apol lo tyres ltd per am bra

8/3/2019 Apol Lo Tyres Ltd Per Am Bra

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Unit Profile

Apollo Tyres Ltd. is a 3200 crore Rupees annual turnover company with its manufacturing

plants at Perambra & Kalamassery in Kerala, Vadodara in Gujarat and Pune in Maharashtra.

Apollo Tyres is engaged in production of Bias and Radial tyres for all types of vehicles. ApolloTyres is a QS 9000 certified company.

Energy Management Policy

Apollo Tyres Ltd. is committed to the preservation of precious energy by minimising

the usage of power and fuel. Our specific energy consumption of power and fuel are the

best in India as well internationally. All members of Apollo family will always striveto achieve the best figures in industry with respect to specific power and specific fuel

consumption. We at Apollo Tyres believe in continuous improvement and innovative

methods to achieve this. Also there will be continual monitoring at the management

level of the energy consumption performance factors.

Energy Conservation Cell

All identified projects are implemented with the active involvement of the personnel in the

concerned area with the responsibility being taken by the concerned sectional engineer. Of late,

remuneration of personnel is also linked to achievements.

HEADENGINEERING

UTILITY MANAGER INSTRUMENTATION

MANAGER

MECHANICAL

MANAGER

ELECTRICAL

MANAGER

ENERGY MANAGER


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Through this kind of energy saving projects, ample opportunity is available to have earnings

based on savings achieved. Awards are also given for the selected projects through suggestion

schemes. As a matter of policy it is ensured that at least one CFT is formed in each section for

improvement activities in which energy conservation is a major item.

Reporting System

Daily Reportsa) The power consumed from grid with other parameters like maximum demand, power

factor, specific energy consumption etc.

b) Machine/feeder wise electrical energy consumption is circulated section wise for

monitoring and analysis by users.c) Daily report on steam consumption, fuel consumption, specific fuel consumption,

condensate recovery are prepared and circulated for analysis.

Monthly Reportsa) Status of energy conservation projects prepared by area in-charges.

b) All efficiency parameters, status of energy conservation projects, best practices followed

etc. are shared between different plants through corporate engineering department.

c) KRA review meetings in which internal bench markings and corresponding

performances are discussed.


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730726

695

639

610

550

600

650

700

750

2002 -

2003

2004 -

2005

2006

2007

(target)

Specific Power Consumption kWH/Ton

2002 - 2003

2003 - 2004

2004 - 2005

2005 -2006

2006 2007 (target)

0

0.5

1

1.5

2

2002 -

2003

2003 -

2004

2004 -

2005

2005 -

2006

2006

2007(target)

Fuel Consumption Mcal/Ton

Mcal/ton

0

1

2

3

4

5

6

2003

-

2004

2004

-

2005

2005

-

2006

% savings of Energy Cost


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Units 2003-2004 2004-2005 2005-2006

Actual production Tonne 70900 78543 89341

Specific energy

consumption

kWh/ tonne 726 695 640

Specific energy

consumption

MkCal/tonne** 1.98 1.84 1.71

Electricity consumed

by the product

Lakhs kWh 514.44 545.87 571.78

Thermal energy

consumed by the

product

MkCal 140632 144837 152490

Bias Tyre Manufacturing Process

Bead

Fillering/

Flipping

Bias

Cutting

Tyre

Building

Tyre

Curing

Ware-

Housing

Finishing

Fabric

Calendering

Tread & Sw

Extrusion

Raw

MaterialsCompound

Mixing

Fabric

Dipping

Bead Winding


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Major Energy Conservation Projects Implemented During

Year 2005-2006

1. Energy Efficient Temperature Control Units

Development of innovative energy efficient Temperature Control Units (TCU).

Tyre industry uses a large number of TCUs for maintaining constant temperature in its

machinery. In the original system tempered water at controlled temperature is circulated

through the machinery using a pump. This water is heated using steam and cooled using

cold water in heat exchanger, as and when required, by using a single point pneumatic

temperature control.

The new design implemented incorporates a compact energy efficient TCU which uses

electricity for heating and radiator for cooling. Since the unit is very small it can be placed

very close to the machine, saving pumping energy and reducing radiation losses. Heating

and cooling controls made through electronic controllers avoid valves and pneumatic

systems. This makes it accurate and energy efficient.

