CaseStudyBooklet

GreenCoGreenCo

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

DISCLAIMER

Copyright

Copyright© 2015 by the Confedera�on of Indian Industry

All rights reserved

Disclaimer

No part of this publica�on may be reproduced, stored in retrieval system, or transmi�ed in any form or by any means electronic, mechanical, photocopying, recording or otherwise, without the prior wri�en permission from CII – Sohrabji Godrej Green Business Centre.

While every care has been taken in compiling the GreenCo Case Study Booklet, CII – Sohrabji Godrej Green Business Centre and suppor�ng organiza�ons accept no claim for compensa�on with respect to any wrong, abbreviated, omi�ed or incorrectly inserted content in the book. The book is only an a�empt to create awareness and share best prac�ces from select GreenCo rated companies. The GreenCo case study booklet has been compiled based upon the inputs received from the industry.

Published ByCII – Sohrabji Godrej Green Business Centre Survey No 64, Kothaguda PostNear Hi-Tech CityHyderabad - 500 084IndiaTel: +91 40 44185111, 101Fax: +91 40 44185189

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

DISCLAIMER

Copyright

Copyright© 2015 by the Confedera�on of Indian Industry

All rights reserved

Disclaimer

No part of this publica�on may be reproduced, stored in retrieval system, or transmi�ed in any form or by any means electronic, mechanical, photocopying, recording or otherwise, without the prior wri�en permission from CII – Sohrabji Godrej Green Business Centre.

While every care has been taken in compiling the GreenCo Case Study Booklet, CII – Sohrabji Godrej Green Business Centre and suppor�ng organiza�ons accept no claim for compensa�on with respect to any wrong, abbreviated, omi�ed or incorrectly inserted content in the book. The book is only an a�empt to create awareness and share best prac�ces from select GreenCo rated companies. The GreenCo case study booklet has been compiled based upon the inputs received from the industry.

Published ByCII – Sohrabji Godrej Green Business Centre Survey No 64, Kothaguda PostNear Hi-Tech CityHyderabad - 500 084IndiaTel: +91 40 44185111, 101Fax: +91 40 44185189

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

The United Na�ons Industrial Development Organiza�on (UNIDO) is the specialized agency of

the United Na�ons that promotes Inclusive and Sustainable Industrial Development (ISID) to

enable its member states to benefit from industrializa�on that creates shared prosperity and

safeguards the environment. This, amongst others, requires exis�ng industries to con�nuously

improve their environmental performance and resource use intensity, whilst in addi�on

promo�ng new green industries to produce and deliver environmental goods and services – in

short Green Industry. UNIDO ini�ated in 2012 at the global level the Green Industry Pla�orm,

which is a global, high-level, mul�-stakeholder partnership and forum to catalyze, mobilize and

mainstream ac�on on Green Industry around the world (www.greenindustrypla�orm.org). It

provides a framework to bring governmental, business and civil society leaders together to

secure concrete commitments and ac�on in support of the Green Industry agenda.

In 2015 UNIDO celebrates 20 years of coopera�on and achievement with the United Na�ons

Environment Programme (UNEP) in fostering adapta�on and adop�on of Resource Efficient

and Cleaner Produc�on (RECP) in developing, emerging and transi�on economies. The RECP

programme is implemented in coopera�on with a network of knowledge ins�tu�ons and

service providers globally, known as RECPnet, of which CII – Godrej GBC is a proud founding

member. Godrej GBC is currently carrying out a project en�tled “Pilot applica�on of innova�ve

assessment and monitoring methods for resource efficient and cleaner produc�on in selected

manufacturing sectors in India”. The aim of the project is to develop, trial and promote RECP

approaches par�cularly in small and medium sized enterprises in developing and emerging

economies and the GreenCo Ra�ng System is selected as an innova�ve assessment and

monitoring method.

UNIDO is pleased to have a con�nuous associa�on with CII – Godrej GBC in various ini�a�ves in

the environmental front. We are glad to know that the GreenCo Ra�ng System has been

receiving an overwhelming response from the Indian industry. We congratulate CII – Godrej

GBC on this achievement and wish them success in all their endeavors. We are pleased to know

that the UNIDO – CII project has led to this compila�on. We look forward to many more

interes�ng and value adding publica�ons from CII.

UNITED NATIONS

INDUSTRIAL DEVELOPMENT ORGANIZATION

MESSAGE FROM UNIDO

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

The United Na�ons Industrial Development Organiza�on (UNIDO) is the specialized agency of

the United Na�ons that promotes Inclusive and Sustainable Industrial Development (ISID) to

enable its member states to benefit from industrializa�on that creates shared prosperity and

safeguards the environment. This, amongst others, requires exis�ng industries to con�nuously

improve their environmental performance and resource use intensity, whilst in addi�on

promo�ng new green industries to produce and deliver environmental goods and services – in

short Green Industry. UNIDO ini�ated in 2012 at the global level the Green Industry Pla�orm,

which is a global, high-level, mul�-stakeholder partnership and forum to catalyze, mobilize and

mainstream ac�on on Green Industry around the world (www.greenindustrypla�orm.org). It

provides a framework to bring governmental, business and civil society leaders together to

secure concrete commitments and ac�on in support of the Green Industry agenda.

In 2015 UNIDO celebrates 20 years of coopera�on and achievement with the United Na�ons

Environment Programme (UNEP) in fostering adapta�on and adop�on of Resource Efficient

and Cleaner Produc�on (RECP) in developing, emerging and transi�on economies. The RECP

programme is implemented in coopera�on with a network of knowledge ins�tu�ons and

service providers globally, known as RECPnet, of which CII – Godrej GBC is a proud founding

member. Godrej GBC is currently carrying out a project en�tled “Pilot applica�on of innova�ve

assessment and monitoring methods for resource efficient and cleaner produc�on in selected

manufacturing sectors in India”. The aim of the project is to develop, trial and promote RECP

approaches par�cularly in small and medium sized enterprises in developing and emerging

economies and the GreenCo Ra�ng System is selected as an innova�ve assessment and

monitoring method.

UNIDO is pleased to have a con�nuous associa�on with CII – Godrej GBC in various ini�a�ves in

the environmental front. We are glad to know that the GreenCo Ra�ng System has been

receiving an overwhelming response from the Indian industry. We congratulate CII – Godrej

GBC on this achievement and wish them success in all their endeavors. We are pleased to know

that the UNIDO – CII project has led to this compila�on. We look forward to many more

interes�ng and value adding publica�ons from CII.

UNITED NATIONS

INDUSTRIAL DEVELOPMENT ORGANIZATION

MESSAGE FROM UNIDO

FOREWORD

Green prac�ces are no longer an extra discipline but an integral part of the business acumen; pursuing growth and preserving ecology is the mantra adopted by the Indian industry. Opportuni�es to increase compe��veness by going green and improving resource efficiency are wide-spread and far-reaching. Companies that are prepared to absorb and exploit these opportuni�es have the chance to gain compe��ve advantage.

The Indian society has the inherent a�tude of respec�ng what we have and ra�on their usage. Resource conserva�on, reuse and recycling seem to be a part of our DNA, which is indeed a healthy sign both for the economy and the ecology. The art of managing constraints and the emerging innova�ve thinking have offered solu�ons making our living and businesses more sustainable. This is what green is all about and this is what the GreenCo Ra�ng System advocates.

GreenCo evaluates the performance of companies on the ecological front in a holis�c manner and guides these enterprises to make their products, services, opera�ons and supply chain greener. We are extremely heartened by the response that GreenCo has been receiving in all these years. We are glad to announce that, as of June 2015, 47 companies are GreenCo rated and more than 110 companies are at different levels of execu�on of the ra�ng system.

The GreenCo rated companies have not only reduced their environmental impact but have also improved their compe��veness. It is encouraging to see the environmental benefits and monetary benefits reported by the companies. This compila�on showcases some of the best prac�ces from select GreenCo rated companies and respec�ve savings achieved by each of them. I congratulate the companies listed as a part of this compila�on that have taken progressive steps to reduce their ecological footprint.

I am confident that this compila�on will inspire Indian industries to be a part of the GreenCo movement to make a change and to contribute to crea�ng a greener world.

PRADEEP BHARGAVACHAIRMANGREENCO RATING SYSTEM

FOREWORD

Green prac�ces are no longer an extra discipline but an integral part of the business acumen; pursuing growth and preserving ecology is the mantra adopted by the Indian industry. Opportuni�es to increase compe��veness by going green and improving resource efficiency are wide-spread and far-reaching. Companies that are prepared to absorb and exploit these opportuni�es have the chance to gain compe��ve advantage.

The Indian society has the inherent a�tude of respec�ng what we have and ra�on their usage. Resource conserva�on, reuse and recycling seem to be a part of our DNA, which is indeed a healthy sign both for the economy and the ecology. The art of managing constraints and the emerging innova�ve thinking have offered solu�ons making our living and businesses more sustainable. This is what green is all about and this is what the GreenCo Ra�ng System advocates.

GreenCo evaluates the performance of companies on the ecological front in a holis�c manner and guides these enterprises to make their products, services, opera�ons and supply chain greener. We are extremely heartened by the response that GreenCo has been receiving in all these years. We are glad to announce that, as of June 2015, 47 companies are GreenCo rated and more than 110 companies are at different levels of execu�on of the ra�ng system.

The GreenCo rated companies have not only reduced their environmental impact but have also improved their compe��veness. It is encouraging to see the environmental benefits and monetary benefits reported by the companies. This compila�on showcases some of the best prac�ces from select GreenCo rated companies and respec�ve savings achieved by each of them. I congratulate the companies listed as a part of this compila�on that have taken progressive steps to reduce their ecological footprint.

I am confident that this compila�on will inspire Indian industries to be a part of the GreenCo movement to make a change and to contribute to crea�ng a greener world.

PRADEEP BHARGAVACHAIRMANGREENCO RATING SYSTEM

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

CONTENTS

Execu�ve summary 1

How to use this book 3

Case Studies 4

Case Study I – Kempegowda Interna�onal Airport Limited, Bengaluru 6

Case Study II – Brakes India Private Limited, Foundry Division, Sholinghur 10

Case Study III – HIL Limited, Golan, Surat 14

Case Study IV – Larsen and Toubro Limited, Powai (West), Mumbai 18

Case Study V – Sundram Fasteners Limited, Krishnapuram 22

Case Study VI – Godrej and Boyce Mfg. Co. Ltd., Godrej Lawkim Motors, Shirwal 26

Case Study VII – Godrej and Boyce Mfg. Co. Ltd., Appliance Division, Shirwal 30

Case Study VIII – Kirloskar Brothers Limited, Coimbatore 34

Case Study IX – ACC Ltd., Kymore Cement Works 38

Case Study X – Tata Motors Ltd., PVBU, Pimpri 42

Case Study XI – Kirloskar Brothers Limited, Sanand 46

Case Study XII – Godrej and Boyce Mfg. Co. Ltd., Interio Division, Vikhroli 50

Case Study XIII – HPCL, Silvassa Lube Oil, Blending Plant 54

Case Study XIV – Godrej and Boyce Mfg. Co. Ltd., Appliance Division, Mohali 58

Case Study XV – Godrej and Boyce Mfg. Co. Ltd., Locking Solu�ons & Systems, Vikhroli 62

Case Study XVI – Tamil Nadu Newsprint and Papers Limited, Kagithapuram 66

Case Study XVII – ITC Limited, PSPD, Unit – Kovai 70

11Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

ACKNOWLEDGEMENT

CII - Sohrabji Godrej Green Business Centre and the United Na�ons Industrial Development Organiza�on

(UNIDO) have been working together on various projects in the environmental front. CII – Godrej GBC

would like to thank UNIDO for the con�nuous associa�on. The thought of bringing together best

prac�ces, to facilitate knowledge sharing and to showcase benefits, put forward by UNIDO, and the

constant support offered, has led to this compila�on.

CII – Godrej GBC also expresses its hear�elt apprecia�on to all the GreenCo Rated Companies for their

recep�veness towards all new ini�a�ves taken by CII. The GreenCo Rated Companies have been our

pillars of support; their interest and commitment towards working for a sustainable environment has

been the reason for us to stay mo�vated. This has led the GreenCo Ra�ng System mark milestones every

progressing year. We sincerely thank all the companies listed as a part of this compila�on, for le�ng us

share their informa�on. We are sure that this compila�on will inspire other industries to be a part of the

green movement and contribute to the country's sustainable growth.

jj

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

CONTENTS

Execu�ve summary 1

How to use this book 3

Case Studies 4

Case Study I – Kempegowda Interna�onal Airport Limited, Bengaluru 6

Case Study II – Brakes India Private Limited, Foundry Division, Sholinghur 10

Case Study III – HIL Limited, Golan, Surat 14

Case Study IV – Larsen and Toubro Limited, Powai (West), Mumbai 18

Case Study V – Sundram Fasteners Limited, Krishnapuram 22

Case Study VI – Godrej and Boyce Mfg. Co. Ltd., Godrej Lawkim Motors, Shirwal 26

Case Study VII – Godrej and Boyce Mfg. Co. Ltd., Appliance Division, Shirwal 30

Case Study VIII – Kirloskar Brothers Limited, Coimbatore 34

Case Study IX – ACC Ltd., Kymore Cement Works 38

Case Study X – Tata Motors Ltd., PVBU, Pimpri 42

Case Study XI – Kirloskar Brothers Limited, Sanand 46

Case Study XII – Godrej and Boyce Mfg. Co. Ltd., Interio Division, Vikhroli 50

Case Study XIII – HPCL, Silvassa Lube Oil, Blending Plant 54

Case Study XIV – Godrej and Boyce Mfg. Co. Ltd., Appliance Division, Mohali 58

Case Study XV – Godrej and Boyce Mfg. Co. Ltd., Locking Solu�ons & Systems, Vikhroli 62

Case Study XVI – Tamil Nadu Newsprint and Papers Limited, Kagithapuram 66

Case Study XVII – ITC Limited, PSPD, Unit – Kovai 70

11Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

ACKNOWLEDGEMENT

CII - Sohrabji Godrej Green Business Centre and the United Na�ons Industrial Development Organiza�on

(UNIDO) have been working together on various projects in the environmental front. CII – Godrej GBC

would like to thank UNIDO for the con�nuous associa�on. The thought of bringing together best

prac�ces, to facilitate knowledge sharing and to showcase benefits, put forward by UNIDO, and the

constant support offered, has led to this compila�on.

CII – Godrej GBC also expresses its hear�elt apprecia�on to all the GreenCo Rated Companies for their

recep�veness towards all new ini�a�ves taken by CII. The GreenCo Rated Companies have been our

pillars of support; their interest and commitment towards working for a sustainable environment has

been the reason for us to stay mo�vated. This has led the GreenCo Ra�ng System mark milestones every

progressing year. We sincerely thank all the companies listed as a part of this compila�on, for le�ng us

share their informa�on. We are sure that this compila�on will inspire other industries to be a part of the

green movement and contribute to the country's sustainable growth.

jj

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

EXECUTIVE SUMMARY

Programme (UNEP) a global programme on Resource Efficient and Cleaner Produc�on (RECP).RECP con�nuously applies preven�ve environmental strategies to processes, products and services. This

increases efficiency and reduces risks to humans and the environment. RECP also recognizes similar types

of preven�ve measures that are needed to advance produc�on efficiency, environmental management

and human development.

Development of the Case Study BookletUNIDO, under its global RECP Programme, along with CII – Godrej GBC is carrying out a project en�tled

“Pilot applica�on of innova�ve assessment and monitoring methods for resource efficient and cleaner

produc�on in selected manufacturing sectors in India”. The aim of the programme is to develop, trial and

promote RECP approaches par�cularly in small and medium sized enterprises in developing and

emerging economies. The GreenCo Ra�ng System is selected as an innova�ve assessment and

monitoring method, and as a part of the project, has intended to bring out case studies of GreenCo Rated

Companies. This compila�on is supported by UNIDO.

The compila�on has been brought forward as a result of the following ac�vi�es – Ü Two-day GreenCo Site Visit Assessments at individual companies as part of the GreenCo Ra�ng

SystemÜ Circula�on of an annual sustenance ques�onnaire to companies who have been GreenCo rated

for more than a year Ü Visit to select GreenCo rated companies to understand the ac�vi�es ini�ated a�er one year of

achieving the GreenCo ra�ng

Every case study in this booklet broadly covers a brief profile of the company, the company's GreenCo

journey, ini�a�ves taken by the companies across various GreenCo parameters and the tangible and

intangible benefits achieved. This compila�on is intended for industries to learn from each other and

replicate wherever possible.

The GreenCo Case Study Booklet was released during the 4th edi�on of the GreenCo Summit 2015 on

25 June 2015 at Mumbai.

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

EXECUTIVE SUMMARY

Pursuing green has become the new driver for companies on the quest towards growth, compe��veness

and global excellence. With number of businesses going green on the rise and several ini�a�ves on

different areas evokes a spark in an individual's mind on 'How Green is a Company'. CII, through an

extensive stakeholder consulta�on and interac�on with experts, has developed the “GreenCo Ra�ng

System” to evaluate how green is a company. This first of its kind in the world ra�ng system, is a holis�c

mechanism to assess and analyze the company's performance on the green front. It is a framework to

measure and monitor the environmental impact of a company's ac�vi�es or opera�ons. The GreenCo

Ra�ng System apart from assessing the companies also defines a path for con�nuous ecological

improvement and guided phase growth.

The GreenCo Ra�ng System has been receiving an excellent response from the Indian industry. As of June

2015, 47 companies are GreenCo Rated and more than 110 companies are at various levels of execu�on

of the ra�ng system. GreenCo's depth and spread of environmental parameters, its mul� sector

applicability and its neither-too-tough-nor-too-easy design are a few characteris�cs that have facilitated

GreenCo to reach out to various companies across various sectors, sizes and regions. One of GreenCo's

dis�nguishing characteris�cs is that the GreenCo Ra�ng System is not just a ra�ng system but a

comprehensive mechanism that helps companies to evolve as those exhibi�ng superior environmental

responsibility and performance.

GreenCo's success vests in encouraging companies whom have been performing good in their

environmental front to perform exceedingly well and companies who haven't ventured into the green

aspects to put in significant efforts to explore op�ons and go higher up the ladder of environmental

performance. Rela�vely newer concepts such as working beyond the fence to conserve water, third party

purchase of renewable energy, raw material conserva�on through reduc�on and subs�tu�on, extending

environmental conserva�on ac�vi�es into the supply chain, responsible manufacture of products, life

cycle assessment as a tool to reduce environmental impact of its product, process and service and many

more are taken up by companies. The GreenCo rated companies have not only reduced their

environmental impact but have also improved their compe��veness.

The United Na�ons Industrial Development Organiza�on (UNIDO) is the specialized agency of the United

Na�ons that promotes industrial development for poverty reduc�on, inclusive globaliza�on and

environmental sustainability. UNIDO implements in coopera�on with the United Na�ons Environment

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

EXECUTIVE SUMMARY

Programme (UNEP) a global programme on Resource Efficient and Cleaner Produc�on (RECP).RECP con�nuously applies preven�ve environmental strategies to processes, products and services. This

increases efficiency and reduces risks to humans and the environment. RECP also recognizes similar types

of preven�ve measures that are needed to advance produc�on efficiency, environmental management

and human development.

Development of the Case Study BookletUNIDO, under its global RECP Programme, along with CII – Godrej GBC is carrying out a project en�tled

“Pilot applica�on of innova�ve assessment and monitoring methods for resource efficient and cleaner

produc�on in selected manufacturing sectors in India”. The aim of the programme is to develop, trial and

promote RECP approaches par�cularly in small and medium sized enterprises in developing and

emerging economies. The GreenCo Ra�ng System is selected as an innova�ve assessment and

monitoring method, and as a part of the project, has intended to bring out case studies of GreenCo Rated

Companies. This compila�on is supported by UNIDO.

