75.99 163.00 220.00 255.00 300.00 Actual 46.10 82.03 44.72 30.57 38.04 21.83 70.53 181.00 311.35 488.30 367.41 Year Target 15-16 Rs 4.0 Cr
ENCON Team work - Energy Management System Energy Management system Daily /Monthly energy reviews
ENCON Team work - On line monitoring system SLD Daily reporting ON line trend History
ENCON Team work - Energy /Fuel Management System
Beyond the fence Vendor Energy Audit To educate our vendor community on Energy Conservation and its importance To share our best practices / expertise on ENCON To optimize their energy cost To support (technical & finance ) vendors for implementing ENCON solutions Awareness programs / Knowledge sharing/project execution No of vendors covered 23 Saving potential identified Rs 60 Lakh With out investment Rs 17 Lakh With investment Rs 43 Lakh
Way forward 1. ISO 50001 Certification 2. Micro level energy monitoring 3. Enhance wind power contribution to 100% 4. Green Co Certification 5. Cyanide Elimination 6. Watch Battery life Enhancement 30 to 70 months / Mercury free Watch batteries
Mr.Bhaskar Bhat Managing Director