This project can be considered as a trend-setter since the payback period is low, the idea is

totally new and the efficiency is maximum.

Agency that executed the project (with complete address and e mail): Done In-house

Total investment, Rs. 50000 per unit Year of implementation: 2005

First year energy cost savings, Rs. 700000 per unit

First year other savings, Rs. NIL

On annual basis KWh

000

Coal

(Tons)

Gas

Nm3

Oil (kL) Other

Energy consumption before 63000 30

Energy consumption after 27000 0

Energy tariff,

Rs/kWh/Ton/Nm3/kL

3.6 19000


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Picture/sketch/drawing before Picture /sketch/drawing after modification


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2. Screw Chiller

Chilled water at 14 degree centigrade is used for the tyre making process .This is produced

by 4 no.s of 120 Ton Reciprocating compressor chillers .The power consumption of

reciprocating chillers is 0.85 kW per Ton of refrigeration. The total consumption of power

by chillers was about 9000 kWh/day which is 5.6 % of the plants total power requirement

.Hence it is identified as major source for energy conservation.

These chillers were replaced with 2 no.s of Helical rotary compressor type chillers of make

TRANE of 215.3 Ton each .The power requirement of each chiller is 106.3 kW .The efficiency

of this type of chiller is 0.494 kW/Ton of refrigeration. This has reduced the total power

consumption of chillers to 6000 kWh /day. In this type of chillers the refrigerant is metered

through the flow system using an electronic expansion valve, this maximises chiller

efficiency at part load.


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Total investment, Rs. 50 lakhs Year of implementation: 2005

First year energy cost savings, Rs. 31.5 lakhs

First year other savings, Rs.

On annual basis KWh000

Coal(Tons)

GasNm3

Oil (kL) Other

Energy consumption before 28 lakhs nil nil nil nil

Energy consumption after 19 lakhs nil nil nil nil

Energy tariff,Rs/kWh/Ton/Nm3/kL

3.5 nil nil nil nil


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3. Weishaupt Burners

Steam is used in the tyre industry for vulcanisation of rubber. The steam consumption of tyre

plants is of the order of 2.2 tons of steam at a pressure of 15 kg/sqcm for every ton of tyre

produced. This is produced by a battery of 5 boilers of which 3 will be running continuously

and 1 will be hot stand by and 1 on maintenance. Previously, the fuel was controlled by a

valve and the air/fuel ratio was preset on a mechanical cam arrangement. This had made

air/fuel ratio inconsistent with high excess air and low efficiency.

This was replaced with Energy efficient burners of make Weishaupt. The electronic control

used in this system controls air/fuel ratio precisely with a consistent performance. The

damper control of the old system was replaced with variable frequency drive, making

savings in electrical energy also.


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Total investment, Rs. 80 lakhs Year of implementation: 2005-06

First year energy cost savings, Rs. 120 lakhs


On annual basis KWh

000

Coal

(Tons)

Gas

Nm3

Oil (kL) Other

Energy consumption before 693 nil nil 16051 nil

Energy consumption after 485 nil nil 15351 nil

Energy tariff,

Rs/kWh/Ton/Nm3/kL

3.5 nil nil 19.00 nil


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4. Energy Efficient Blowers for AC Motor Cooling

In the plant there are 45 no.s of tyre building machines and each machine has one 3-speed

AC motor. As the number of operations per minute of these motors are very high it gets

heated up and external cooling is required for safe operation. In the previous system the

cooling was achieved through a 375 watts 3 phase centrifugal blower which ran

continuously.

This blower has been replaced with an energy efficient blower. The design of the blower

impeller and the axial flow of air makes its energy efficient and light weight. The sound

produced by this blower is very low reducing the sound level in the shop floor. It consumes

only 110 watts and provides sufficient cooling to the motor also. 12 machines were converted

with this blower in the year 2005-06.


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Total investment, Rs. 60000/- Year of implementation: 2005-06

First year energy cost savings, Rs. 94492 /-


On annual basis KWh

000

Coal

(Tons)

Gas

Nm3

Oil (kL) Other

Energy consumption before 37800 nil nil nil nil

Energy consumption after 11088 nil nil nil nil

Energy tariff,

Rs/kWh/Ton/Nm3/kL

3.5 nil nil nil nil


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5. Energy Efficient Blowers for DC Motor Cooling

DC motors are used in the Calendaring and Dipping machines. Since the motors are running at

different speeds it requires forced cooling.