The compila�on has been brought forward as a result of the following ac�vi�es – Ü Two-day GreenCo Site Visit Assessments at individual companies as part of the GreenCo Ra�ng

SystemÜ Circula�on of an annual sustenance ques�onnaire to companies who have been GreenCo rated

for more than a year Ü Visit to select GreenCo rated companies to understand the ac�vi�es ini�ated a�er one year of

achieving the GreenCo ra�ng

Every case study in this booklet broadly covers a brief profile of the company, the company's GreenCo

journey, ini�a�ves taken by the companies across various GreenCo parameters and the tangible and

intangible benefits achieved. This compila�on is intended for industries to learn from each other and

replicate wherever possible.

The GreenCo Case Study Booklet was released during the 4th edi�on of the GreenCo Summit 2015 on

25 June 2015 at Mumbai.

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

EXECUTIVE SUMMARY

Pursuing green has become the new driver for companies on the quest towards growth, compe��veness

and global excellence. With number of businesses going green on the rise and several ini�a�ves on

different areas evokes a spark in an individual's mind on 'How Green is a Company'. CII, through an

extensive stakeholder consulta�on and interac�on with experts, has developed the “GreenCo Ra�ng

System” to evaluate how green is a company. This first of its kind in the world ra�ng system, is a holis�c

mechanism to assess and analyze the company's performance on the green front. It is a framework to

measure and monitor the environmental impact of a company's ac�vi�es or opera�ons. The GreenCo

Ra�ng System apart from assessing the companies also defines a path for con�nuous ecological

improvement and guided phase growth.

The GreenCo Ra�ng System has been receiving an excellent response from the Indian industry. As of June

2015, 47 companies are GreenCo Rated and more than 110 companies are at various levels of execu�on

of the ra�ng system. GreenCo's depth and spread of environmental parameters, its mul� sector

applicability and its neither-too-tough-nor-too-easy design are a few characteris�cs that have facilitated

GreenCo to reach out to various companies across various sectors, sizes and regions. One of GreenCo's

dis�nguishing characteris�cs is that the GreenCo Ra�ng System is not just a ra�ng system but a

comprehensive mechanism that helps companies to evolve as those exhibi�ng superior environmental

responsibility and performance.

GreenCo's success vests in encouraging companies whom have been performing good in their

environmental front to perform exceedingly well and companies who haven't ventured into the green

aspects to put in significant efforts to explore op�ons and go higher up the ladder of environmental

performance. Rela�vely newer concepts such as working beyond the fence to conserve water, third party

purchase of renewable energy, raw material conserva�on through reduc�on and subs�tu�on, extending

environmental conserva�on ac�vi�es into the supply chain, responsible manufacture of products, life

cycle assessment as a tool to reduce environmental impact of its product, process and service and many

more are taken up by companies. The GreenCo rated companies have not only reduced their

environmental impact but have also improved their compe��veness.

The United Na�ons Industrial Development Organiza�on (UNIDO) is the specialized agency of the United

Na�ons that promotes industrial development for poverty reduc�on, inclusive globaliza�on and

environmental sustainability. UNIDO implements in coopera�on with the United Na�ons Environment

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

HOW TO USE THIS BOOK

GreenCo Case Study Booklet is a compila�on of best prac�ces from select GreenCo Rated Companies.

Broadly every case study includes an introduc�on of the company, its GreenCo journey and the benefits

that it has achieved through the GreenCo Ra�ng System. A best prac�ce cannot be a best prac�ce if it is

not shared with and adopted by others. You can contact every company men�oned as a part of this

compila�on, to learn more about the best prac�ces which you are planning to adopt. Each of them is

commi�ed to sharing informa�on and answering all your queries about their best prac�ces.

You can also reach out to Mr N Muthusezhiyan, Principal Counsellor, CII – Sohrabji Godrej Green Business

Centre at n.muthu@cii.in to find out more about the GreenCo Ra�ng System and the GreenCo rated

companies

Case Studies

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

HOW TO USE THIS BOOK

GreenCo Case Study Booklet is a compila�on of best prac�ces from select GreenCo Rated Companies.

Broadly every case study includes an introduc�on of the company, its GreenCo journey and the benefits

that it has achieved through the GreenCo Ra�ng System. A best prac�ce cannot be a best prac�ce if it is

not shared with and adopted by others. You can contact every company men�oned as a part of this

compila�on, to learn more about the best prac�ces which you are planning to adopt. Each of them is

commi�ed to sharing informa�on and answering all your queries about their best prac�ces.

You can also reach out to Mr N Muthusezhiyan, Principal Counsellor, CII – Sohrabji Godrej Green Business

Centre at n.muthu@cii.in to find out more about the GreenCo Ra�ng System and the GreenCo rated

companies

Case Studies

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Kempegowda Interna�onal Airport Limited (KIAL), Bengaluru (formerly Bangalore Interna�onal Airport Limited, BIAL) has the dis�nc�on of being the first airport in India, to be constructed through a public-private partnership. Built and operated along the highest interna�onal standards, KIAL is commi�ed to establishing this airport as one of India's leading projects in terms of quality and efficiency.

KIAL has the dis�nc�on of being the First GreenCo Rated Company in India. With all its effort, KIAL has achieved in GreenCo Silverthe year 2012. KIAL also has achieved the LEED Gold ra�ng and is in Level 3 - Op�miza�on Level under Airport Carbon Accredita�on Program.

Company Profile

Kempegowda Interna�onal

Airport Limited

May2011

July2011

2012

Launch ofGreenCo

Training & Handholding

On-siteAssessment

Feb2012

Bengaluru

Case Study I

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Kempegowda Interna�onal Airport Limited (KIAL), Bengaluru (formerly Bangalore Interna�onal Airport Limited, BIAL) has the dis�nc�on of being the first airport in India, to be constructed through a public-private partnership. Built and operated along the highest interna�onal standards, KIAL is commi�ed to establishing this airport as one of India's leading projects in terms of quality and efficiency.

KIAL has the dis�nc�on of being the First GreenCo Rated Company in India. With all its effort, KIAL has achieved in GreenCo Silverthe year 2012. KIAL also has achieved the LEED Gold ra�ng and is in Level 3 - Op�miza�on Level under Airport Carbon Accredita�on Program.

Company Profile

Kempegowda Interna�onal

Airport Limited

May2011

July2011

2012

Launch ofGreenCo

Training & Handholding

On-siteAssessment

Feb2012

Bengaluru

Case Study I

GreenCo Ra�ng BenefitsKIAL has developed a clear framework to address the environmental sustainability parameters

within the facility which is laid down as a part of its Environment Management System (EMS). The key achievements of KIAL and the benefits achieved as a result of undergoing the GreenCo

Ra�ng System is as shown below -

1. Energy Efficiency, Renewable Energy and GHG Mi�ga�on Defined short term and long term targets for reduc�on in specific energy consump�onÜ Inclusion of energy efficiency as a parameter in the KPI for individual staffÜ By design, KIAL has taken up several energy efficiency projects. However, the GreenCo Ü

assessment has brought in addi�onal focus on energy conserva�on through – Stricter monitoring Ø Aspira�onal target se�ng Ø Maximizing opera�onal efficiency of systems by bringing together various service Ø

providers and many more 3 Lane Taxiway system on Apron resul�ng in Ü Improved airport efficiencyØ Reduced ATF fuel consump�on (1300 MT in 2012-13) Ø Reduced environmental impact through elimina�on of CO2 emissions Ø (4114.37 MTCO2 emissions in 2012-13) KIAL has put in significant efforts in addressing the opportuni�es for improvement that

emerged from the GreenCo Ra�ng System. Shown below are the various ini�a�ves taken - Restora�on of VFD opera�on in AHUsÜ Opera�on of secondary pumping system through VFDÜ Replacement of fluorescent lamps with LED Lamps in elevator cabinÜ Switching off the escalators during off peak dura�on in walkwayÜ Installa�on of PIR sensors & occupancy sensors, power factor improvement, etc. Ü Reduc�on in idle �me of “Baggage Handling Conveyor” from 10 min to 5 min. for Ü

interna�onal carousals and to 3 min for domes�c carousals Power Conserva�on by AHU scheduling and through Tunnel Ven�la�on fan Opera�onal Ü Control in T1A

KIAL has a target of mee�ng 25% of its energy requirements through the use of renewable

energy by 2016-17. The renewable energy systems in place available and planned at KIAL

are as shown below - 55 solar powered ligh�ng poles Ü 30 solar powered security cabins Ü Installa�on of 2 MW solar power plant under implementa�on Ü 600 KW solar system powering the car parking is under implementa�onÜ Green power purchase of 20 million units through open access in 2015-16Ü Increase of bio-diesel consump�on within the airport premisesÜ

Saved 1.72 Million units of electricity and ` 11.85 Million

through the implementa�on

of energy efficiency ini�a�ves

Annual recurring savings achieved

through implemen�ng

various environmental

projects is ` 25.84 Million

ICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

2. Waste Management & Material Conserva�on, Recycling & Recyclability KIAL has become “First Plas�c-Free Airport in the Country”, by completely switching over to

eco-bags (paper / cloth bags), thus elimina�ng consump�on of approximately 5,00,000

plas�c bags annually. They have also taken an ini�a�ve of “refusal” for non-eco friendly

products (e.g. toilet rolls, cleaning chemicals etc.)

KIAL has done significant work in the area of waste management and material conserva�on.

It has a clear cut mechanism for collec�ng, segrega�ng and disposal of wastes within the

facility.

Following are some of the excellent ini�a�ves taken by KIAL for effec�ve collec�on,

segrega�on, recycle, reuse, recovery, treatment and disposal of different types of wastes: Source segrega�on and inventory management for different types of wastesÜ Primary Waste Accumula�on Point (PWAP) set upÜ Segrega�on of recyclable wastes at source within KIALÜ Dedicated waste collec�on centerÜ Community involvement and awareness crea�onÜ Waste disposal & treatment through outsourced agencies Ü Zero Liquid Discharge facility liquid waste Ü

First Plas�c-Free Airport in the

Country by completely

switching over to eco-bags

WASTE COLLECTION, SEGREGATION AND DISPOSAL MECHANISM

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng BenefitsKIAL has developed a clear framework to address the environmental sustainability parameters

within the facility which is laid down as a part of its Environment Management System (EMS). The key achievements of KIAL and the benefits achieved as a result of undergoing the GreenCo

Ra�ng System is as shown below -

1. Energy Efficiency, Renewable Energy and GHG Mi�ga�on Defined short term and long term targets for reduc�on in specific energy consump�onÜ Inclusion of energy efficiency as a parameter in the KPI for individual staffÜ By design, KIAL has taken up several energy efficiency projects. However, the GreenCo Ü

assessment has brought in addi�onal focus on energy conserva�on through – Stricter monitoring Ø Aspira�onal target se�ng Ø Maximizing opera�onal efficiency of systems by bringing together various service Ø

providers and many more 3 Lane Taxiway system on Apron resul�ng in Ü Improved airport efficiencyØ Reduced ATF fuel consump�on (1300 MT in 2012-13) Ø Reduced environmental impact through elimina�on of CO2 emissions Ø (4114.37 MTCO2 emissions in 2012-13) KIAL has put in significant efforts in addressing the opportuni�es for improvement that

emerged from the GreenCo Ra�ng System. Shown below are the various ini�a�ves taken - Restora�on of VFD opera�on in AHUsÜ Opera�on of secondary pumping system through VFDÜ Replacement of fluorescent lamps with LED Lamps in elevator cabinÜ Switching off the escalators during off peak dura�on in walkwayÜ Installa�on of PIR sensors & occupancy sensors, power factor improvement, etc. Ü Reduc�on in idle �me of “Baggage Handling Conveyor” from 10 min to 5 min. for Ü

interna�onal carousals and to 3 min for domes�c carousals Power Conserva�on by AHU scheduling and through Tunnel Ven�la�on fan Opera�onal Ü Control in T1A

KIAL has a target of mee�ng 25% of its energy requirements through the use of renewable

energy by 2016-17. The renewable energy systems in place available and planned at KIAL

are as shown below - 55 solar powered ligh�ng poles Ü 30 solar powered security cabins Ü Installa�on of 2 MW solar power plant under implementa�on Ü 600 KW solar system powering the car parking is under implementa�onÜ Green power purchase of 20 million units through open access in 2015-16Ü Increase of bio-diesel consump�on within the airport premisesÜ

Saved 1.72 Million units of electricity and ` 11.85 Million

through the implementa�on

of energy efficiency ini�a�ves

Annual recurring savings achieved

through implemen�ng

various environmental

projects is ` 25.84 Million

ICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

2. Waste Management & Material Conserva�on, Recycling & Recyclability KIAL has become “First Plas�c-Free Airport in the Country”, by completely switching over to

eco-bags (paper / cloth bags), thus elimina�ng consump�on of approximately 5,00,000

plas�c bags annually. They have also taken an ini�a�ve of “refusal” for non-eco friendly

products (e.g. toilet rolls, cleaning chemicals etc.)

KIAL has done significant work in the area of waste management and material conserva�on.

It has a clear cut mechanism for collec�ng, segrega�ng and disposal of wastes within the

facility.

Following are some of the excellent ini�a�ves taken by KIAL for effec�ve collec�on,

segrega�on, recycle, reuse, recovery, treatment and disposal of different types of wastes: Source segrega�on and inventory management for different types of wastesÜ Primary Waste Accumula�on Point (PWAP) set upÜ Segrega�on of recyclable wastes at source within KIALÜ Dedicated waste collec�on centerÜ Community involvement and awareness crea�onÜ Waste disposal & treatment through outsourced agencies Ü Zero Liquid Discharge facility liquid waste Ü

First Plas�c-Free Airport in the

Country by completely

switching over to eco-bags

WASTE COLLECTION, SEGREGATION AND DISPOSAL MECHANISM

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

ICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

3. Green Supply Chain KIAL has developed an excellent “Green Procurement Policy” that encourages – Ü Use of eco-friendly productsØ Sourcing of materials from less pollu�ng sources or those from cleaner technologiesØ Concessionaries that use recycled material, etc. Ø

KIAL has also defined its suppliers into four categories – Ü� Material suppliersØ Passengers & airlinesØ ConcessionariesØ Service providers and contractorsØ

A matrix is created that explains the different cer�fica�ons achieved by its suppliers. This Ü

is a pioneering ini�a�ve to understand where the suppliers stand and the kind of

environmental cer�fica�ons achieved by individual suppliers.

In order to create awareness amongst its stakeholders on environmental sustainability, Ü

KIAL organizes the program “Hasiru Habba” every year, which is a�ended by all

concessionaires and 80% of KIAL's suppliers and contractors. KIAL also sends emails to

suppliers about environmental ini�a�ves taken and supports its suppliers whenever

required.

The philosophy behind “BIAL Pinnacle Awards” is to resonate the vision of the airport 'To

excel in consistent, efficient and friendly delivery of airport services as the gateway to South

India'. It is cons�tuted to applaud the stakeholders' contribu�on that has been helping KIAL

walk towards a�aining an elevated posi�on among the airports across the globe.

The award is aimed at acknowledging star performances from among various airport

stakeholders in several categories and also to inculcate the spirit of compe��on which will

enable improved performance. Individuals and organiza�ons that have gone through

transforma�ons to reach the pinnacle of excellence are being awarded. The program is

conducted by KIAL on an annual basis.

By embarking in to the GreenCo Journey, the company has taken various ini�a�ves to

improve their environmental performance. This focused and systema�c approach will

enable KIAL, Bangalore to remain as one of the leaders in the avia�on industry, as far as

environmental sustainability is concerned.

BIAL PINNACLE AWARD

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Brakes India Limited is one of the leading manufacturers of Automo�ve Braking Systems and Ferrous Cas�ngs in India. In 1981, Brakes India established a Foundry Division at Sholinghur, Vellore district of Tamil Nadu. The plant was established to manufacture Permanent Mould Grey Iron cas�ngs at 5,000 MTPA which has been increased to 12,000 MTPA. A total of 5 sand foundries were installed, all of which amounts to a total capacity of 80,000 MTPA.

Brakes India Ltd, Foundry Division (BIF) is cer�fied under ISO 14001 and OHSAS 18001. BIF won the pres�gious 'Energy Conserva�on Award' ins�tuted by the Ministry of Power, Govt. of India and 'The Green Foundry Award' from The Ins�tute of Indian Foundry men in the year 2005. In the year 2000-2001, the unit has become Zero discharge facility in the areas of process water and pollutants.

Dec2011

Jan2012

Company Profile

Launch ofGreenCo

Training & Handholding

On-siteAssessment

Jan2013

BrakesIndia Pvt. Ltd.,

Foundry DivisionSholinghur

Case Study II

ICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

3. Green Supply Chain KIAL has developed an excellent “Green Procurement Policy” that encourages – Ü Use of eco-friendly productsØ Sourcing of materials from less pollu�ng sources or those from cleaner technologiesØ Concessionaries that use recycled material, etc. Ø

KIAL has also defined its suppliers into four categories – Ü� Material suppliersØ Passengers & airlinesØ ConcessionariesØ Service providers and contractorsØ

A matrix is created that explains the different cer�fica�ons achieved by its suppliers. This Ü

is a pioneering ini�a�ve to understand where the suppliers stand and the kind of

environmental cer�fica�ons achieved by individual suppliers.

In order to create awareness amongst its stakeholders on environmental sustainability, Ü

KIAL organizes the program “Hasiru Habba” every year, which is a�ended by all

concessionaires and 80% of KIAL's suppliers and contractors. KIAL also sends emails to

suppliers about environmental ini�a�ves taken and supports its suppliers whenever

required.

The philosophy behind “BIAL Pinnacle Awards” is to resonate the vision of the airport 'To

excel in consistent, efficient and friendly delivery of airport services as the gateway to South

India'. It is cons�tuted to applaud the stakeholders' contribu�on that has been helping KIAL

walk towards a�aining an elevated posi�on among the airports across the globe.

The award is aimed at acknowledging star performances from among various airport

stakeholders in several categories and also to inculcate the spirit of compe��on which will

enable improved performance. Individuals and organiza�ons that have gone through

transforma�ons to reach the pinnacle of excellence are being awarded. The program is

conducted by KIAL on an annual basis.

By embarking in to the GreenCo Journey, the company has taken various ini�a�ves to

improve their environmental performance. This focused and systema�c approach will

enable KIAL, Bangalore to remain as one of the leaders in the avia�on industry, as far as

environmental sustainability is concerned.

BIAL PINNACLE AWARD

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Brakes India Limited is one of the leading manufacturers of Automo�ve Braking Systems and Ferrous Cas�ngs in India. In 1981, Brakes India established a Foundry Division at Sholinghur, Vellore district of Tamil Nadu. The plant was established to manufacture Permanent Mould Grey Iron cas�ngs at 5,000 MTPA which has been increased to 12,000 MTPA. A total of 5 sand foundries were installed, all of which amounts to a total capacity of 80,000 MTPA.

Brakes India Ltd, Foundry Division (BIF) is cer�fied under ISO 14001 and OHSAS 18001. BIF won the pres�gious 'Energy Conserva�on Award' ins�tuted by the Ministry of Power, Govt. of India and 'The Green Foundry Award' from The Ins�tute of Indian Foundry men in the year 2005. In the year 2000-2001, the unit has become Zero discharge facility in the areas of process water and pollutants.

Dec2011

Jan2012

Company Profile

Launch ofGreenCo

Training & Handholding

On-siteAssessment

Jan2013

BrakesIndia Pvt. Ltd.,

Foundry DivisionSholinghur

Case Study II

IICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Wind power meets 25% of BIF's energy

requirement. Developed joint

venture agreement with Sun Edison for

an 8 MW Solar Power Plant which

will cater to addi�onal 10% of

energy requirement

GreenCo Ra�ng Benefits BIF, as a proac�ve corporate, has demonstrated excellent commitment towards environmental sustainability. The unit has been taking steady steps to reduce their environment footprint and has done good work in areas of energy efficiency, renewable energy, GHG mi�ga�on, waste management and material conserva�on.Some of the key ini�a�ves and benefits experienced by BIF through the GreenCo journey are highlighted below -

1. Energy Efficiency & Renewable EnergyBIF has done excellent work in improving their energy efficiency and subs�tu�ng a significant percentage of their energy requirements through renewable energy.

Ü First unit in the foundry sector whose Energy Management System has been cer�fied in accordance with BS En 16001:2009

Ü Achieved global benchmark status in mel�ng energy consump�onÜ Online monitoring of energy consump�on and repor�ng across 6 foundries in the site,

with more than 150 energy meters integrated into the ERP systemÜ Upgrada�on of old mel�ng furnaces with the latest 12 pulse converters, with high power

density, state of the art fume extrac�on and very low genera�on of harmonicsÜ Wind power meets nearly 25% of the BIF's energy requirement. BIF has also developed a

joint venture agreement with Sun Edison for an 8 MW Solar Power Plant which will cater addi�onal 10% of its energy requirements

Ü Installa�on of automa�c power controller in the mel�ng furnaces for energy, input weight, temperature, charge composi�on and traceability

Ü 40% of energy requirement is met through gas turbines run on flared gas from oil fieldsÜ Installed solar streetlights, water heaters and grid connected solar power plants

8 MW SOLAR POWER PLANT

ENERGY SCORE CARD

2. Water Conserva�on BIF, Sholinghur has a very good water management system that focuses on minimizing water consump�on, treatment and recycle / reuse of wastewater. Some of the notable best prac�ces by BIF, Sholinghur are described below -

Ü A cross func�onal water management team as a part of the IMS (Integrated Management System) team which is headed by the Execu�ve Director

Ü Structured training for all employees and encouragement of ideas with cash reward system for selected sugges�ons

Ü Conducts water audit at regular interval and implements the iden�fied projects for water conserva�on

Ü Daily monitoring of water consump�on at various levels with over 80 flow meters installed across the plant

Ü Installed PLC/SCADA water control system for the mel�ng and sand plant to ensure op�mum u�liza�on of water

Ü Use of treated water for gardening, cupola shell cooling and cooling towersÜ

2 Rain water harvested from roof tops of 28,000 m in the factory, is used for reuse in the produc�on process

Ü Eliminated the need for 3 cooling towers out of 15 through upgrada�on of the equipment and thereby increasing the natural dra� cooling.

3. Waste Management & Material Conserva�on, Recycling & Recyclability BIF, Sholinghur has excelled in the area of waste management & material conserva�on. It has a well-defined mechanism for collec�on, segrega�on and disposal of waste within the facility, with specific roles defined to plant personnel to address various waste management related ac�vi�es. The plant emphasizes op�mal u�liza�on of raw materials, maximizing the 3R (Reduce-Reuse-Recycle) concept.

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

RAIN WATER HARVESTING POND

IICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Wind power meets 25% of BIF's energy

requirement. Developed joint

venture agreement with Sun Edison for

an 8 MW Solar Power Plant which

will cater to addi�onal 10% of

energy requirement

GreenCo Ra�ng Benefits BIF, as a proac�ve corporate, has demonstrated excellent commitment towards environmental sustainability. The unit has been taking steady steps to reduce their environment footprint and has done good work in areas of energy efficiency, renewable energy, GHG mi�ga�on, waste management and material conserva�on.Some of the key ini�a�ves and benefits experienced by BIF through the GreenCo journey are highlighted below -

1. Energy Efficiency & Renewable EnergyBIF has done excellent work in improving their energy efficiency and subs�tu�ng a significant percentage of their energy requirements through renewable energy.

Ü First unit in the foundry sector whose Energy Management System has been cer�fied in accordance with BS En 16001:2009

Ü Achieved global benchmark status in mel�ng energy consump�onÜ Online monitoring of energy consump�on and repor�ng across 6 foundries in the site,

with more than 150 energy meters integrated into the ERP systemÜ Upgrada�on of old mel�ng furnaces with the latest 12 pulse converters, with high power

density, state of the art fume extrac�on and very low genera�on of harmonicsÜ Wind power meets nearly 25% of the BIF's energy requirement. BIF has also developed a

joint venture agreement with Sun Edison for an 8 MW Solar Power Plant which will cater addi�onal 10% of its energy requirements

Ü Installa�on of automa�c power controller in the mel�ng furnaces for energy, input weight, temperature, charge composi�on and traceability

Ü 40% of energy requirement is met through gas turbines run on flared gas from oil fieldsÜ Installed solar streetlights, water heaters and grid connected solar power plants

8 MW SOLAR POWER PLANT

ENERGY SCORE CARD

2. Water Conserva�on BIF, Sholinghur has a very good water management system that focuses on minimizing water consump�on, treatment and recycle / reuse of wastewater. Some of the notable best prac�ces by BIF, Sholinghur are described below -

Ü A cross func�onal water management team as a part of the IMS (Integrated Management System) team which is headed by the Execu�ve Director

Ü Structured training for all employees and encouragement of ideas with cash reward system for selected sugges�ons

Ü Conducts water audit at regular interval and implements the iden�fied projects for water conserva�on

Ü Daily monitoring of water consump�on at various levels with over 80 flow meters installed across the plant

Ü Installed PLC/SCADA water control system for the mel�ng and sand plant to ensure op�mum u�liza�on of water

Ü Use of treated water for gardening, cupola shell cooling and cooling towersÜ

2 Rain water harvested from roof tops of 28,000 m in the factory, is used for reuse in the produc�on process

Ü Eliminated the need for 3 cooling towers out of 15 through upgrada�on of the equipment and thereby increasing the natural dra� cooling.

3. Waste Management & Material Conserva�on, Recycling & Recyclability BIF, Sholinghur has excelled in the area of waste management & material conserva�on. It has a well-defined mechanism for collec�on, segrega�on and disposal of waste within the facility, with specific roles defined to plant personnel to address various waste management related ac�vi�es. The plant emphasizes op�mal u�liza�on of raw materials, maximizing the 3R (Reduce-Reuse-Recycle) concept.

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

RAIN WATER HARVESTING POND

IICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Following are some of the laudable ini�a�ves taken by BIF, Sholinghur, showing its commitment towards resource conserva�on -

Ü Source segrega�on, inventory and separate storage facility for both hazardous and non-hazardous wastes

Ü Patented “Stabilized Mud Block Technology” to u�lize waste sand from the process to be u�lized for building construc�on and in roads

Ü Waste Sand is u�lized for growing kitchen garden, flowering trees and cul�va�on, to restrict the use of Ø

water to 20% of its usual consump�on as RDM as well as well as RDF in Cement PlantsØ U�liza�on of en�re treated effluent for gardening, cooling towers and cupola cooling Ü

(zero water discharge unit) Taken projects to reduce rare earth metal consump�on, improve yield and reduce usage Ü

of oil ERP system powered by SAP for monitoring material consump�on Ü Usage of simula�on so�ware to improve yield and regularly monitor yield, which has a Ü

major implica�on on consump�on of raw materials Achieved significant reduc�on in virgin material consump�on over the years and have a Ü

process which by design uses recycled metal as a major raw material Over 80% of the product shipments are made in reusable packaging Ü Online process monitoring and installa�on of on-line shot blas�ng to ensure very low Ü

level of process rejec�on

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

HIL Limited is a flagship Company of the C.K. Birla Group of Companies. HIL Limited is one of the market leaders in manufacturing of Aerated Autoclaved Construc�on (AAC) Building Block, an eco-friendly construc�on material. As Green Building concept has gained wide acceptance in India, the number of consumers showing interest in green products have increased substan�ally.

The manufacturing facility of Aerated Autoclaved Concrete Blocks (AAC Blocks) of HIL Limited is situated in Golan near Surat, Gujarat. It was established in 2008 and the commercial produc�on commenced in 2009. Aerocon blocks are made out of 'Fly Ash' which is a by-product of thermal power plants.

Oct2012

Nov2012

Company Profile

Launch ofGreenCo

Training & Handholding

On-siteAssessment

May2013

HILLimited

Golan, Surat

Case Study III

IICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Following are some of the laudable ini�a�ves taken by BIF, Sholinghur, showing its commitment towards resource conserva�on -

Ü Source segrega�on, inventory and separate storage facility for both hazardous and non-hazardous wastes

Ü Patented “Stabilized Mud Block Technology” to u�lize waste sand from the process to be u�lized for building construc�on and in roads

Ü Waste Sand is u�lized for growing kitchen garden, flowering trees and cul�va�on, to restrict the use of Ø

water to 20% of its usual consump�on as RDM as well as well as RDF in Cement PlantsØ U�liza�on of en�re treated effluent for gardening, cooling towers and cupola cooling Ü

(zero water discharge unit) Taken projects to reduce rare earth metal consump�on, improve yield and reduce usage Ü

of oil ERP system powered by SAP for monitoring material consump�on Ü Usage of simula�on so�ware to improve yield and regularly monitor yield, which has a Ü

major implica�on on consump�on of raw materials Achieved significant reduc�on in virgin material consump�on over the years and have a Ü

process which by design uses recycled metal as a major raw material Over 80% of the product shipments are made in reusable packaging Ü Online process monitoring and installa�on of on-line shot blas�ng to ensure very low Ü

level of process rejec�on

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

HIL Limited is a flagship Company of the C.K. Birla Group of Companies. HIL Limited is one of the market leaders in manufacturing of Aerated Autoclaved Construc�on (AAC) Building Block, an eco-friendly construc�on material. As Green Building concept has gained wide acceptance in India, the number of consumers showing interest in green products have increased substan�ally.

The manufacturing facility of Aerated Autoclaved Concrete Blocks (AAC Blocks) of HIL Limited is situated in Golan near Surat, Gujarat. It was established in 2008 and the commercial produc�on commenced in 2009. Aerocon blocks are made out of 'Fly Ash' which is a by-product of thermal power plants.

Oct2012

Nov2012

Company Profile

Launch ofGreenCo

Training & Handholding

On-siteAssessment

May2013

HILLimited

Golan, Surat

Case Study III

IIICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Savings of INR 1.90 Million has been achieved

due to the implementa�on

of various energy efficiency

ini�a�ves

GreenCo Ra�ng BenefitsHIL Ltd, Golan Unit led by a proac�ve corporate, has shown an excellent commitment towards environmental sustainability. The unit has been taking steady steps to reduce their environmental footprint and has done good work in areas of energy efficiency, renewable energy, GHG mi�ga�on, waste management and material conserva�on.

The key achievements and benefits achieved by HIL, Golan through their GreenCo journey are highlighted -

1. Energy Efficiency, Renewable Energy and GHG mi�ga�onMajor ini�a�ves taken by plant in the areas of energy efficiency renewable energy and GHG mi�ga�on are as men�oned below : Developed an exclusive cell to monitor the overall energy consump�on of the unit and Ü

ini�ate various energy conserva�on measures Have set its electrical and thermal energy reduc�on targets based oninterna�onal Ü

standards. The SEC of the plant is 11 kWh of electricity/Cum, which is one of the lowest even globallyØ 9 liters of Furnace Oil/Cum, which is on par with some of the best plants Ø

interna�onally KRA of individual employees have energy reduc�on as one of the components with Ü nearly 20% weightage assigned to it

HIL Limited, Golan has done commendable work by mee�ng its en�re electrical energy requirements through renewable energy. HIL also has an aspira�onal target of being powered through 100% renewable energy, both, electrical and thermal, by the year 2016. Presently, the plant has two windmills of 1.8 MW each at Bhuj, Gujarat with an Ü

investment of INR 255 Million. The power generated by these windmills caters to the electrical energy requirement and the surplus power is sold to the state electricity board

HIL, Golan has also planned for an addi�onal on-site RE system to meet its thermal Ü requirements.

1.8 MW EACH WIND MILL

2. Water Conserva�on HIL Limited, Golan unit has developed a dedicated and a cross-func�onal team to monitor the overall water consump�on in the plant, to develop strategies and to implement water conserva�on projects. HIL Golan has taken several awareness crea�on and employee involvement ini�a�ves on water conserva�on. Some of its ac�vi�es are men�oned below - Conduct regular water auditsÜ Offer advanced training programs for facility managers and staff leadersÜ Reduced fresh water consump�on by 2325 kL in 2014-15Ü Taken up project on rain water harves�ngÜ Create awareness on aspects such as cost involved in the opera�on & maintenance Ü

of water pumping, water treatment and wastewater treatment, piping, metering, leak detec�on and others

Water-smart landscaping, gardening, efficient irriga�on, and lawn care prac�cesÜ Convey the importance of water conserva�on, new technologies, ideas, programs Ü

and incen�ves Developed a process to inform, involve, and educate the public Ü HIL Limited, Golan is a “Zero Water Discharge” unit; it is also working consistently to Ü

reduce its specific water consump�on thereby achieving 38% reduc�on in the last three years

3. Waste Management & Material Conserva�on HIL Limited, Golan unit has a well defined mechanism for collec�on, segrega�on and disposal of different types of wastes generated from the facility. The unit has clear short term and long term targets for various raw material conserva�on. Nirmal Abhiyan program for employeesÜ Employee involvement ini�a�ve for waste management ac�vi�es; it also mo�vates Ø

employees through various incen�ve mechanisms Maximum u�liza�on of fly ash as raw material Ü More than 65% of HIL Golan's raw material is fly ash from power plants. Since there is Ø

a growing demand for fly ash, HIL has explored the possibility of use of pond ash which is also a waste material from the power plant. Through this, HIL will reduce its dependency on fly ash and contribute to pollu�on reduc�on

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

NIRMAL ABHIYAN PROGRAM

IIICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Savings of INR 1.90 Million has been achieved

due to the implementa�on

of various energy efficiency

ini�a�ves

GreenCo Ra�ng BenefitsHIL Ltd, Golan Unit led by a proac�ve corporate, has shown an excellent commitment towards environmental sustainability. The unit has been taking steady steps to reduce their environmental footprint and has done good work in areas of energy efficiency, renewable energy, GHG mi�ga�on, waste management and material conserva�on.

The key achievements and benefits achieved by HIL, Golan through their GreenCo journey are highlighted -

1. Energy Efficiency, Renewable Energy and GHG mi�ga�onMajor ini�a�ves taken by plant in the areas of energy efficiency renewable energy and GHG mi�ga�on are as men�oned below : Developed an exclusive cell to monitor the overall energy consump�on of the unit and Ü

ini�ate various energy conserva�on measures Have set its electrical and thermal energy reduc�on targets based oninterna�onal Ü

standards. The SEC of the plant is 11 kWh of electricity/Cum, which is one of the lowest even globallyØ 9 liters of Furnace Oil/Cum, which is on par with some of the best plants Ø

interna�onally KRA of individual employees have energy reduc�on as one of the components with Ü nearly 20% weightage assigned to it

HIL Limited, Golan has done commendable work by mee�ng its en�re electrical energy requirements through renewable energy. HIL also has an aspira�onal target of being powered through 100% renewable energy, both, electrical and thermal, by the year 2016. Presently, the plant has two windmills of 1.8 MW each at Bhuj, Gujarat with an Ü

investment of INR 255 Million. The power generated by these windmills caters to the electrical energy requirement and the surplus power is sold to the state electricity board

HIL, Golan has also planned for an addi�onal on-site RE system to meet its thermal Ü requirements.

1.8 MW EACH WIND MILL

2. Water Conserva�on HIL Limited, Golan unit has developed a dedicated and a cross-func�onal team to monitor the overall water consump�on in the plant, to develop strategies and to implement water conserva�on projects. HIL Golan has taken several awareness crea�on and employee involvement ini�a�ves on water conserva�on. Some of its ac�vi�es are men�oned below - Conduct regular water auditsÜ Offer advanced training programs for facility managers and staff leadersÜ Reduced fresh water consump�on by 2325 kL in 2014-15Ü Taken up project on rain water harves�ngÜ Create awareness on aspects such as cost involved in the opera�on & maintenance Ü

of water pumping, water treatment and wastewater treatment, piping, metering, leak detec�on and others

Water-smart landscaping, gardening, efficient irriga�on, and lawn care prac�cesÜ Convey the importance of water conserva�on, new technologies, ideas, programs Ü

and incen�ves Developed a process to inform, involve, and educate the public Ü HIL Limited, Golan is a “Zero Water Discharge” unit; it is also working consistently to Ü

reduce its specific water consump�on thereby achieving 38% reduc�on in the last three years

3. Waste Management & Material Conserva�on HIL Limited, Golan unit has a well defined mechanism for collec�on, segrega�on and disposal of different types of wastes generated from the facility. The unit has clear short term and long term targets for various raw material conserva�on. Nirmal Abhiyan program for employeesÜ Employee involvement ini�a�ve for waste management ac�vi�es; it also mo�vates Ø

employees through various incen�ve mechanisms Maximum u�liza�on of fly ash as raw material Ü More than 65% of HIL Golan's raw material is fly ash from power plants. Since there is Ø

a growing demand for fly ash, HIL has explored the possibility of use of pond ash which is also a waste material from the power plant. Through this, HIL will reduce its dependency on fly ash and contribute to pollu�on reduc�on

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

NIRMAL ABHIYAN PROGRAM

IIICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

100% of the product is recyclableÜ A pilot project was done to check possibility of reusing broken AAC blocks in the Ø

process. With the results indica�ng that 100% of the product is recyclable, HIL Golan has decided to reuse the broken blocks in powder form in the process

24% reduc�on in packing material was achieved by reduc�on in strap width and reuse of Ü PP strap

4. Green Supply Chain HIL Limited, Golan unit has developed a “Green Supply Chain Policy” thatÜ highlights the commitment of the company to ensure a greener and a sustainable Ø

supply chain guides HIL in defining short term & long term targets for greening its supply chainØ Implemented several tools and techniques to monitor the performance of the supply Ü

chain Development of a green procurement policy to encourage use of eco-friendly material Ü

for the raw materials, capital goods, packaging material and consumables Ini�a�ves such as logis�cs op�miza�on, supplier audits to evaluate and improve their Ü

performance and many more.

During the GreenCo journey, HIL has implemented several ini�a�ves and measures to enhance efficiency and op�mize resource intensity. The journey ahead in the path towards environmental excellence has immense scope for improvement as brought out by this ra�ng exercise.

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Larsen & Toubro is an engineering, construc�on, manufacturing and financial services conglomerate, with global opera�ons. Larsen & Toubro is globally acknowledged as one of the top five companies in heavy engineering. The heavy engineering division offers custom made equipment for process plant equipment used in fer�lizer, petrochemical, thermal power plants, defense, nuclear and aerospace, etc. Plate cu�ng, fabrica�on, welding & machining are the major opera�ons done at the heavy engineering division.

Company Profile

Larsen &Toubro Limited

Powai (West), Mumbai

Sep'12-Aug'13

Implementa�onof Sugges�ons

Iden�fied

On-siteAssessment

Sep2013

Aug2012

FeasibilityStudy

Aug2012

Registra�onfor Feasibility

Case Study IV

IIICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

100% of the product is recyclableÜ A pilot project was done to check possibility of reusing broken AAC blocks in the Ø

process. With the results indica�ng that 100% of the product is recyclable, HIL Golan has decided to reuse the broken blocks in powder form in the process

24% reduc�on in packing material was achieved by reduc�on in strap width and reuse of Ü PP strap

4. Green Supply Chain HIL Limited, Golan unit has developed a “Green Supply Chain Policy” thatÜ highlights the commitment of the company to ensure a greener and a sustainable Ø

supply chain guides HIL in defining short term & long term targets for greening its supply chainØ Implemented several tools and techniques to monitor the performance of the supply Ü

chain Development of a green procurement policy to encourage use of eco-friendly material Ü

for the raw materials, capital goods, packaging material and consumables Ini�a�ves such as logis�cs op�miza�on, supplier audits to evaluate and improve their Ü

performance and many more.

During the GreenCo journey, HIL has implemented several ini�a�ves and measures to enhance efficiency and op�mize resource intensity. The journey ahead in the path towards environmental excellence has immense scope for improvement as brought out by this ra�ng exercise.

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Larsen & Toubro is an engineering, construc�on, manufacturing and financial services conglomerate, with global opera�ons. Larsen & Toubro is globally acknowledged as one of the top five companies in heavy engineering. The heavy engineering division offers custom made equipment for process plant equipment used in fer�lizer, petrochemical, thermal power plants, defense, nuclear and aerospace, etc. Plate cu�ng, fabrica�on, welding & machining are the major opera�ons done at the heavy engineering division.