In the old system the cooling was provided by 3 phase blowers of 1.5 kW capacity each which ran

continuously.

These blowers were replaced with energy efficient blowers in 7 motors. Because of its improved

design of impeller with low weight, a 370 watts blower provides the same amount of cooling. This

saves energy and produces less sound reducing the sound level in the shop floor.


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Total investment, Rs. 49000 /_ Year of implementation: 2005-06

First year energy cost savings, Rs. 232554 /-


On annual basis KWh

000

Coal

(Tons)

Gas

Nm3

Oil (kL) Other



Energy tariff,

Rs/kWh/Ton/Nm3/kL

3.5 nil nil nil nil



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6. Energy Efficient Motors for MillsIn the plant there are 25 Mixing mills which use motors of 250 HP. These motors are 30 years

old and rewound more than 10 times making it inefficient. The efficiency was about 87 % at

full load. We made it a policy to replace these motors in a phased manner with 2 motors

every year. The new motors are of eff2 efficiency class with latest energy efficient design.

The efficiency of the new motors is 95 % which is maintained in the range of 60 to 100 %

load. This saves energy and improves reliability.


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Total investment, Rs 10 lakhs /_ Year of implementation: 2005-06


Annual Savings in 2 motors, Rs. 1. 4 lakhs

On annual basis KWh

000

Coal

(Tons)

Gas

Nm3

Oil (kL) Other



Energy tariff,

Rs/kWh/Ton/Nm3/kL

3.5 nil nil nil nil



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7. Boiler Efficiency Improvement

14 TPH Boiler efficiency improvements by controlling the excess air through Oxygen

trimming & F.D fan power reduction with Variable frequency drive.


First year energy cost savings , Rs. 147000+


On annual basis KWh

000

Coal

(Tons)

Gas

Nm3

Oil (kL) Other



Energy tariff,

Rs/kWh/Ton/Nm3/kL

3.5 nil nil nil nil


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8. Blow Down Heat Recovery System

There is a battery of 5 Boilers, which feeds on steam for its processes.

In the old system the hot water and steam escaped out during every blow-down operation of

the boiler, which was wastage of energy. We have installed a Boiler blow-down heat

recovery system. The blow down lines of all the boilers are connected to this system. The

flash steam generated is utilised in the boiler deaerator for heating the boiler feed-water. The

temperature of the hot water is utilised for pre-heating of the boiler feed water by using a

heat exchanger.


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First year energy cost savings, Rs. 18 lakhs

Fuel savings 140 KL / Year

On annual basis KWh

000

Coal

(Tons)

Gas

Nm3

Oil (kL) Other



Energy tariff,

Rs/kWh/Ton/Nm3/kL

3.5 nil nil nil nil


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9. Solar Water Heater for Canteen

Apollo Tyres, Perambra has about 3000 employees. The canteen which meets the

requirement of these employees works 24 hours a day.10KL of hot water is used everyday

for cleaning of vessels and other applications. This was produced by an electric heater of

rating 32 kW which consumed a power of approximately 2.24 lakhs per year.

A solar heater has been installed which works along with the electric heater. The hot water

requirement is being shared by both electric and solar heaters reducing the power

consumption.


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On annual basis KWh

000

Coal

(Tons)

Gas

Nm3

Oil (kL) Other



Energy tariff,

Rs/kWh/Ton/Nm3/kL

3.5 nil nil nil nil


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Environment and Safety

1. State-of-art effluent treatment plant commissioned for treating canteen effluents in 2002

and 100% clear discharge from ETP being utilised for gardening and plantation. A 5000 sq.

mtrs. of green belt of lawns and gardens have been developed.

2. Discontinued the usage of asbestos roofing material by using pre-engineered galvalume

sheets since 2002.

3. Commissioned new treatment plant to treat the effluents of fabric processing in 2003.

4. Four new dust collectors commissioned in 2003 replacing old dust collectors of banbury

mixers.