Company Profile

Larsen &Toubro Limited

Powai (West), Mumbai

Sep'12-Aug'13

Implementa�onof Sugges�ons

Iden�fied

On-siteAssessment

Sep2013

Aug2012

FeasibilityStudy

Aug2012

Registra�onfor Feasibility

Case Study IV

IVCase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng BenefitsL&T, as a commi�ed organiza�on towards achieving environmental sustainability, had implemented several ini�a�ves and projects across various GreenCo parameters even before the GreenCo Ra�ng System. The implementa�on of GreenCo helped L&T enhance its environmental performance. Some of L&T's ini�a�ves are described below – ÜTarget Se�ngThe sustainability roadmap L&T is based on the eight Missions of the Na�onal Ac�on Plan on Climate Change. Its targets are stated below -

Ø 15% increase in energy savingsØ 5% reduc�on in energy consump�on intensity (Per employee) Ø 5% reduc�on in scope 1 GHG emission intensity and 3% reduc�on in scope 2 emissions intensity Ø 5% reduc�on in water consump�on intensity( per employee)Ø 5% reduc�on in direct material consump�on and/or increase the share of recycled input materials

1. Energy EfficiencyÜ L&T, Powai West has reduced its specific energy consump�on (intensity per employee) by

36% in the last three years. Ü Process Op�miza�on and implementa�on of new technologies has resulted in good

energy savings and monetary benefits. Ü The plant has an online energy management system and has taken several efforts to

improve energy efficiency. Some of which are men�oned - Ø Quarterly energy performance reports are generated where the weekly chiller performance is compared with design efficiency (in kW/TR). If the actual efficiency is found to be less than the design efficiency, correc�ve ac�ons are taken to improve the performance of the chillers

The plant has created Energy Performance Index (EPI) for various buildings in the Ø facility as shown in the graphs below.

2. Renewable EnergyL&T, Powai has a tripar�te agreement with Enercon and the Maharashtra State Electricity Board to purchase renewable energy power equivalent to 150 Lakh units per year. The plant has increased the wind power u�liza�on to 80 % of their total power consump�on.

Wind Power Purchase Agreement Biogas plant was commissioned in 2010 that converts organic waste from canteen into methane. The biogas generated from food waste is used for cooking in the canteen. The plant has also installed 18500 Litres/day capacity solar water heater systems to fulfill their hot water requirements and has also installed a 4 KW Solar PV system.

9.1 MW WIND MILLS BIOGAS PLANT

SEC reduc�on from 3,468 units per employee to 2,224 units per

employee

Energy efficiency ini�a�ves taken in the last three

years saved nearly 6 Lakh units and ` 4

million

Power Purchase Agreement with

Renewable Energy Power Producer since 2003 for an annual supply of 150 Lakh Units

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Use of Biogas resulted in saving

of 109,300 equivalent kWH

units

IVCase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng BenefitsL&T, as a commi�ed organiza�on towards achieving environmental sustainability, had implemented several ini�a�ves and projects across various GreenCo parameters even before the GreenCo Ra�ng System. The implementa�on of GreenCo helped L&T enhance its environmental performance. Some of L&T's ini�a�ves are described below – ÜTarget Se�ngThe sustainability roadmap L&T is based on the eight Missions of the Na�onal Ac�on Plan on Climate Change. Its targets are stated below -

Ø 15% increase in energy savingsØ 5% reduc�on in energy consump�on intensity (Per employee) Ø 5% reduc�on in scope 1 GHG emission intensity and 3% reduc�on in scope 2 emissions intensity Ø 5% reduc�on in water consump�on intensity( per employee)Ø 5% reduc�on in direct material consump�on and/or increase the share of recycled input materials

1. Energy EfficiencyÜ L&T, Powai West has reduced its specific energy consump�on (intensity per employee) by

36% in the last three years. Ü Process Op�miza�on and implementa�on of new technologies has resulted in good

energy savings and monetary benefits. Ü The plant has an online energy management system and has taken several efforts to

improve energy efficiency. Some of which are men�oned - Ø Quarterly energy performance reports are generated where the weekly chiller performance is compared with design efficiency (in kW/TR). If the actual efficiency is found to be less than the design efficiency, correc�ve ac�ons are taken to improve the performance of the chillers

The plant has created Energy Performance Index (EPI) for various buildings in the Ø facility as shown in the graphs below.

2. Renewable EnergyL&T, Powai has a tripar�te agreement with Enercon and the Maharashtra State Electricity Board to purchase renewable energy power equivalent to 150 Lakh units per year. The plant has increased the wind power u�liza�on to 80 % of their total power consump�on.

Wind Power Purchase Agreement Biogas plant was commissioned in 2010 that converts organic waste from canteen into methane. The biogas generated from food waste is used for cooking in the canteen. The plant has also installed 18500 Litres/day capacity solar water heater systems to fulfill their hot water requirements and has also installed a 4 KW Solar PV system.

9.1 MW WIND MILLS BIOGAS PLANT

SEC reduc�on from 3,468 units per employee to 2,224 units per

employee

Energy efficiency ini�a�ves taken in the last three

years saved nearly 6 Lakh units and ` 4

million

Power Purchase Agreement with

Renewable Energy Power Producer since 2003 for an annual supply of 150 Lakh Units

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Use of Biogas resulted in saving

of 109,300 equivalent kWH

units

IVCase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

3. Water Conserva�onL&T, Powai (West) has a set target to reduce specific water consump�on per employee by 5% in the next three years. Due to the efforts taken by the team such as increasing the use of treated wastewater, auto irriga�on, rain water harves�ng and use of water efficient fixtures, specific water consump�on reduced by 32% in the last three years.

The unit has done a comprehensive water foot print study and is cer�fied as a water posi�ve campus by 3rd party with 1:1.65 recharging (Water debit: Water Credit ra�o)

To achieve water posi�ve status, the plant has involved itself in the construc�on of check dams. This has resulted in recharging 193,178 m3 of rainwater and also resulted in increase in water availability for the communi�es in the district.

4. GHG Emissions Mi�ga�onL & T Powai (West) has been conduc�ng several climate change awareness campaigns for their employees and has released a guidance manual for tree planta�on. The plant monitors scope 1 and scope 2 emissions at plant level and monitors scope 3 emissions at corporate level.

Select ini�a�ves taken by the plant to reduce GHG emissions are:Ü Change of fuel from High Speed Diesel (HSD) to Piped Natural Gas(PNG)/Liquefied Petroleum Gas (LPG)Ü Op�miza�on of heat treatment furnaces for fuel efficiencyÜ Op�miza�on of produc�on shop layout to reduce energy consump�on and related GHG emissionÜ Building Management System for office buildingsÜ Increasing the use of videoconferencing / telepresence facili�esÜ Increasing the percentage of green fleet for employee commu�ng

5. Waste Management and Material Conserva�onReuse, Recycle and Recover is the company's core waste management and material

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Sundram Fasteners Limited (SFL) is one of India's largest and most diversified Auto Components Manufacturing Company. SFL is a part of the US$ 6 billion TVS group, based in South India and was set up in 1966 to manufacture high-tensile fasteners.

Sundram Fasteners Limited, Krishnapuram was established in the year 1981 to meet increasing customer requirements and to cater to the interna�onal market. Sprawling across 85 acres of land, SFL Krishnapuram, manufactures a variety of products such as high tensile fasteners like bolts, nuts, studs, screws and powder metallurgy parts.

The company has focused on mee�ng stringent quality requirements of its global customers. SFL, Krishnapuram was the first Indian engineering company to get the “TPM Excellence Award” in 1998 and the TPM consistency award in 2004-05. SFL, Krishnapuram also has a unique IR record of not losing a single man-day since 45 years. The employees are almost employed for life with lowest a�ri�on levels.

Oct2012

Jan2013

Company Profile

Launch ofGreenCo

Training & Handholding

Site VisitAssessment

Nov2013

SundramFasteners Limited

Krishnapuram

Case Study V

IVCase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

3. Water Conserva�onL&T, Powai (West) has a set target to reduce specific water consump�on per employee by 5% in the next three years. Due to the efforts taken by the team such as increasing the use of treated wastewater, auto irriga�on, rain water harves�ng and use of water efficient fixtures, specific water consump�on reduced by 32% in the last three years.

The unit has done a comprehensive water foot print study and is cer�fied as a water posi�ve campus by 3rd party with 1:1.65 recharging (Water debit: Water Credit ra�o)

To achieve water posi�ve status, the plant has involved itself in the construc�on of check dams. This has resulted in recharging 193,178 m3 of rainwater and also resulted in increase in water availability for the communi�es in the district.

4. GHG Emissions Mi�ga�onL & T Powai (West) has been conduc�ng several climate change awareness campaigns for their employees and has released a guidance manual for tree planta�on. The plant monitors scope 1 and scope 2 emissions at plant level and monitors scope 3 emissions at corporate level.

Select ini�a�ves taken by the plant to reduce GHG emissions are:Ü Change of fuel from High Speed Diesel (HSD) to Piped Natural Gas(PNG)/Liquefied Petroleum Gas (LPG)Ü Op�miza�on of heat treatment furnaces for fuel efficiencyÜ Op�miza�on of produc�on shop layout to reduce energy consump�on and related GHG emissionÜ Building Management System for office buildingsÜ Increasing the use of videoconferencing / telepresence facili�esÜ Increasing the percentage of green fleet for employee commu�ng

5. Waste Management and Material Conserva�onReuse, Recycle and Recover is the company's core waste management and material

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Sundram Fasteners Limited (SFL) is one of India's largest and most diversified Auto Components Manufacturing Company. SFL is a part of the US$ 6 billion TVS group, based in South India and was set up in 1966 to manufacture high-tensile fasteners.

Sundram Fasteners Limited, Krishnapuram was established in the year 1981 to meet increasing customer requirements and to cater to the interna�onal market. Sprawling across 85 acres of land, SFL Krishnapuram, manufactures a variety of products such as high tensile fasteners like bolts, nuts, studs, screws and powder metallurgy parts.

The company has focused on mee�ng stringent quality requirements of its global customers. SFL, Krishnapuram was the first Indian engineering company to get the “TPM Excellence Award” in 1998 and the TPM consistency award in 2004-05. SFL, Krishnapuram also has a unique IR record of not losing a single man-day since 45 years. The employees are almost employed for life with lowest a�ri�on levels.

Oct2012

Jan2013

Company Profile

Launch ofGreenCo

Training & Handholding

Site VisitAssessment

Nov2013

SundramFasteners Limited

Krishnapuram

Case Study V

VCase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng BenefitsSFL, Krishnapuram has been doing a commendable work across most of the GreenCo parameters and its strength lie in the areas of Energy efficiency, Renewable Energy, Water Conserva�on, Waste Management and Material Conserva�on. Undergoing the exercise of the GreenCo Ra�ng System has strengthened SFL's efforts across various environmental sustainability parameters.

The GreenCo journey has improved focus for SFL, Krishnapuram in the following areas – Ü Awareness crea�on and training for employees and stakeholders

A cross func�onal approach and concerted employee involvementÜ Strategic planning and execu�on of improvement ac�onsÜ Periodic review by the top managementÜ Some of the significant areas of improvement as a result of their Green ini�a�ves are highlighted

1. Energy Efficiency, Renewable Energy and GHG mi�ga�onThe plant has done very good work in energy efficiency.

Ü An exclusive energy policy that focuses on SFL, Krishnapuram to have the lowest SEC in the auto-component sector

Separate fixed and variable energy consump�on monitoring to improve monitoring Ü efficiency Ü Daily variance analysis for high energy efficient equipment immediate correc�ve

ac�ons taken wherever necessary 14% reduc�on in specific energy consump�on through implementa�on of 17 major Ü

projects. Some of which are, Ø Elimina�on of electric motors and gear boxes in conveyorsØ Downsizing drive capacity from 60 HP to 50 HPØ Replacing reciproca�ng compressor by screw compressorØ Improving loading pa�ern in furnace Ø Waste heat recovery in furnaces

SFL, Krishnapuram strongly believes that the energy supplied from renewable sources diversifies its risks from the use of conven�onal energy sources in addi�on to delivering GHG reduc�on benefits. RE share has increased from 12% to 70% throughÜ

Ø Solar water heater plant Ø Bio-gas plant Ø Wind power

SFL also has a target to ÜØ Increase the RE share to 75% by procurement of solar power from third par�es, which will meet the plant's electrical energy requirementØ Set up a solar steam cooking system to meet its canteen' thermal energy requirement.

Increased RE share from 12% to 70%

and has a target to achieve 75%

by 2016

Greenhouse gas emissions are con�nuously monitored by the company. Ü 57% reduc�on in specific intensity (1230 kg to 528 kg CO /MT)2

Ü GreenCo Ra�ng System has encouraged SFL to inventorize its scope 3 emissions and the following categories are accounted for –

Ø Employee commuteØ Business travel Ø Raw material transport

Ü SFL, Krishnapuram aims to move towards carbon neutrality

2. Water Conserva�onSFL, Krishnapuram has an exclusive water policy that guides SFL to focus on conserving water and reducing its water consump�on. Some of the ac�vi�es and ini�a�ves carried out at SFL, Krishnapuram are men�oned below -

Ü Target of being the lowest specific water consuming unit in the auto-component sectorÜ Establishment of a dedicated team for monitoring water consump�onÜ More than 80% of its water consump�on points are meteredÜ More than 75% of the rain water harves�ng poten�al has been capturedÜ Construc�on of rain water harves�ng (RWH) structures in surrounding villages

3. Waste Management SFL, Krishnapuram has done excellent work in waste management and material conserva�on.

Ü Separate, well maintained storage yards for hazardous waste and non-hazardous waste Ü Installed a bio gas plant that treats wet waste from canteen and the domes�c sewageÜ An excellent effluent treatment plant that has helped SFL, Krishnapuram be a zero effluent discharge plant

Ø More than 95 % of the effluent is reused for gardeningÜ A full-fledged sewage treatment plant with a highly efficient mechanical vapor recompression unit

Ø Treated water is reused in the opera�on

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Nirmal Abhiyan Program1.8 MW Each Wind Mill

19% reduc�on in hazardous waste genera�on & 21% reduc�on in non-hazardous waste

genera�on

RAIN WATER HARVESTING TANK WASTE WATER TREATMENT PLANT

VCase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng BenefitsSFL, Krishnapuram has been doing a commendable work across most of the GreenCo parameters and its strength lie in the areas of Energy efficiency, Renewable Energy, Water Conserva�on, Waste Management and Material Conserva�on. Undergoing the exercise of the GreenCo Ra�ng System has strengthened SFL's efforts across various environmental sustainability parameters.

The GreenCo journey has improved focus for SFL, Krishnapuram in the following areas – Ü Awareness crea�on and training for employees and stakeholders

A cross func�onal approach and concerted employee involvementÜ Strategic planning and execu�on of improvement ac�onsÜ Periodic review by the top managementÜ Some of the significant areas of improvement as a result of their Green ini�a�ves are highlighted

1. Energy Efficiency, Renewable Energy and GHG mi�ga�onThe plant has done very good work in energy efficiency.

Ü An exclusive energy policy that focuses on SFL, Krishnapuram to have the lowest SEC in the auto-component sector

Separate fixed and variable energy consump�on monitoring to improve monitoring Ü efficiency Ü Daily variance analysis for high energy efficient equipment immediate correc�ve

ac�ons taken wherever necessary 14% reduc�on in specific energy consump�on through implementa�on of 17 major Ü

projects. Some of which are, Ø Elimina�on of electric motors and gear boxes in conveyorsØ Downsizing drive capacity from 60 HP to 50 HPØ Replacing reciproca�ng compressor by screw compressorØ Improving loading pa�ern in furnace Ø Waste heat recovery in furnaces

SFL, Krishnapuram strongly believes that the energy supplied from renewable sources diversifies its risks from the use of conven�onal energy sources in addi�on to delivering GHG reduc�on benefits. RE share has increased from 12% to 70% throughÜ

Ø Solar water heater plant Ø Bio-gas plant Ø Wind power

SFL also has a target to ÜØ Increase the RE share to 75% by procurement of solar power from third par�es, which will meet the plant's electrical energy requirementØ Set up a solar steam cooking system to meet its canteen' thermal energy requirement.

Increased RE share from 12% to 70%

and has a target to achieve 75%

by 2016

Greenhouse gas emissions are con�nuously monitored by the company. Ü 57% reduc�on in specific intensity (1230 kg to 528 kg CO /MT)2

Ü GreenCo Ra�ng System has encouraged SFL to inventorize its scope 3 emissions and the following categories are accounted for –

Ø Employee commuteØ Business travel Ø Raw material transport

Ü SFL, Krishnapuram aims to move towards carbon neutrality

2. Water Conserva�onSFL, Krishnapuram has an exclusive water policy that guides SFL to focus on conserving water and reducing its water consump�on. Some of the ac�vi�es and ini�a�ves carried out at SFL, Krishnapuram are men�oned below -

Ü Target of being the lowest specific water consuming unit in the auto-component sectorÜ Establishment of a dedicated team for monitoring water consump�onÜ More than 80% of its water consump�on points are meteredÜ More than 75% of the rain water harves�ng poten�al has been capturedÜ Construc�on of rain water harves�ng (RWH) structures in surrounding villages

3. Waste Management SFL, Krishnapuram has done excellent work in waste management and material conserva�on.

Ü Separate, well maintained storage yards for hazardous waste and non-hazardous waste Ü Installed a bio gas plant that treats wet waste from canteen and the domes�c sewageÜ An excellent effluent treatment plant that has helped SFL, Krishnapuram be a zero effluent discharge plant

Ø More than 95 % of the effluent is reused for gardeningÜ A full-fledged sewage treatment plant with a highly efficient mechanical vapor recompression unit

Ø Treated water is reused in the opera�on

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Nirmal Abhiyan Program1.8 MW Each Wind Mill

19% reduc�on in hazardous waste genera�on & 21% reduc�on in non-hazardous waste

genera�on

RAIN WATER HARVESTING TANK WASTE WATER TREATMENT PLANT

VCase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

4. Material Conserva�on SFL, Krishnapuram's ini�a�ves in material conserva�on and the respec�ve improvements / savings are highlighted –

Ü Installed in-line eddy-current sorter in wire drawing machine resulted in reduc�on in raw material consump�on by elimina�ng RM scrapÜ Introduced mul�-cavity tools in powder metallurgy compac�on which resulted in increase in machine outputÜ Percentage increase in recycling of consumables between 5% to 56% in various consumables categoriesÜ Introduced double side tools in Bolt, Nut forging and Thread rolling reduced the consump�on of steel for toolsÜ Reduced weight of the packaging material of two products' packaging by 18% and 2.8%

5. Green Supply Chain One area where all GreenCo Rated Companies improved substan�ally was in improving the sustainability of their supply chain and so did SFL, Krishnapuram.

Ü Framed a structured audit program to evaluate the environmental performance of its cri�cal suppliers

Ø Developed a system of ra�ng for its suppliers based on their environmental performance

Ü Devised an ac�on plan for mapping and monitoring energy efficiency, water conserva�on and waste management ac�vi�es of its cri�cal suppliersÜ Examples of ac�vi�es carried out by SFL, Krishnapuram in greening the supply chain -

Ø Shop in Shop concept that has eliminated material movement to vendorsØ Milk Run model introduced to reduce distances travelled by materials Ø Integra�on of opera�ons of vendors Ø Centraliza�on of raw material supply by maintaining a local supplier stock yardØ Implementa�on of GreenCo parameters among top 5 vendors

6. Product StewardshipThe TQM approach is followed to focus on maintaining the quality of products during manufacture, storage and use.

Ü Advanced Product Quality Planning (APQP) technique is used for product planning and in engaging customers in new product developmentÜ Introduc�on of ELV (End of Life Vehicle) compliant surface coa�ngs free from Hexavalent Chromium

Ø ELV requirements are met as per REACH, Bharath III and Euro norms Ü Migra�on to trivalent chrome passiva�on from hazardous hexavalent chrome Ü Migra�on to chrome free zinc flake coa�ngs Ü Educa�ng customers during product design stage to adopt hazard free coa�ngs

SFL, Krishnapuram has been a pioneer in ini�a�ng environmental sustainability ini�a�ves. Venturing into the GreenCo journey has helped them move into higher levels of environmental sustainability. SFL, Krishnapuram aspires to con�nuously learn through GreenCo, expand the concept to other vendors, suppliers and stakeholders, become cost compe��ve in the market to con�nue to be a leader and ul�mately achieve GreenCo Pla�num Ra�ng.

Recorded raw material yield from 86.2% to 86.5% in

the last three years

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Godrej & Boyce Mfg. Co. Ltd. has a vision to be in every home and workplace with a mission to enrich quality of life everyday and everywhere. Environment is one of the core values of the company and an enduring source of the company's strength. The company's vision is three fold –

ÜCrea�ng a greener India ÜEnsuring employability ÜInnova�ng for good & green products

Godrej Lawkim Motors Group is one of the divisions of Godrej & Boyce Mfg. Co. Ltd. Located in Shindewadi, Godrej Lawkim Motors was established in 1992 which sprawls across an area of 16 acres. The company's customers include Godrej Appliances, Hitachi, Reliance, Jet Airways, ONGC, Carrier, Atlas, Emerson, etc. The company set up the Naoroji Godrej Centre for Plant Research (NGCPR), first of its kind ins�tute in India that is dedicated to preserva�on of threatened species and medicinal plants.

Sep2013

Oct2013

Company Profile

Launch ofGreenCo

Training & Handholding

Site VisitAssessment

Apr2014

Godrej & BoyceMfg. Co. Ltd.,

Shirwal

Godrej Lawkim Motors

Case Study VI

VCase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

4. Material Conserva�on SFL, Krishnapuram's ini�a�ves in material conserva�on and the respec�ve improvements / savings are highlighted –

Ü Installed in-line eddy-current sorter in wire drawing machine resulted in reduc�on in raw material consump�on by elimina�ng RM scrapÜ Introduced mul�-cavity tools in powder metallurgy compac�on which resulted in increase in machine outputÜ Percentage increase in recycling of consumables between 5% to 56% in various consumables categoriesÜ Introduced double side tools in Bolt, Nut forging and Thread rolling reduced the consump�on of steel for toolsÜ Reduced weight of the packaging material of two products' packaging by 18% and 2.8%

5. Green Supply Chain One area where all GreenCo Rated Companies improved substan�ally was in improving the sustainability of their supply chain and so did SFL, Krishnapuram.

Ü Framed a structured audit program to evaluate the environmental performance of its cri�cal suppliers

Ø Developed a system of ra�ng for its suppliers based on their environmental performance

Ü Devised an ac�on plan for mapping and monitoring energy efficiency, water conserva�on and waste management ac�vi�es of its cri�cal suppliersÜ Examples of ac�vi�es carried out by SFL, Krishnapuram in greening the supply chain -

Ø Shop in Shop concept that has eliminated material movement to vendorsØ Milk Run model introduced to reduce distances travelled by materials Ø Integra�on of opera�ons of vendors Ø Centraliza�on of raw material supply by maintaining a local supplier stock yardØ Implementa�on of GreenCo parameters among top 5 vendors

6. Product StewardshipThe TQM approach is followed to focus on maintaining the quality of products during manufacture, storage and use.

Ü Advanced Product Quality Planning (APQP) technique is used for product planning and in engaging customers in new product developmentÜ Introduc�on of ELV (End of Life Vehicle) compliant surface coa�ngs free from Hexavalent Chromium

Ø ELV requirements are met as per REACH, Bharath III and Euro norms Ü Migra�on to trivalent chrome passiva�on from hazardous hexavalent chrome Ü Migra�on to chrome free zinc flake coa�ngs Ü Educa�ng customers during product design stage to adopt hazard free coa�ngs

SFL, Krishnapuram has been a pioneer in ini�a�ng environmental sustainability ini�a�ves. Venturing into the GreenCo journey has helped them move into higher levels of environmental sustainability. SFL, Krishnapuram aspires to con�nuously learn through GreenCo, expand the concept to other vendors, suppliers and stakeholders, become cost compe��ve in the market to con�nue to be a leader and ul�mately achieve GreenCo Pla�num Ra�ng.

Recorded raw material yield from 86.2% to 86.5% in

the last three years

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Godrej & Boyce Mfg. Co. Ltd. has a vision to be in every home and workplace with a mission to enrich quality of life everyday and everywhere. Environment is one of the core values of the company and an enduring source of the company's strength. The company's vision is three fold –

ÜCrea�ng a greener India ÜEnsuring employability ÜInnova�ng for good & green products

Godrej Lawkim Motors Group is one of the divisions of Godrej & Boyce Mfg. Co. Ltd. Located in Shindewadi, Godrej Lawkim Motors was established in 1992 which sprawls across an area of 16 acres. The company's customers include Godrej Appliances, Hitachi, Reliance, Jet Airways, ONGC, Carrier, Atlas, Emerson, etc. The company set up the Naoroji Godrej Centre for Plant Research (NGCPR), first of its kind ins�tute in India that is dedicated to preserva�on of threatened species and medicinal plants.

Sep2013

Oct2013

Company Profile

Launch ofGreenCo

Training & Handholding

Site VisitAssessment

Apr2014

Godrej & BoyceMfg. Co. Ltd.,

Shirwal

Godrej Lawkim Motors

Case Study VI

VICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng Benefits During the GreenCo assessment several improvement opportuni�es were brought out. The plant has implemented the following ini�a�ves on environmental sustainability:

1. Renewable Energy Godrej Lawkim Motors will be able to source 48% of its total energy from renewable sources from the following projects - The plant has signed a contract with third party agreement for solar power purchase Ü

agreement. This new mechanism will subs�tute nearly 22% of the conven�onal energy genera�ng about 18 lakh units per annum

The plant has also installed a producer gas furnace inside the factory. The producer gas Ü plant will provide a savings of Rupees 1.97 Crore per year.

The two renewable energy projects have helped the plant in subs�tu�ng 48% of its Ü total energy with renewable sources.

2. Water Conserva�on The plant has conducted a detailed hydrogeological survey before construc�ng the rainwater harves�ng structures inside the factory.

Ü 100% of the rainwater harves�ng poten�al has been captured that ensures not a singledrop of rainwater is wasted

Rainwater harves�ng pondÜ Harves�ng ponds of 90 Lakh liters capacity have been constructedÜ The plant has also constructed check dams and harvested more than 25 Lakh liters of Ü

water in a government plot close to the factory. The water harvested is not withdrawn for industrial use and is allowed to recharge the aquifer, thus benefi�ng the socie�es living in the neighbourhood

In addi�on to rainwater harves�ng, the plant has taken the following ini�a�ves to Ü reduce the water consump�on inside the plant -

Displayed signs and several other sessions are conducted to create awareness on Øwater conserva�on

Water consump�on is displayed at prominent loca�ons inside the plantØ Employees are nominated to par�cipate in training programs on drip irriga�on, water Ø

footprint measurement, water reuse & recycle, etc. Installa�on of new pipelines above ground to arrest hidden leakagesØ Installa�on of flow meters at all consump�on pointsØ Re-use of RO reject waterØ Reduced water pressure in taps to reduce domes�c water consump�onØ Leakage arrested in all areas of the plant – annealing cooling tower, machine shop, Ø

canteen, compressor shop motor, etc.

3. Material Conserva�on The plant has done excellent work on material conserva�on and has a clear ac�on plan for material conserva�on in the coming years. The plant incurred a savings of ` 95 Lakhs due to inventory enablers in flow manufacturing. Other ini�a�ves on material conserva�on - Implementa�on of new technologies like motor winding for making high efficiency Ü

motors Lamina�on redesign to reduce material content Ü Double row punching tools instead of single row punching which also leads to reduc�on Ü

in material consump�on Ü Op�miza�on in the winding process thus reducing the quan�ty of Copper wire used

Op�miza�on in die cas�ng ga�ng system Ü Eliminated usage of wood for packaging and saved ̀ 1 million per annumÜ Redesigned packaging so that the packaging material can be reused Ü Use of automa�on resul�ng in huge material savingsÜ

4.Green Supply Chain The plant has a target to conduct carbon footprint for copper wire suppliers & localize suppliers as much as possible. Through the cluster program, the plant has circulated ques�onnaire on Greening Produc�on Systems to several suppliers. In the vendors meet, the plant conducted awareness sessions on lean & green manufacturingThe plant has implemented projects at the suppliers' end with the objec�ve of reducing the resource intensity of suppliers, some of which are highlighted -

Ü Reducing the energy consump�on at M/S Kedareshwar Engineering in the punching & welding areaÜ Reducing energy consump�on & improving rainwater harves�ng at M/S Automek Products Ü Implemen�ng rainwater harves�ng & reusing ETP treated water at M/S Precision Wire Ltd

5. BiodiversityThe plant has done commendable work in preserving the biodiversity inside the plant as well as in the neighbouring areas. Inside the plant, 13 species of bamboo trees, 267 species of medicinal and other useful plants, 72 endemic and threatened species, 55 orchids, and more than 2,000 trees can be found. NGCPR was set up in 1991 with the objec�ve to preserve the biodiversity in the area and provide a research space to the community. Two new flowering plants were discovered by NGCPR - Brachystelma Naoroji & Arysaema murrayi var. soonubeniae. Two globally threatened species have also been preserved- frerea indica & abu�lon ranadeii. Endangered species

RAIN WATER HARVESTING POND DOUBLE ROW / THREE ROW PUNCHING TOOLS

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Nirmal Abhiyan Program1.8 MW Each Wind Mill REDUCTION IN PACKAGING ENDANGERED SPECIES

VICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng Benefits During the GreenCo assessment several improvement opportuni�es were brought out. The plant has implemented the following ini�a�ves on environmental sustainability:

1. Renewable Energy Godrej Lawkim Motors will be able to source 48% of its total energy from renewable sources from the following projects - The plant has signed a contract with third party agreement for solar power purchase Ü

agreement. This new mechanism will subs�tute nearly 22% of the conven�onal energy genera�ng about 18 lakh units per annum

The plant has also installed a producer gas furnace inside the factory. The producer gas Ü plant will provide a savings of Rupees 1.97 Crore per year.

The two renewable energy projects have helped the plant in subs�tu�ng 48% of its Ü total energy with renewable sources.

2. Water Conserva�on The plant has conducted a detailed hydrogeological survey before construc�ng the rainwater harves�ng structures inside the factory.

Ü 100% of the rainwater harves�ng poten�al has been captured that ensures not a singledrop of rainwater is wasted

Rainwater harves�ng pondÜ Harves�ng ponds of 90 Lakh liters capacity have been constructedÜ The plant has also constructed check dams and harvested more than 25 Lakh liters of Ü

water in a government plot close to the factory. The water harvested is not withdrawn for industrial use and is allowed to recharge the aquifer, thus benefi�ng the socie�es living in the neighbourhood

In addi�on to rainwater harves�ng, the plant has taken the following ini�a�ves to Ü reduce the water consump�on inside the plant -

Displayed signs and several other sessions are conducted to create awareness on Øwater conserva�on

Water consump�on is displayed at prominent loca�ons inside the plantØ Employees are nominated to par�cipate in training programs on drip irriga�on, water Ø

footprint measurement, water reuse & recycle, etc. Installa�on of new pipelines above ground to arrest hidden leakagesØ Installa�on of flow meters at all consump�on pointsØ Re-use of RO reject waterØ Reduced water pressure in taps to reduce domes�c water consump�onØ Leakage arrested in all areas of the plant – annealing cooling tower, machine shop, Ø

canteen, compressor shop motor, etc.

3. Material Conserva�on The plant has done excellent work on material conserva�on and has a clear ac�on plan for material conserva�on in the coming years. The plant incurred a savings of ` 95 Lakhs due to inventory enablers in flow manufacturing. Other ini�a�ves on material conserva�on - Implementa�on of new technologies like motor winding for making high efficiency Ü

motors Lamina�on redesign to reduce material content Ü Double row punching tools instead of single row punching which also leads to reduc�on Ü

in material consump�on Ü Op�miza�on in the winding process thus reducing the quan�ty of Copper wire used

Op�miza�on in die cas�ng ga�ng system Ü Eliminated usage of wood for packaging and saved ̀ 1 million per annumÜ Redesigned packaging so that the packaging material can be reused Ü Use of automa�on resul�ng in huge material savingsÜ

4.Green Supply Chain The plant has a target to conduct carbon footprint for copper wire suppliers & localize suppliers as much as possible. Through the cluster program, the plant has circulated ques�onnaire on Greening Produc�on Systems to several suppliers. In the vendors meet, the plant conducted awareness sessions on lean & green manufacturingThe plant has implemented projects at the suppliers' end with the objec�ve of reducing the resource intensity of suppliers, some of which are highlighted -

Ü Reducing the energy consump�on at M/S Kedareshwar Engineering in the punching & welding areaÜ Reducing energy consump�on & improving rainwater harves�ng at M/S Automek Products Ü Implemen�ng rainwater harves�ng & reusing ETP treated water at M/S Precision Wire Ltd

5. BiodiversityThe plant has done commendable work in preserving the biodiversity inside the plant as well as in the neighbouring areas. Inside the plant, 13 species of bamboo trees, 267 species of medicinal and other useful plants, 72 endemic and threatened species, 55 orchids, and more than 2,000 trees can be found. NGCPR was set up in 1991 with the objec�ve to preserve the biodiversity in the area and provide a research space to the community. Two new flowering plants were discovered by NGCPR - Brachystelma Naoroji & Arysaema murrayi var. soonubeniae. Two globally threatened species have also been preserved- frerea indica & abu�lon ranadeii. Endangered species

RAIN WATER HARVESTING POND DOUBLE ROW / THREE ROW PUNCHING TOOLS

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Nirmal Abhiyan Program1.8 MW Each Wind Mill REDUCTION IN PACKAGING ENDANGERED SPECIES

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

The Godrej Group is one of the largest players of Home Appliances in India. In 1958, Godrej was the First Indian Company to manufacture Refrigerators and since then, it has become synonymous with the category.

Godrej and Boyce Mfg. Co. Ltd., Appliance Division, Shirwal manufactures Direct Cool Refrigerators and Frost Free Refrigerators in four manufacturing lines and a separate line for the manufacture of Chotukool. Fully automa�c and semiautoma�c washing machines are manufactured in a single line. The plant is also equipped with a state-of-the-art facility that was built in consulta�on with GIZ, Germany for the manufacture of Split Air-condi�oners. Godrej Appliances launched India's first 100% green refrigerator series in 2002 which was CFC, HFC and HCFC free and is the only company to have 100% green refrigerators un�l date.

Company Profile

Godrej & BoyceMfg. Co. Ltd.,

Shirwal

Appliance Division

Oct'13-Apr'14

Implementa�onof Sugges�ons

Iden�fied

On-siteRe-Assessment

May2014

Oct2013

GreenCoGold Ra�ng

Aug2013

Launch ofGreenCo

Case Study VII

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

The Godrej Group is one of the largest players of Home Appliances in India. In 1958, Godrej was the First Indian Company to manufacture Refrigerators and since then, it has become synonymous with the category.

Godrej and Boyce Mfg. Co. Ltd., Appliance Division, Shirwal manufactures Direct Cool Refrigerators and Frost Free Refrigerators in four manufacturing lines and a separate line for the manufacture of Chotukool. Fully automa�c and semiautoma�c washing machines are manufactured in a single line. The plant is also equipped with a state-of-the-art facility that was built in consulta�on with GIZ, Germany for the manufacture of Split Air-condi�oners. Godrej Appliances launched India's first 100% green refrigerator series in 2002 which was CFC, HFC and HCFC free and is the only company to have 100% green refrigerators un�l date.

Company Profile

Godrej & BoyceMfg. Co. Ltd.,

Shirwal

Appliance Division

Oct'13-Apr'14

Implementa�onof Sugges�ons

Iden�fied

On-siteRe-Assessment

May2014

Oct2013

GreenCoGold Ra�ng

Aug2013

Launch ofGreenCo

Case Study VII

VIICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng BenefitsGodrej and Boyce Mfg. Co. Ltd., Appliance Division, Shirwal led by a proac�ve corporate had taken a lot of environmental sustainability ini�a�ves even before the implementa�on of the GreenCo Ra�ng System. During its transi�on from Gold to Pla�num, GreenCo helped GAD iden�fy specific and important areas for it to work on and improve its environmental performance. The ac�vi�es ini�ated as a result of the implementa�on of the GreenCo Ra�ng System are described below - 1. Energy EfficiencyThrough consistent efforts and several ini�a�ves, Godrej Appliances Shirwal has shown a good specific energy consump�on reduc�on trend of 56% over a period of nine years. The GreenCo assessment brought out various opportuni�es for improvement and some of the major improvement ac�ons taken are described below -

Ü Developed energy index for equipmentÜ Process wise benchmarking was done for injec�on moulding and vacuum forming processes. Benchmarking of Injec�on Moulding (IM) process was done with other industries having the IM process. GAD, Shirwal included the following for the IM process benchmarking -

Ø Manufacturers supplying components to the appliances industry Ø Manufacturers of auto components

Through this exercise, GAD, Shirwal has iden�fied newer op�ons such as use of servo controlled drives for injec�on moulding instead of hydraulic drives Ü Conducted flame profile study for producer gas plantÜ Undertook a study based on the load capacity to evaluate op�mum usage of compressorsÜ Reduc�on of power consump�on from 1.6 units per appliance to 1.43 units per appliance through

Ø Reduc�on in air leakage from 14% to 8% which was achieved by assigning a dedicated team for iden�fying and correc�ng air leakage and also by the use of an ultrasonic air leak tester

Ø Development of an in-house auto air compressor selec�on unit to eliminate manual interven�on in air compressor selec�on

Evapora�ve cooling unit in conference hall Ü Implementa�on of energy scorecard at the shop floor to improve opera�onal efficiency Ü

through performance comparison of equipments & operators

GAD, Shirwal recorded 18% reduc�on in SEC post GreenCo implementa�on in comparison to 13% reduc�on in the previous years.

Reduc�on in powerconsump�on1.6 units per

appliance to 1.43 units perappliance

Annual Recurring Savings achieved

a�er first GreenCo assessment by implemen�ng

addi�onal resource conserva�on

projects & improved systems is `5 Million

SEC REDUCTION TREND BEFORE AND AFTER GREENCO ASSESSMENT

2.Water Conserva�onFraming aspira�onal targets and execu�ng them was one of the suggested improvement areas. GAD, Shirwal revised its target of achieving water neutral status to 2015-16 from 2020. The benefits achieved by the ac�vi�es undertaken a�er GreenCo Assessment is shown below

Improvement in water metering and monitoring 90.58% to 92.62%

Reduc�on in specific 95 litres per appliance to 84 litres water consump�on per appliance

The ac�vi�es that were executed are highlighted - Separate monitoring for fixed and variable water consump�on is conducted; this has |Ü

iden�fied opportuni�es which led to reduc�on in water consump�on by 4% Developed zone wise water index to ensure improved monitoringÜ Monthly pressure test to monitor the condi�on of underground pipelines and leakage Ü

mapping for en�re plant was conducted Enhanced use of water efficient gadgets in washrooms an�cipa�ng savings of minimum Ü

1cum per year per water outlet Use of ter�ary water in the pre-treatment process by recycling 450 cum of water Ü

annually

3.Renewable Energy and Greenhouse Gas Emission reduc�onRenewable energy has been an area of focus for GAD, Shirwal and the major projects executed and ac�vi�es planned are men�oned below – Combined solar hea�ng for laboratories saving nearly 25000 units of electricity Ü

Ü Installed roo�op solar panels that powers office computers and ligh�ng equipment Target to increase RE share by 70% through offsite power purchase agreement Ü Use of ba�ery operated clamp forkli� in place of diesel forkli�Ü Use of producer gas generated from bio-mass for hanger burningÜPercentage share of renewable energy is 23% and target to achieve 70% by 2017 The excellent efforts put into the use of renewable energy and improving energy efficiency has resulted in reduced GHG emissions. The reduc�on achieved is as shown -

Percentage share of renewable

energy is 23% and target to achieve

70% by 2017

REDUCTION TREND IN GHG EMISSIONS

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

IMPROVEMENT IN WATER MANAGEMENT

VIICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng BenefitsGodrej and Boyce Mfg. Co. Ltd., Appliance Division, Shirwal led by a proac�ve corporate had taken a lot of environmental sustainability ini�a�ves even before the implementa�on of the GreenCo Ra�ng System. During its transi�on from Gold to Pla�num, GreenCo helped GAD iden�fy specific and important areas for it to work on and improve its environmental performance. The ac�vi�es ini�ated as a result of the implementa�on of the GreenCo Ra�ng System are described below - 1. Energy EfficiencyThrough consistent efforts and several ini�a�ves, Godrej Appliances Shirwal has shown a good specific energy consump�on reduc�on trend of 56% over a period of nine years. The GreenCo assessment brought out various opportuni�es for improvement and some of the major improvement ac�ons taken are described below -

Ü Developed energy index for equipmentÜ Process wise benchmarking was done for injec�on moulding and vacuum forming processes. Benchmarking of Injec�on Moulding (IM) process was done with other industries having the IM process. GAD, Shirwal included the following for the IM process benchmarking -

Ø Manufacturers supplying components to the appliances industry Ø Manufacturers of auto components

Through this exercise, GAD, Shirwal has iden�fied newer op�ons such as use of servo controlled drives for injec�on moulding instead of hydraulic drives Ü Conducted flame profile study for producer gas plantÜ Undertook a study based on the load capacity to evaluate op�mum usage of compressorsÜ Reduc�on of power consump�on from 1.6 units per appliance to 1.43 units per appliance through

Ø Reduc�on in air leakage from 14% to 8% which was achieved by assigning a dedicated team for iden�fying and correc�ng air leakage and also by the use of an ultrasonic air leak tester

Ø Development of an in-house auto air compressor selec�on unit to eliminate manual interven�on in air compressor selec�on

Evapora�ve cooling unit in conference hall Ü Implementa�on of energy scorecard at the shop floor to improve opera�onal efficiency Ü

through performance comparison of equipments & operators

GAD, Shirwal recorded 18% reduc�on in SEC post GreenCo implementa�on in comparison to 13% reduc�on in the previous years.