5. Rain water harvesting initiated.

6. Replaced the Freon (ODS) type reciprocating chillers with screw chillers working on

environment friendly refrigerant with an investment of Rs. 60 lakhs in 2004.

7. In 2005 installed flue gas analyser, in-line oxygen analyser and "effimax" system for boilers

to improve burner efficiency and cleaner stack emissions.

8. The new T5 and T8 tube lights have lesser mercury compared to conventional T13 tubes.


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Safety

To add up the commitment to society, our company has drafted, documented and declared a

safety and health policy. The policy has decreed the role of management, workers and

supervisors in the line of accident prevention programme. A safety officer and a welfare

officer have been appointed to overlook the safety, health promotional activities.

Our plant is the most modern plant using the latest technology. The incident rate of accidents

are very much low. There was no major incident of physical injuries or dangerous occurrence

reported for the last few years. To achieve best safety results, training starts from induction of

the employees. The training does not stop there. It goes like ..On the job, refresher, re-

training. We believe that one of the major reasons for accidents is physical unfitness. Keeping

this in mind we recruit people through a stringent physical and biological examination. Also,

we believe that healthy body gives quality & quantity. Hence all employees undergo periodical

health check up to upkeep health standards.

A safety committee constituted with participation from employees representative and

management representatives give a boost to accident prevention program. Monthly

deliberations in the meeting keep the accident prevention program always afloat. Competitions

like essay, quiz and cartoon drawing keeps the minds of the employees open to safety.

Periodical emergency drill and fire drill demonstrations make employees alert


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We keep machinery in high order by verifying them through competent bodies. Lifting

equipment, Hoist, Pressure vessels, mobile trolleys are checked half yearly.

Work permit system is needed to undertake any kind of dangerous work in the plant. This

system keeps accidents at bay during maintenance. Anywhere in the industry, contract labours

are prone to accidents. Keeping this in mind we gives high alertness and equal attention while

getting jobs done by them. Company does not show any difference between regular and

contract employees


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Corporate Social Responsibility

1. As part of our social responsibility we have launched a campaign against AIDS named

as Mission PRATHYASA all over India.


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2. Traffic signal system in our near-by

town Chalakudy is installed and

maintained by Apollo Tyres Ltd.

3. Passenger waiting shelters were

constructed and are maintained by

Apollo for the welfare of traveling

public


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Employees Satisfaction

PEOPLE is the key factor for Apollo Tyres in its journey to excellence. As an organization,

our company has been sharing a philosophy of Caring People. The satisfaction level of our

employees is assessed/measured through Employee Satisfaction Survey. Formal and informal

feed backs taken from employees also helps to assess satisfaction levels. This creates the basis

for a positive business model.

A series of small and big steps taken during the last several years helped us to institutionalize

systems in the organization. They are:

Working Environment

We are committed to the maintenance of our surroundings and the 18,000-sq. ft. lawn built

around our factory is a testimony for that.

Our commitment to maintain environment

In the operations floor, space is provided in compliance with statutory requirements. The

working environment is maintained under the principle of 5S (Right things at the right place).

Now, we are embarking a journey to adopt TPM (Total Productive Maintenance) as a system,

which can promote good working environment. Appropriate health and safety measures are

provided for the creation of a healthy work environment.


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Recognition Schemes

We have the following recognition schemes covering employees and their children:

Attendance Champion

Every year, employees securing more than 95% attendance is recognized and rewarded in a

public function.

Suggestion Scheme

The good suggestions received are rewarded under this scheme.

Appreciation Letters

Outstanding performance is recognized by issuing appreciation letters.

Newsletter

Publishing of achievements in company newsletter.

Cash Award for Academic Performance

Employees children with outstanding academic record are encouraged as per this scheme.

Target Setting and Reward

The target to be achieved at each machine centre is clearly specified. This helps the employees

to have a focussed approach. The incentive scheme is defined in such a way that employee

earns more when the output with required quality is increased. Supervisory cadre is governed

by individual KRAs (Key Result Areas).

Job Security

This unit saw an exponential growth in its capacity by more than 130% in the last 5 years. This

has generated additional employment. We have communicated the philosophy that our jobs

will be secure if organization is able to maintain its health.

apol lo tyres ltd per am bra

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