Reduc�on in powerconsump�on1.6 units per

appliance to 1.43 units perappliance

Annual Recurring Savings achieved

a�er first GreenCo assessment by implemen�ng

addi�onal resource conserva�on

projects & improved systems is `5 Million

SEC REDUCTION TREND BEFORE AND AFTER GREENCO ASSESSMENT

2.Water Conserva�onFraming aspira�onal targets and execu�ng them was one of the suggested improvement areas. GAD, Shirwal revised its target of achieving water neutral status to 2015-16 from 2020. The benefits achieved by the ac�vi�es undertaken a�er GreenCo Assessment is shown below

Improvement in water metering and monitoring 90.58% to 92.62%

Reduc�on in specific 95 litres per appliance to 84 litres water consump�on per appliance

The ac�vi�es that were executed are highlighted - Separate monitoring for fixed and variable water consump�on is conducted; this has |Ü

iden�fied opportuni�es which led to reduc�on in water consump�on by 4% Developed zone wise water index to ensure improved monitoringÜ Monthly pressure test to monitor the condi�on of underground pipelines and leakage Ü

mapping for en�re plant was conducted Enhanced use of water efficient gadgets in washrooms an�cipa�ng savings of minimum Ü

1cum per year per water outlet Use of ter�ary water in the pre-treatment process by recycling 450 cum of water Ü

annually

3.Renewable Energy and Greenhouse Gas Emission reduc�onRenewable energy has been an area of focus for GAD, Shirwal and the major projects executed and ac�vi�es planned are men�oned below – Combined solar hea�ng for laboratories saving nearly 25000 units of electricity Ü

Ü Installed roo�op solar panels that powers office computers and ligh�ng equipment Target to increase RE share by 70% through offsite power purchase agreement Ü Use of ba�ery operated clamp forkli� in place of diesel forkli�Ü Use of producer gas generated from bio-mass for hanger burningÜPercentage share of renewable energy is 23% and target to achieve 70% by 2017 The excellent efforts put into the use of renewable energy and improving energy efficiency has resulted in reduced GHG emissions. The reduc�on achieved is as shown -

Percentage share of renewable

energy is 23% and target to achieve

70% by 2017

REDUCTION TREND IN GHG EMISSIONS

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

IMPROVEMENT IN WATER MANAGEMENT

First refrigerator manufacturer in

India to introduce 100% CFC, HFC,

HCFC free refrigerators

VIICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

4.Waste Management & Material Conserva�onGAD, Shirwal has excellent systems in place to monitor its waste management and material conserva�on ac�vi�es. Some of its ac�vi�es in these areas are highlighted Use of ETP sludge and hanger burning ash for brick manufacturingÜ Reuse of foam pieces from rejected refrigeratorsÜ Reuse of all plas�c scrap a�er regrinding and palle�zingÜ Oil filtra�on, degasifica�on and reuseÜ Carton packing replaced with stretch film packagingÜ Use of pulp and paper packaging for refrigerators in places of PS sheetsÜ

5. Green Supply Chain GAD, Shirwal aims to extend its sustainability ini�a�ves in its supply chain and adopts a cluster approach for suppliers. In addi�on to the implementa�on of concepts such as 5S, my machine concept, quality & produc�vity improvement, GAD, Shirwal has incorporated several Green concepts in the cluster approach. Highlighted below is some of GAD, Shirwal's ini�a�ves -

Ü Development of green sourcing policy and green procurement guidelines Encouraged 2 suppliers to locate near the plant thereby increasing close proximity Ü

procurement Iden�fica�on and implementa�on of methods for indigeniza�on or localiza�on of Ü

imported components 100% RoHS compliant material procurement since 1st May 2014Ü 58 cri�cal suppliers covered under the mapping & monitoring exercise for Ü

Energy/Water/Waste/Toxicity

6. Product Stewardship GAD, Shirwal has taken all possible measures to ensure the quality of its products throughout the supply chain. Ini�a�ves taken in areas of product stewardship and LCA are men�oned below -

Ü First refrigerator manufacturer in India to introduce 100% CFC, HFC, HCFC free refrigerators way back in 2002. GAD, Shirwal has switched over to HC refrigerant which has zero ODS and a GWP of 3

Achieved 100% RoHS compliance for all products and processesÜ Implementa�on of bar code system for component traceability and to trace B2B warranty Ü

in case of component failure Manufacturing and usage of high EER compressorsÜ Improvement in insula�on proper�es to reduce losses during opera�onÜ Documenta�on of best prac�ces for product handlingÜ Developed customer sa�sfac�on index. Customer survey is conducted through third Ü

party and improvement ac�ons are taken based on the feedback

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Kirloskar Brothers Limited (KBL) is an electrical pump manufacturing company with exper�se in engineering and manufacture of systems for fluid management. KBL provides complete fluid management solu�ons for large infrastructure projects in the areas of water supply, power plants, irriga�on, oil & gas and marine & defense.

Kirloskar Brothers Limited, Coimbatore is located in Kaniyur village of Coimbatore district. This small compact plant started its opera�on in the year 2011. The unit manufactures 50,000 pumps per month on an average. KBL Coimbatore is the “First unit in the mini pump manufacturing sector” to a�ain the pres�gious GreenCo Ra�ng. Good efforts in all ver�cals of resource conserva�on, supplier educa�on and facilita�on of green prac�ces of suppliers and vendors, implementa�on of systems such as SMDS, KANBAN, ERP and many more, has earned the plant several awards and accolades.

Company Profile

Kirloskar BrothersLimited

Coimbatore

Case Study VIII

Sep2013

Sep2013

Launch ofGreenCo

Training & Handholding

On-site Assessment

June2014

First refrigerator manufacturer in

India to introduce 100% CFC, HFC,

HCFC free refrigerators

VIICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

4.Waste Management & Material Conserva�onGAD, Shirwal has excellent systems in place to monitor its waste management and material conserva�on ac�vi�es. Some of its ac�vi�es in these areas are highlighted Use of ETP sludge and hanger burning ash for brick manufacturingÜ Reuse of foam pieces from rejected refrigeratorsÜ Reuse of all plas�c scrap a�er regrinding and palle�zingÜ Oil filtra�on, degasifica�on and reuseÜ Carton packing replaced with stretch film packagingÜ Use of pulp and paper packaging for refrigerators in places of PS sheetsÜ

5. Green Supply Chain GAD, Shirwal aims to extend its sustainability ini�a�ves in its supply chain and adopts a cluster approach for suppliers. In addi�on to the implementa�on of concepts such as 5S, my machine concept, quality & produc�vity improvement, GAD, Shirwal has incorporated several Green concepts in the cluster approach. Highlighted below is some of GAD, Shirwal's ini�a�ves -

Ü Development of green sourcing policy and green procurement guidelines Encouraged 2 suppliers to locate near the plant thereby increasing close proximity Ü

procurement Iden�fica�on and implementa�on of methods for indigeniza�on or localiza�on of Ü

imported components 100% RoHS compliant material procurement since 1st May 2014Ü 58 cri�cal suppliers covered under the mapping & monitoring exercise for Ü

Energy/Water/Waste/Toxicity

6. Product Stewardship GAD, Shirwal has taken all possible measures to ensure the quality of its products throughout the supply chain. Ini�a�ves taken in areas of product stewardship and LCA are men�oned below -

Ü First refrigerator manufacturer in India to introduce 100% CFC, HFC, HCFC free refrigerators way back in 2002. GAD, Shirwal has switched over to HC refrigerant which has zero ODS and a GWP of 3

Achieved 100% RoHS compliance for all products and processesÜ Implementa�on of bar code system for component traceability and to trace B2B warranty Ü

in case of component failure Manufacturing and usage of high EER compressorsÜ Improvement in insula�on proper�es to reduce losses during opera�onÜ Documenta�on of best prac�ces for product handlingÜ Developed customer sa�sfac�on index. Customer survey is conducted through third Ü

party and improvement ac�ons are taken based on the feedback

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Kirloskar Brothers Limited (KBL) is an electrical pump manufacturing company with exper�se in engineering and manufacture of systems for fluid management. KBL provides complete fluid management solu�ons for large infrastructure projects in the areas of water supply, power plants, irriga�on, oil & gas and marine & defense.

Kirloskar Brothers Limited, Coimbatore is located in Kaniyur village of Coimbatore district. This small compact plant started its opera�on in the year 2011. The unit manufactures 50,000 pumps per month on an average. KBL Coimbatore is the “First unit in the mini pump manufacturing sector” to a�ain the pres�gious GreenCo Ra�ng. Good efforts in all ver�cals of resource conserva�on, supplier educa�on and facilita�on of green prac�ces of suppliers and vendors, implementa�on of systems such as SMDS, KANBAN, ERP and many more, has earned the plant several awards and accolades.

Company Profile

Kirloskar BrothersLimited

Coimbatore

Case Study VIII

Sep2013

Sep2013

Launch ofGreenCo

Training & Handholding

On-site Assessment

June2014

VIIICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng BenefitsKBL, Coimbatore has taken good efforts to comply with the GreenCo Ra�ng System which has led to significant improvements in its overall environmental performance. Several Ini�a�ves and projects were implemented across the GreenCo parameters by KBL, Coimbatore before and a�er the GreenCo Assessment. Some of their ini�a�ves are highlighted –

1. Energy EfficiencyKBL Coimbatore has been implemen�ng several energy efficiency and produc�vity improvement projects. The plant has achieved 17.1% reduc�on in specific energy consump�on in the last three years. KBL Coimbatore is one amongst the few companies to have benchmarked their energy performance with their peers and compe�tors.

2. Renewable EnergyKBL Coimbatore has replaced all the street lights into solar street lights within their facility. Kirloskar Brothers Limited, as a corporate ini�a�ve, owns seven windmills supplying about 5.6 MW of wind power. KBL Coimbatore receives share about 4.15% of the total wind power generated. The plant has planned to install 20 KWp Solar PV power sta�ons with ba�ery back up in the year 2015-16. 3. Water Conserva�onEven though the water consump�on is less in the plant, KBL Coimbatore has implemented several ini�a�ves to conserve water. The plant has achieved 10% reduc�on in specific water consump�on in the last three years of its opera�on.

The plant has put in sincere efforts in capturing the rain water harves�ng poten�al of their region. With collec�on and dispersion trenches inside their facility, they have been able to capture 100% of their total rain water harves�ng poten�al of their roof top and paved areas.

4. GHG Emissions Mi�ga�onKBL Coimbatore has been inventorizing its scope1, 2 and 3 GHG emissions for the last tree years. As a result of op�mizing the inbound and outbound logis�cs, KBL Coimbatore has reduced GHG emissions from inbound logis�cs by 46 %, through migra�ng from pickup vans to larger tempos and GHG emissions from out bound logis�cs significantly reduced through the u�liza�on of full load trucks.

5. Waste Management and Material Conserva�onSome of KBL Coimbatore's ini�a�ves on waste management and material conserva�on are shown below –

Ü Reduc�on in disposal of used oil by 87.5% and oil soaked co�on waste by 33%Ü Clear framework on material procurement using Synchronized Manufacturing and Distribu�on Systems (SMDS), KANBAN and ERP systemsÜ 31% reduc�on in virgin material consump�onÜ 16% reduc�on in packaging material consump�on

Ø Switching over to bulk packaging from individual cartonsØ Reuse of carton boxes for a minimum of five �mesØ Switching from large carton boxes to large reusable steel wire mesh bins

6. Green Supply ChainKBL Coimbatore has made sincere efforts to iden�fy their cri�cal suppliers and work with them to minimize their environmental impact.

Ü The unit has an established system for conduc�ng supplier and vendor evalua�on during their vendor registra�on process

KBL, Coimbatore has introduced environmental criteria in their vendor evalua�on tool. Ü Preference is given to vendors with good scores

KBL, as a group, has implemented the vendor portal tool for online communica�on with Ü their vendors.

7.Product StewardshipSome of KBL, Coimbatore's ini�a�ves are shown below -

Ü KBL Coimbatore has subs�tuted the hazardous substance in its product, cu�ng oil, with food grade oil

Subs�tuted hazardous substance in the process, lead, through the use of lead free Ü soldering flux

The organiza�on has taken several measures to enhance resource efficiency that has helped them to emerge as a Rated unit. GreenCo is a con�nuous journey and many new GreenCo Silverini�a�ves have been taken up by the plant for implementa�on. The plant has worked extensively on material reduc�on, toxicity reduc�on, be�er inventory management, use of online vendor portal and Green Cover development which has helped them gain cost benefits and improve their overall compe��veness.

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Nirmal Abhiyan Program1.8 MW Each Wind Mill Reduc�on in Packaging Endangered Species

VIIICase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng BenefitsKBL, Coimbatore has taken good efforts to comply with the GreenCo Ra�ng System which has led to significant improvements in its overall environmental performance. Several Ini�a�ves and projects were implemented across the GreenCo parameters by KBL, Coimbatore before and a�er the GreenCo Assessment. Some of their ini�a�ves are highlighted –

1. Energy EfficiencyKBL Coimbatore has been implemen�ng several energy efficiency and produc�vity improvement projects. The plant has achieved 17.1% reduc�on in specific energy consump�on in the last three years. KBL Coimbatore is one amongst the few companies to have benchmarked their energy performance with their peers and compe�tors.

2. Renewable EnergyKBL Coimbatore has replaced all the street lights into solar street lights within their facility. Kirloskar Brothers Limited, as a corporate ini�a�ve, owns seven windmills supplying about 5.6 MW of wind power. KBL Coimbatore receives share about 4.15% of the total wind power generated. The plant has planned to install 20 KWp Solar PV power sta�ons with ba�ery back up in the year 2015-16. 3. Water Conserva�onEven though the water consump�on is less in the plant, KBL Coimbatore has implemented several ini�a�ves to conserve water. The plant has achieved 10% reduc�on in specific water consump�on in the last three years of its opera�on.

The plant has put in sincere efforts in capturing the rain water harves�ng poten�al of their region. With collec�on and dispersion trenches inside their facility, they have been able to capture 100% of their total rain water harves�ng poten�al of their roof top and paved areas.

4. GHG Emissions Mi�ga�onKBL Coimbatore has been inventorizing its scope1, 2 and 3 GHG emissions for the last tree years. As a result of op�mizing the inbound and outbound logis�cs, KBL Coimbatore has reduced GHG emissions from inbound logis�cs by 46 %, through migra�ng from pickup vans to larger tempos and GHG emissions from out bound logis�cs significantly reduced through the u�liza�on of full load trucks.

5. Waste Management and Material Conserva�onSome of KBL Coimbatore's ini�a�ves on waste management and material conserva�on are shown below –

Ü Reduc�on in disposal of used oil by 87.5% and oil soaked co�on waste by 33%Ü Clear framework on material procurement using Synchronized Manufacturing and Distribu�on Systems (SMDS), KANBAN and ERP systemsÜ 31% reduc�on in virgin material consump�onÜ 16% reduc�on in packaging material consump�on

Ø Switching over to bulk packaging from individual cartonsØ Reuse of carton boxes for a minimum of five �mesØ Switching from large carton boxes to large reusable steel wire mesh bins

6. Green Supply ChainKBL Coimbatore has made sincere efforts to iden�fy their cri�cal suppliers and work with them to minimize their environmental impact.

Ü The unit has an established system for conduc�ng supplier and vendor evalua�on during their vendor registra�on process

KBL, Coimbatore has introduced environmental criteria in their vendor evalua�on tool. Ü Preference is given to vendors with good scores

KBL, as a group, has implemented the vendor portal tool for online communica�on with Ü their vendors.

7.Product StewardshipSome of KBL, Coimbatore's ini�a�ves are shown below -

Ü KBL Coimbatore has subs�tuted the hazardous substance in its product, cu�ng oil, with food grade oil

Subs�tuted hazardous substance in the process, lead, through the use of lead free Ü soldering flux

The organiza�on has taken several measures to enhance resource efficiency that has helped them to emerge as a Rated unit. GreenCo is a con�nuous journey and many new GreenCo Silverini�a�ves have been taken up by the plant for implementa�on. The plant has worked extensively on material reduc�on, toxicity reduc�on, be�er inventory management, use of online vendor portal and Green Cover development which has helped them gain cost benefits and improve their overall compe��veness.

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Nirmal Abhiyan Program1.8 MW Each Wind Mill Reduc�on in Packaging Endangered Species

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Established in 1936, ACC Ltd. has been a pioneer and trend-se�er in cement and concrete technology. Among the first companies in India to include commitment towards environment protec�on as a corporate objec�ve, ACC Ltd. has won accolades for environment friendly measures taken at its plants and mines, and has also been felicitated for its acts of good corporate ci�zenship. ACC Ltd. is one of the largest producers of cement in the country with an installed capacity of about 27 million tonnes per annum.

ACC Ltd., Kymore Cement Works (KCW) was established in 1923 with total capacity of 0.09 MTPA. In 2012, the plant was rated the 1st among ACC plants and 4th in the Holcim group based on the group's internal performance index which covers produc�on cost, product quality, energy consump�on, maintenance cost, environmental protec�on, etc.

Company Profile

ACC LimitedKymore Cement Works

Case Study IX

March2014

Apr'2014

Launch ofGreenCo

Training & Handholding

On-site Assessment

June2014

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Established in 1936, ACC Ltd. has been a pioneer and trend-se�er in cement and concrete technology. Among the first companies in India to include commitment towards environment protec�on as a corporate objec�ve, ACC Ltd. has won accolades for environment friendly measures taken at its plants and mines, and has also been felicitated for its acts of good corporate ci�zenship. ACC Ltd. is one of the largest producers of cement in the country with an installed capacity of about 27 million tonnes per annum.

ACC Ltd., Kymore Cement Works (KCW) was established in 1923 with total capacity of 0.09 MTPA. In 2012, the plant was rated the 1st among ACC plants and 4th in the Holcim group based on the group's internal performance index which covers produc�on cost, product quality, energy consump�on, maintenance cost, environmental protec�on, etc.

Company Profile

ACC LimitedKymore Cement Works

Case Study IX

March2014

Apr'2014

Launch ofGreenCo

Training & Handholding

On-site Assessment

June2014

IXCase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng Benefits The GreenCo assessment brought out several improvement opportuni�es and some of the ini�a�ves that have been implemented by KCW are men�oned below:

1. Energy Efficiency Ü The plant has system of having upfront financial resource alloca�on for energy saving

projects. This is to ensure that any ideas on energy saving projects are not wai�ng for financial resources and can be implemented without any delay

Ü Energy scorecard: The performance appraisal of certain employees is based on the successful reduc�on of energy consump�on inside the plant. Factors included in individual's KPI are – Ø Specific Thermal Energy Consump�on Ø Electrical Energy Consump�on in clinkering Ø Electrical Energy Consump�on in grinding Ø Electrical Energy Consump�on cementØ Total Energy Consump�on for cement manufactured

Major energy efficiency projects implemented include – ÜØ MV VFD for Emill fanØ Ter�ary crusher – closed circui�ngØ Installa�on of high efficiency fan with VFD for Kiln 1 Bag houseØ Cyclone op�miza�on by conduc�ng CFD analysisØ Installa�on of LT VFD for BFP in power plantØ Installa�on of high efficiency fan with VFD for Kiln 2

2. Water Conserva�on The plant has conducted a detailed hydrogeological survey before construc�ng rainwater harves�ng structures inside the factory as well as beyond the fence. In 1960, the plant constructed Harvey canal and converted the mined out pits to water reservoirs to store rainwater. The runoff from the neighbouring Kymore hills is collected in reservoirs and is available for communi�es around the factory for domes�c water usage as well as agriculture.

3. Waste Management The company's commitment towards ecological sustainability is clearly visible in the exclusive Alternate Fuel and Raw Material policy. The plant has set up a world class pre-processing pla�orm to handle municipal solid waste and other hazardous waste that can be used as alterna�ve fuel in the cement plant. The maximum design capacity for pre-processing & co-processing is 52,000 tons. Waste from FMCG companies, paint sludge, ETP sludge, waste tyre scrap, plas�c waste, carbon black and other hazardous industrial waste are used as alternate fuel. The plant has a very clear target to achieve thermal subs�tu�on rate of 16.3% at kiln 1 & 7.5% at kiln 2 by 2016. A separate budget of Rupees 800 million has been set aside to achieve this target.

4. Green Logis�cs ACC Ltd., at a corporate level, ini�ated a major program to op�mize the logis�cs thereby reducing the opera�ng cost and emissions.

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Nirmal Abhiyan Program1.8 MW Each Wind Mill Reduc�on in Packaging Endangered Species

ACC has rolled out a logis�c excellence programme at three plants — Tikaria in U�ar Pradesh, Damodhar in West Bengal and Thondebhavi in Karnataka. It is installing radio frequency iden�fica�on (RFID) so�ware along with global posi�on system (GPS) on all the 12,000 vehicles serving the company. RFID is a tracking system that uses intelligent bar codes to track items.

Adop�on Modern Technologies like RFID with GPS in vehicles Ü

Monitor consump�on / km / tonÜ

Improved truck loading, reduced turnaround �me, reduced loading hours at plantÜ

Gradual implementa�on in all 17 plantsÜ

As a pilot project, it installed RFID and GPS in 600 vehicles servicing the three plants. The company can now load 58 rail rakes in 7-9 hours compared with 16-20 hours taken earlier. Similarly, truck movement inside the Tikaria plant was reduced from 120 to 20 by improving efficiency. With the installa�on of RFID, the loading schedule has been fine-tuned to reduce the wai�ng �me of trucks inside the plant to two hours from five hours earlier.

A�er the successful pilot, the company intends to install GPS and RFID in all 17 plants over two to three years.

IXCase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng Benefits The GreenCo assessment brought out several improvement opportuni�es and some of the ini�a�ves that have been implemented by KCW are men�oned below:

1. Energy Efficiency Ü The plant has system of having upfront financial resource alloca�on for energy saving

projects. This is to ensure that any ideas on energy saving projects are not wai�ng for financial resources and can be implemented without any delay

Ü Energy scorecard: The performance appraisal of certain employees is based on the successful reduc�on of energy consump�on inside the plant. Factors included in individual's KPI are – Ø Specific Thermal Energy Consump�on Ø Electrical Energy Consump�on in clinkering Ø Electrical Energy Consump�on in grinding Ø Electrical Energy Consump�on cementØ Total Energy Consump�on for cement manufactured

Major energy efficiency projects implemented include – ÜØ MV VFD for Emill fanØ Ter�ary crusher – closed circui�ngØ Installa�on of high efficiency fan with VFD for Kiln 1 Bag houseØ Cyclone op�miza�on by conduc�ng CFD analysisØ Installa�on of LT VFD for BFP in power plantØ Installa�on of high efficiency fan with VFD for Kiln 2

2. Water Conserva�on The plant has conducted a detailed hydrogeological survey before construc�ng rainwater harves�ng structures inside the factory as well as beyond the fence. In 1960, the plant constructed Harvey canal and converted the mined out pits to water reservoirs to store rainwater. The runoff from the neighbouring Kymore hills is collected in reservoirs and is available for communi�es around the factory for domes�c water usage as well as agriculture.

3. Waste Management The company's commitment towards ecological sustainability is clearly visible in the exclusive Alternate Fuel and Raw Material policy. The plant has set up a world class pre-processing pla�orm to handle municipal solid waste and other hazardous waste that can be used as alterna�ve fuel in the cement plant. The maximum design capacity for pre-processing & co-processing is 52,000 tons. Waste from FMCG companies, paint sludge, ETP sludge, waste tyre scrap, plas�c waste, carbon black and other hazardous industrial waste are used as alternate fuel. The plant has a very clear target to achieve thermal subs�tu�on rate of 16.3% at kiln 1 & 7.5% at kiln 2 by 2016. A separate budget of Rupees 800 million has been set aside to achieve this target.

4. Green Logis�cs ACC Ltd., at a corporate level, ini�ated a major program to op�mize the logis�cs thereby reducing the opera�ng cost and emissions.

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Nirmal Abhiyan Program1.8 MW Each Wind Mill Reduc�on in Packaging Endangered Species

ACC has rolled out a logis�c excellence programme at three plants — Tikaria in U�ar Pradesh, Damodhar in West Bengal and Thondebhavi in Karnataka. It is installing radio frequency iden�fica�on (RFID) so�ware along with global posi�on system (GPS) on all the 12,000 vehicles serving the company. RFID is a tracking system that uses intelligent bar codes to track items.

Adop�on Modern Technologies like RFID with GPS in vehicles Ü

Monitor consump�on / km / tonÜ

Improved truck loading, reduced turnaround �me, reduced loading hours at plantÜ

Gradual implementa�on in all 17 plantsÜ

As a pilot project, it installed RFID and GPS in 600 vehicles servicing the three plants. The company can now load 58 rail rakes in 7-9 hours compared with 16-20 hours taken earlier. Similarly, truck movement inside the Tikaria plant was reduced from 120 to 20 by improving efficiency. With the installa�on of RFID, the loading schedule has been fine-tuned to reduce the wai�ng �me of trucks inside the plant to two hours from five hours earlier.

A�er the successful pilot, the company intends to install GPS and RFID in all 17 plants over two to three years.

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Tata Motors Ltd. is India's largest automobile company. Tata Motors Ltd. manufactures a variety of products across the commercial vehicles segment and the passenger vehicles segment. Tata Motors equally focuses on using environment friendly technologies in emission reduc�on and u�lizing alterna�ve fuels. It has developed electric and hybrid vehicles both for personal and public transporta�on. It has also been implemen�ng several environment-friendly technologies in manufacturing processes, significantly enhancing resource conserva�on.

Tata Motors Ltd., Passenger Vehicle Business Unit, Pimpri, with a total plot area of 8.21 Lakh sq. meters, started its opera�ons in 1998. Tata Motors Limited PVBU, was rated in GreenCo GoldJune 2014.

Company Profile

Tata Motors LimitedPassenger Vehicle

Business UnitPimpri, Pune

Case Study X

Nov2013

Dec2013

Launch ofGreenCo

Training & Handholding

On-siteAssessment

June2014

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Tata Motors Ltd. is India's largest automobile company. Tata Motors Ltd. manufactures a variety of products across the commercial vehicles segment and the passenger vehicles segment. Tata Motors equally focuses on using environment friendly technologies in emission reduc�on and u�lizing alterna�ve fuels. It has developed electric and hybrid vehicles both for personal and public transporta�on. It has also been implemen�ng several environment-friendly technologies in manufacturing processes, significantly enhancing resource conserva�on.

Tata Motors Ltd., Passenger Vehicle Business Unit, Pimpri, with a total plot area of 8.21 Lakh sq. meters, started its opera�ons in 1998. Tata Motors Limited PVBU, was rated in GreenCo GoldJune 2014.

Company Profile

Tata Motors LimitedPassenger Vehicle

Business UnitPimpri, Pune

Case Study X

Nov2013

Dec2013

Launch ofGreenCo

Training & Handholding

On-siteAssessment

June2014

XCase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng Benefits Some of the ini�a�ves taken by Tata Motors Ltd. across various GreenCo parameters are men�oned below: 1. Water Conserva�on The plant has done commendable work in subs�tu�ng freshwater with harvested rainwater. The rainwater is first collected in a storage tank and then sent for chlorina�on, filtra�on through pressure sand filter and ac�vated carbon filters. Filtered water is mixed with raw water and used in the process. In addi�on to rain water harves�ng, the plant has taken the following ini�a�ves to reduce the water consump�on inside the plant - Filtered treated effluent water used for secondary use such as toilet flushing, vehicle Ü

washing and floor washing Increased the use of treated effluent supply for hor�culture purpose by expanding and Ü

revamping the hor�culture supply distribu�on network Use of low flow faucets and valves to control the flow of waterÜ Awareness crea�on on water conserva�on through displaysÜ Thorough water footprint study by an external expertÜ Awareness sessions conducted throughout the year to sensi�ze the employees on the Ü

urgent need to save water Arrested underground leakageÜ

38,590 cubic meters of

harvested rain water was reused

in the process which resulted in an annual savings

of ` 9.75 Lakh per annum

85 Lakh kWh savings was achieved by

implementa�on of several

energy saving ideas

Wind UnitsRupee

Savings/AnnumCO Emissions2

Offset / Annum

80.35 MillionUnits

Rs. 76.8 Million75,226 tonnes of

CO2

SAVINGS ACHIEVED BY SUBSTITUTING CONVENTIONAL ENERGY WITH RENEWABLE ENERGY

RAIN WATER HARVESTING TANK

2. Energy Efficiency Tata Motors Ltd. monitors fixed and variable energy consump�on separately for efficient Ü

monitoring of energy consump�on Daily variance analysis helps the plant in monitoring and understanding the energy Ü

consump�on inside the plant 59 energy saving ideas were implemented in a year in different sec�ons of the plant such Ü

as paint-shop, welding, press-shop which brought in significant savings Tata Motors Ltd. is commi�ed to u�lizing renewable energy which is reflected in the Ü

investment made in wind farms offsite to subs�tute 42% of its total energy needs

The company owns cap�ve wind mills in Satara and Supa in Maharashtra. In order to maximize the benefits of use of renewable power, the plant also has third party contracts with companies like M/s Karma Energy Ltd & Weizmann Ltd, M/s Sarla Performance Fibers Ltd., M/s Global Energy Ltd.

3. Waste Management The plant has taken several ini�a�ves to reuse and recycle waste and some of them are men�oned below - In-house Central Oil Reclama�on Centre for recovery of dirty oils to extend the useful life Ü

of waste oil Dirty flushing thinner is recycled and the recovered thinner is used for low end uses in the Ü

paint shop Paint sludge is recycled back and used in the industrial primerÜ Residual sealant containers are sent back along with empty containers to OEM for Ü

recovery and re-blending Training manual on waste Management Ü Trials are on for stabiliza�on / solidifica�on of ETP sludge to produce pavers and bricksÜ Procurement of paint sludge granula�on machine for reducing the wet weight of paint Ü

sludge is planned 4. Life Cycle AssessmentTata Motors, Ltd. is one of the progressive companies in India to conduct LCA of a passenger car and compare the environmental performance with its compe�tors. Five components were analyzed for environmental parameters viz. acidifica�on poten�al, Ü

aqua�c eutrophica�on, global warming poten�al, photochemical ozone forma�on for both impact on human health & materials and impact on vegeta�on, stratospheric ozone deple�on and terrestrial eutrophica�on

Changing the material of the components at design stage has shown reduc�on in Üenvironmental impacts including reduc�on in carbon footprint

The results of the LCA study has offered several opportuni�es to improve the Üenvironmental performance of Tata Motors, Ltd in its supply chain

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Nirmal Abhiyan Program1.8 MW Each Wind Mill Reduc�on in Packaging Endangered Species

XCase Study

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Ra�ng Benefits Some of the ini�a�ves taken by Tata Motors Ltd. across various GreenCo parameters are men�oned below: 1. Water Conserva�on The plant has done commendable work in subs�tu�ng freshwater with harvested rainwater. The rainwater is first collected in a storage tank and then sent for chlorina�on, filtra�on through pressure sand filter and ac�vated carbon filters. Filtered water is mixed with raw water and used in the process. In addi�on to rain water harves�ng, the plant has taken the following ini�a�ves to reduce the water consump�on inside the plant - Filtered treated effluent water used for secondary use such as toilet flushing, vehicle Ü

washing and floor washing Increased the use of treated effluent supply for hor�culture purpose by expanding and Ü

revamping the hor�culture supply distribu�on network Use of low flow faucets and valves to control the flow of waterÜ Awareness crea�on on water conserva�on through displaysÜ Thorough water footprint study by an external expertÜ Awareness sessions conducted throughout the year to sensi�ze the employees on the Ü

urgent need to save water Arrested underground leakageÜ

38,590 cubic meters of

harvested rain water was reused

in the process which resulted in an annual savings

of ` 9.75 Lakh per annum

85 Lakh kWh savings was achieved by

implementa�on of several

energy saving ideas

Wind UnitsRupee

Savings/AnnumCO Emissions2

Offset / Annum

80.35 MillionUnits

Rs. 76.8 Million75,226 tonnes of

CO2

SAVINGS ACHIEVED BY SUBSTITUTING CONVENTIONAL ENERGY WITH RENEWABLE ENERGY

RAIN WATER HARVESTING TANK

2. Energy Efficiency Tata Motors Ltd. monitors fixed and variable energy consump�on separately for efficient Ü

monitoring of energy consump�on Daily variance analysis helps the plant in monitoring and understanding the energy Ü

consump�on inside the plant 59 energy saving ideas were implemented in a year in different sec�ons of the plant such Ü

as paint-shop, welding, press-shop which brought in significant savings Tata Motors Ltd. is commi�ed to u�lizing renewable energy which is reflected in the Ü

investment made in wind farms offsite to subs�tute 42% of its total energy needs

The company owns cap�ve wind mills in Satara and Supa in Maharashtra. In order to maximize the benefits of use of renewable power, the plant also has third party contracts with companies like M/s Karma Energy Ltd & Weizmann Ltd, M/s Sarla Performance Fibers Ltd., M/s Global Energy Ltd.

3. Waste Management The plant has taken several ini�a�ves to reuse and recycle waste and some of them are men�oned below - In-house Central Oil Reclama�on Centre for recovery of dirty oils to extend the useful life Ü

of waste oil Dirty flushing thinner is recycled and the recovered thinner is used for low end uses in the Ü

paint shop Paint sludge is recycled back and used in the industrial primerÜ Residual sealant containers are sent back along with empty containers to OEM for Ü

recovery and re-blending Training manual on waste Management Ü Trials are on for stabiliza�on / solidifica�on of ETP sludge to produce pavers and bricksÜ Procurement of paint sludge granula�on machine for reducing the wet weight of paint Ü

sludge is planned 4. Life Cycle AssessmentTata Motors, Ltd. is one of the progressive companies in India to conduct LCA of a passenger car and compare the environmental performance with its compe�tors. Five components were analyzed for environmental parameters viz. acidifica�on poten�al, Ü

aqua�c eutrophica�on, global warming poten�al, photochemical ozone forma�on for both impact on human health & materials and impact on vegeta�on, stratospheric ozone deple�on and terrestrial eutrophica�on

Changing the material of the components at design stage has shown reduc�on in Üenvironmental impacts including reduc�on in carbon footprint

The results of the LCA study has offered several opportuni�es to improve the Üenvironmental performance of Tata Motors, Ltd in its supply chain

Confedera�on of Indian Industry CII – Sohrabji Godrej Green Business Centre

Nirmal Abhiyan Program1.8 MW Each Wind Mill Reduc�on in Packaging Endangered Species

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Kirloskar Brothers Limited (KBL) is an electrical pump manufacturing company with expertise in engineering and manufacture of systems for fluid management. KBL engineers and manufacture industrial, agriculture & domestic pumps, valves and hydro turbines. Kirloskar Brothers Limited, Sanand is located in Sanand of Ahmedabad district. The unit manufactures submersible pump sets and presently has a production capacity of about 55,000 pumps per annum on an average. KBL Sanand is 3rd unit in the pump manufacturing sector to attain the prestigious GreenCo Silver Rating.

July2014

Aug2014

Company Profile

Kirloskar Brothers

Limited

2014

Launch ofGreenCo

Training & Handholding

On-siteAssessment

Nov2014

Case Study XI

Sanand

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Kirloskar Brothers Limited (KBL) is an electrical pump manufacturing company with expertise in engineering and manufacture of systems for fluid management. KBL engineers and manufacture industrial, agriculture & domestic pumps, valves and hydro turbines. Kirloskar Brothers Limited, Sanand is located in Sanand of Ahmedabad district. The unit manufactures submersible pump sets and presently has a production capacity of about 55,000 pumps per annum on an average. KBL Sanand is 3rd unit in the pump manufacturing sector to attain the prestigious GreenCo Silver Rating.

July2014

Aug2014

Company Profile

Kirloskar Brothers

Limited

2014

Launch ofGreenCo

Training & Handholding

On-siteAssessment

Nov2014

Case Study XI

Sanand

GreenCo Rating BenefitsKBL, Sanand, led by a proactive corporate, has shown excellent commitment towards environmental sustainability. KBL, as a corporate, is a signatory of the CII - Code for Ecologically Sustainable Business Growth (MSG Code). KBL Sanand has been taking steady steps to reduce their environment footprint and has done good work in areas of energy efficiency, waste management, material conservation and product stewardship related areas. Some of the key achievements and benefits experienced by KBL, Sanand during the journey of GreenCo are highlighted -

1. Energy Efficiency, Renewable Energy and GHG MitigationKirloskar Brothers Limited, as a group, has a focused approach towards energy management and conservation activities. KBL Sanand has a target to reduce its specific energy consumption in terms of kWh / Ü

pump by 2-6% Y-O-Y for the next 10 years KBL, Sanand has inventorized its scope 3 emissions in addition to scope 1 and scope 2 Ü

emissions Set clear short term, long term targets and action plan to achieve the targetsØ Key vendors are relocated near the plant thereby reducing the emissions due to Ø

transport of incoming material Various initiatives taken on energy efficiency. Few projects are listed below : Ü Utilization of biomass substituting use of 20 MT of LPG Ø Installation of solar PV to meet electricity requirements of admin buildingØ 10% of overall energy consumption is met through renewable energyð KBL, Sanand has replaced nearly 58% of the conventional street lights by solar street Ø

lights. A 15 kW solar power plant within the premises is used to run WTP/ ETP/ STP plants, Ø gas bank, distribution pumps, borewells, etc.2. Water Conservation KBL, Sanand has taken several measures to reduce its water footprint. Zero water discharge unit through recycle and reuse of treated waste water for process Ü

use well as other domestic application Rain water harvesting pits to capture more than 50% of the total rain water harvesting Ü

potential resulting in an increase in ground water table level3. Waste Management & Material Conservation, Recycling & Recyclability KBL Sanand has been performing exceedingly well with respect to raw material conservation, use of recycled material and increasing the recyclable percentage of their product. Minimum inventory time to handle their raw material incoming and work-in-progress Ü

activity Use of Synchronized Manufacturing and Distribution Systems (SMDS), KANBAN and ERP Ü

system for material management Raw material optimization through Ü Incorporating changes in design stageØ Reuse of stator and rotor kraft tubeØ Elimination of packaging wasteØ Horizontal deployment of twin tubes, etc.Ø Following are some of the key initiatives taken and benefits achieved by the plant;Ü Replacement of Cast Iron DOL assembly with noryl assembly (Noryl is 100% Ø

recyclable) resulted in annual savings of Rupees 0.1 million. The weight of the product also reduced by 89.76% and saved raw material of more than 2000 kg / year

Energy efficiency projects resulted into ` 2.8 Million savings annually

XICase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Reduction in weight of raw material and SS impeller through VAVE (Value Addition, ØValue Engineering) projects resulted in raw material savings of more than 5000 kg and offered monetary benefits of Rupees 1.35 million annually

Change in bearing material from cast iron to stainless steel resulted in component Øweight reduction by 65.12%, raw material saving of 8000 kg raw material annually and cost saving of Rupees 0.44 million

Elimination of packing material in stator rotor incoming resulted in saving of 10,860 kg Øof kraft paper per annum

Weight reduction in packaging material in KS4 pump series, through VAVE projects Øresulting in savings of 550 kg per annum

Modification of the delivery flange profile to a simple tightening operation through Øpneumatic tools resulted in better use of manpower reducing their fatigue, cycle time reduction material conservation

4.Green Supply Chain KBL as a group has developed the Green procurement Policy for all its unitsÜ A vendor portal tool for online communication with their vendors. Ü Some of the key initiatives taken by KBL, Sanand to improve its performance in the supply Ü

chain is highlighted Use of milk run model to transport locally procured raw materials resulted in avoiding Ø

33,000 kg CO annually2

Procurement of packing material from local vendors / relocation of vendors in close Øvicinity resulted in CO emission reduction of 76,600 kg per annum 2

Route optimization to minimize finished good transportation distance from KBL ØSanand plant to various regional offices all over India

DELIVERY OPTIMISATION

PACKAGING OPTIMISATION

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Rating BenefitsKBL, Sanand, led by a proactive corporate, has shown excellent commitment towards environmental sustainability. KBL, as a corporate, is a signatory of the CII - Code for Ecologically Sustainable Business Growth (MSG Code). KBL Sanand has been taking steady steps to reduce their environment footprint and has done good work in areas of energy efficiency, waste management, material conservation and product stewardship related areas. Some of the key achievements and benefits experienced by KBL, Sanand during the journey of GreenCo are highlighted -

1. Energy Efficiency, Renewable Energy and GHG MitigationKirloskar Brothers Limited, as a group, has a focused approach towards energy management and conservation activities. KBL Sanand has a target to reduce its specific energy consumption in terms of kWh / Ü

pump by 2-6% Y-O-Y for the next 10 years KBL, Sanand has inventorized its scope 3 emissions in addition to scope 1 and scope 2 Ü

emissions Set clear short term, long term targets and action plan to achieve the targetsØ Key vendors are relocated near the plant thereby reducing the emissions due to Ø

transport of incoming material Various initiatives taken on energy efficiency. Few projects are listed below : Ü Utilization of biomass substituting use of 20 MT of LPG Ø Installation of solar PV to meet electricity requirements of admin buildingØ 10% of overall energy consumption is met through renewable energyð KBL, Sanand has replaced nearly 58% of the conventional street lights by solar street Ø

lights. A 15 kW solar power plant within the premises is used to run WTP/ ETP/ STP plants, Ø gas bank, distribution pumps, borewells, etc.2. Water Conservation KBL, Sanand has taken several measures to reduce its water footprint. Zero water discharge unit through recycle and reuse of treated waste water for process Ü

use well as other domestic application Rain water harvesting pits to capture more than 50% of the total rain water harvesting Ü

potential resulting in an increase in ground water table level3. Waste Management & Material Conservation, Recycling & Recyclability KBL Sanand has been performing exceedingly well with respect to raw material conservation, use of recycled material and increasing the recyclable percentage of their product. Minimum inventory time to handle their raw material incoming and work-in-progress Ü

activity Use of Synchronized Manufacturing and Distribution Systems (SMDS), KANBAN and ERP Ü

system for material management Raw material optimization through Ü Incorporating changes in design stageØ Reuse of stator and rotor kraft tubeØ Elimination of packaging wasteØ Horizontal deployment of twin tubes, etc.Ø Following are some of the key initiatives taken and benefits achieved by the plant;Ü Replacement of Cast Iron DOL assembly with noryl assembly (Noryl is 100% Ø

recyclable) resulted in annual savings of Rupees 0.1 million. The weight of the product also reduced by 89.76% and saved raw material of more than 2000 kg / year

Energy efficiency projects resulted into ` 2.8 Million savings annually

XICase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Reduction in weight of raw material and SS impeller through VAVE (Value Addition, ØValue Engineering) projects resulted in raw material savings of more than 5000 kg and offered monetary benefits of Rupees 1.35 million annually

Change in bearing material from cast iron to stainless steel resulted in component Øweight reduction by 65.12%, raw material saving of 8000 kg raw material annually and cost saving of Rupees 0.44 million

Elimination of packing material in stator rotor incoming resulted in saving of 10,860 kg Øof kraft paper per annum

Weight reduction in packaging material in KS4 pump series, through VAVE projects Øresulting in savings of 550 kg per annum

Modification of the delivery flange profile to a simple tightening operation through Øpneumatic tools resulted in better use of manpower reducing their fatigue, cycle time reduction material conservation

4.Green Supply Chain KBL as a group has developed the Green procurement Policy for all its unitsÜ A vendor portal tool for online communication with their vendors. Ü Some of the key initiatives taken by KBL, Sanand to improve its performance in the supply Ü

chain is highlighted Use of milk run model to transport locally procured raw materials resulted in avoiding Ø

33,000 kg CO annually2

Procurement of packing material from local vendors / relocation of vendors in close Øvicinity resulted in CO emission reduction of 76,600 kg per annum 2

Route optimization to minimize finished good transportation distance from KBL ØSanand plant to various regional offices all over India

DELIVERY OPTIMISATION

PACKAGING OPTIMISATION

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Godrej Interio is a business unit of Godrej & Boyce Mfg. Co. Ltd. - part of the Godrej Group, one of India's largest engineering and consumer product groups.

Godrej Interio offers home and office furniture, along with solutions for laboratories, hospitals and healthcare establishments, education and training institutes, shipyards and navy, auditoriums and stadiums.

Godrej Interio Division has four manufacturing locations two of which are in Mumbai, one plant in Shirwal and one in Bhagwanpur. Major products manufactured are sheet metal products having mix of knocked down and welded construction, new design chairs which consist of mid back and high back chairs which come in cushion and net back options.

Nov2013

Dec2013

Company Profile

Godrej & Boyce Mfg. Co. Ltd., Interio Division

Vikhroli

2014

Launch ofGreenCo

Training & Handholding

On-site Assessment

June2014

Case Study XII

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Godrej Interio is a business unit of Godrej & Boyce Mfg. Co. Ltd. - part of the Godrej Group, one of India's largest engineering and consumer product groups.

Godrej Interio offers home and office furniture, along with solutions for laboratories, hospitals and healthcare establishments, education and training institutes, shipyards and navy, auditoriums and stadiums.

Godrej Interio Division has four manufacturing locations two of which are in Mumbai, one plant in Shirwal and one in Bhagwanpur. Major products manufactured are sheet metal products having mix of knocked down and welded construction, new design chairs which consist of mid back and high back chairs which come in cushion and net back options.

Nov2013

Dec2013

Company Profile

Godrej & Boyce Mfg. Co. Ltd., Interio Division

Vikhroli

2014

Launch ofGreenCo

Training & Handholding

On-site Assessment

June2014

Case Study XII

GreenCo Rating BenefitsGodrej Interio Division has done good work in various aspects of GreenCo Rating system. The plant has implemented several projects during the execution of the GreenCo Rating System. All major sustainability initiatives are driven by Godrej’s Good and Green Vision.Godrej Interio Division’s Good and Green Vision is backed by policies that highlight the commitment of Godrej Interio striving towards environmental sustainability. Various initiatives and projects taken by Godrej Interio are mentioned below:1. Energy Efficiency, Renewable Energy and Greenhouse Gas Emission reductionGodrej Interio has a clear framework for addressing the energy conservation activities within the facility. The plant has implemented several initiatives and measures for reducing energy consumption. The corporate energy policy has cascaded to all divisions of Godrej and Godrej Interio has a document EMPOWER that highlights its energy commitment A clear-cut road map for implementing energy conservation activities has been Ü

developed. 28.8% reduction in SEC has been achieved in the last three years as a result of several initiatives

Replacement of conventional pressurized hot water generator with non pressurized Üboiler close to the point of operation has saved 1.32 Lakh scm/year of PNG consumption

Time based control systems for machines have been installed by the plant to reduce idle Ürunning of machines

Consistent monitoring of scope 1 and scope 2 emissions and initiation of scope 3 Üemissions monitoring. Scope wise emission reduction action plan has been devised

2. Water ConservationGodrej Interio Division has established an Integrated Management Policy which focuses on efficient water consumption and improving water efficiency. 15% reduction in specific water consumption in the last three yearsÜ Efforts to benchmark their water consumption with international companies having Ü

similar operations RO permeate is reused in the process and the RO reject is treated in the common ETP of Ü

the Godrej Campus3. Waste Management Godrej Interio has done extensive work in waste management activities. Source segregation, colour coding for waste collection bins, dedicated waste storage area are a few of its features. Some of the major activities carried out by the plant are mentioned below: 61% reduction in hazardous waste generation and 20% reduction in non-hazardous waste Ü

generation Specific action plan to further reduce the waste generation Ü Process effluent is treated in common ETP and treated water is reused in the process after Ü

treatment Substitution of diesel fuel with natural gas, a cleaner source of energy, for powder coating Ü

application4. Material ConservationGodrej Interio, Vikhroli uses steel as its major raw material. Also, a significant quantity of powder is used in the powder coating application. Several initiatives have been taken to reduce material consumption and enhance utilization of recycled raw material. Major projects taken by Godrej Interio are mentioned below: A three pronged approach is followed for yield improvement; value engineering, Ü

reduction of process scrap and reduction in rejects

XIICase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

28.8%Reduction in

Specific Energy consumption

12.3%Reduction in Specific Fresh

Water consumption

61% Reduction in hazardous waste generation & 20% in non-hazardous waste generation

25.7%Reduction in Specific GHG

emission

Use of contact free trolley for storage and handling of shelves resulted in reduction of Üdamage and rejects

Several initiatives to reduce the packaging material used and increase the use of Übiodegradable packaging. Eg. Switched from thermocol and bubble bag to honeycomb carton packing

5. Green Supply Chain Godrej Interio has done very good work in greening its supply chain. Some of its initiatives are mentioned below: Incentivized and facilitated 23 suppliers to undergo EMS certificationsÜ Godrej Interio encourages its suppliers to be a part of the green pledge in the annual Ü

suppliers meet; suppliers take up voluntary commitments on pollution prevention, 3R, increasing use of recycled and recyclable content, reducing use of toxic chemicals, switching to biodegradable materials, reducing energy consumption and water consumption

Achieved a reduction of approximately 285 tons of CO emissions per year through 2Ülocalization of suppliers instead of import

Godrej Interio along with recyclekaro, manages and recycles waste generated at the Üsuppliers’ end

6. Product Stewardship Godrej Interio has framed a Design for Environment policy. Some of its initiatives under product stewardship are highlighted - WECYCLE initiative on product take back to ensure recycling of end of life products. Ü

Various IT and Service sector companies have been involved in this initiative to recycle waste furniture

Initiatives to reduce toxic and hazardous substance going into the products. For example, Üall synthetic glue was replaced with hot melt glue

Godrej Interio has conducted life cycle assessment study for major projects namely, Wish Üworkstation, Flutter and Storewel M2. The results of the study are considered during new product manufacture and modification of existing products to minimize the environmental impacts

CONTACT FREE TROLLEY GREEN PLEDGE BY SUPPLIERS

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Rating BenefitsGodrej Interio Division has done good work in various aspects of GreenCo Rating system. The plant has implemented several projects during the execution of the GreenCo Rating System. All major sustainability initiatives are driven by Godrej’s Good and Green Vision.Godrej Interio Division’s Good and Green Vision is backed by policies that highlight the commitment of Godrej Interio striving towards environmental sustainability. Various initiatives and projects taken by Godrej Interio are mentioned below:1. Energy Efficiency, Renewable Energy and Greenhouse Gas Emission reductionGodrej Interio has a clear framework for addressing the energy conservation activities within the facility. The plant has implemented several initiatives and measures for reducing energy consumption. The corporate energy policy has cascaded to all divisions of Godrej and Godrej Interio has a document EMPOWER that highlights its energy commitment A clear-cut road map for implementing energy conservation activities has been Ü

developed. 28.8% reduction in SEC has been achieved in the last three years as a result of several initiatives

Replacement of conventional pressurized hot water generator with non pressurized Üboiler close to the point of operation has saved 1.32 Lakh scm/year of PNG consumption

Time based control systems for machines have been installed by the plant to reduce idle Ürunning of machines

Consistent monitoring of scope 1 and scope 2 emissions and initiation of scope 3 Üemissions monitoring. Scope wise emission reduction action plan has been devised

2. Water ConservationGodrej Interio Division has established an Integrated Management Policy which focuses on efficient water consumption and improving water efficiency. 15% reduction in specific water consumption in the last three yearsÜ Efforts to benchmark their water consumption with international companies having Ü

similar operations RO permeate is reused in the process and the RO reject is treated in the common ETP of Ü

the Godrej Campus3. Waste Management Godrej Interio has done extensive work in waste management activities. Source segregation, colour coding for waste collection bins, dedicated waste storage area are a few of its features. Some of the major activities carried out by the plant are mentioned below: 61% reduction in hazardous waste generation and 20% reduction in non-hazardous waste Ü

generation Specific action plan to further reduce the waste generation Ü Process effluent is treated in common ETP and treated water is reused in the process after Ü

treatment Substitution of diesel fuel with natural gas, a cleaner source of energy, for powder coating Ü

application4. Material ConservationGodrej Interio, Vikhroli uses steel as its major raw material. Also, a significant quantity of powder is used in the powder coating application. Several initiatives have been taken to reduce material consumption and enhance utilization of recycled raw material. Major projects taken by Godrej Interio are mentioned below: A three pronged approach is followed for yield improvement; value engineering, Ü

reduction of process scrap and reduction in rejects

XIICase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

28.8%Reduction in

Specific Energy consumption

12.3%Reduction in Specific Fresh

Water consumption

61% Reduction in hazardous waste generation & 20% in non-hazardous waste generation

25.7%Reduction in Specific GHG

emission

Use of contact free trolley for storage and handling of shelves resulted in reduction of Üdamage and rejects

Several initiatives to reduce the packaging material used and increase the use of Übiodegradable packaging. Eg. Switched from thermocol and bubble bag to honeycomb carton packing

5. Green Supply Chain Godrej Interio has done very good work in greening its supply chain. Some of its initiatives are mentioned below: Incentivized and facilitated 23 suppliers to undergo EMS certificationsÜ Godrej Interio encourages its suppliers to be a part of the green pledge in the annual Ü

suppliers meet; suppliers take up voluntary commitments on pollution prevention, 3R, increasing use of recycled and recyclable content, reducing use of toxic chemicals, switching to biodegradable materials, reducing energy consumption and water consumption

Achieved a reduction of approximately 285 tons of CO emissions per year through 2Ülocalization of suppliers instead of import

Godrej Interio along with recyclekaro, manages and recycles waste generated at the Üsuppliers’ end

6. Product Stewardship Godrej Interio has framed a Design for Environment policy. Some of its initiatives under product stewardship are highlighted - WECYCLE initiative on product take back to ensure recycling of end of life products. Ü

Various IT and Service sector companies have been involved in this initiative to recycle waste furniture

Initiatives to reduce toxic and hazardous substance going into the products. For example, Üall synthetic glue was replaced with hot melt glue

Godrej Interio has conducted life cycle assessment study for major projects namely, Wish Üworkstation, Flutter and Storewel M2. The results of the study are considered during new product manufacture and modification of existing products to minimize the environmental impacts

CONTACT FREE TROLLEY GREEN PLEDGE BY SUPPLIERS

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Hindustan Petroleum Corporation Limited (HPCL) is a Government of India Enterprise with a Navratna Status and a Fortune Global 500 and Forbes 2000 company.

The Company has launched a new Cultural motto 'HP First', FIRST stands for F: Free, Frank and Fair, I: Integrity, R: Respect for Individual, S: Sustainable Performance, T: Team Spirit. HP First is a renewed identity for HPCL.

HPCL, Silvassa Lube Oil Blending Plant manufactures multiple grades of Lubes, Grease and Speciality products in strict conformance with HPCL's standards and international quality standards. HPCL, Silvassa Lube Oil Blending Terminal has now ventured into sustainable development, has undergone the GreenCo Rating System and is rated . HPCL, Silvassa has earned the GreenCo Silverdistinction of being the first public sector enterprise in India to have received the prestigious GreenCo Rating.

June2014

July2014

Company Profile

HPCLSilvassa Lube Oil

Blending Plant

Launch ofGreenCo

Training & Handholding

Site VisitAssessment

Feb 2014

Case Study XIII

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Hindustan Petroleum Corporation Limited (HPCL) is a Government of India Enterprise with a Navratna Status and a Fortune Global 500 and Forbes 2000 company.

The Company has launched a new Cultural motto 'HP First', FIRST stands for F: Free, Frank and Fair, I: Integrity, R: Respect for Individual, S: Sustainable Performance, T: Team Spirit. HP First is a renewed identity for HPCL.

HPCL, Silvassa Lube Oil Blending Plant manufactures multiple grades of Lubes, Grease and Speciality products in strict conformance with HPCL's standards and international quality standards. HPCL, Silvassa Lube Oil Blending Terminal has now ventured into sustainable development, has undergone the GreenCo Rating System and is rated . HPCL, Silvassa has earned the GreenCo Silverdistinction of being the first public sector enterprise in India to have received the prestigious GreenCo Rating.

June2014

July2014

Company Profile

HPCLSilvassa Lube Oil

Blending Plant

Launch ofGreenCo

Training & Handholding

Site VisitAssessment

Feb 2014

Case Study XIII

GreenCo Rating BenefitsHPCL, Silvassa, between July 2014 and February 2015, has taken commendable efforts to comply with the GreenCo Rating System which has led to significant improvements in its overall environmental performance. The GreenCo Rating System being a combination of Systems and Performance has driven HPCL, Silvassa to improve their existing monitoring systems and develop new ones wherever required. PolicyÜ HPCL, at the corporate level and Silvassa, at the plant level, have instituted good policies,

all of which have been driving excellence in productivity and management. Excellence in environmental performance has gained priority in HPCL, Silvassa and an act to substantiate its commitment was the introduction of specific policies namely the Energy Policy, Water Policy and Material & Resource Policy to guide and monitor its environmental activities.

Employee InvolvementÜ GreenCo has helped HPCL, Silvassa ensure that their employees play a major part in all of

their activities. While the policy remains to serve as the base, to build on their commitment and to show improved environmental performance, HPCL, Silvassa, involving their employees, has formed various groups such as the energy management cell, water management cell, etc. The members of the respective teams execute their roles and get themselves involved in various awareness and training programs to execute it better.

TargetsÜ A focused and targeted approach to excellence in environmental performance was HPCL,

Silvassa’s strategy. The plant has taken targets with respect to reduction in specific energy consumption, dependence on conventional fuels, specific water consumption, raw material and consumables consumption and so on. HPCL, Silvassa has set clear reduction targets and devise appropriate action plans to meet the set targets.

Structured Monitoring Mechanism Ü Consumption details of energy, water, waste, materials, etc. are monitored through a

structured monitoring mechanism that was incorporated by HPCL, Silvassa. These systems facilitate continuous monitoring of consumption details on a daily and a monthly basis, status of targets, projects implementation, equipment wise performance details and many more.

HPCL, Silvassa Lube Oil Blending Plant along with its proactive corporate, has initiated a number of noteworthy steps to improve its environmental footprint. Initiatives and projects already implemented by HPCL, Silvassa across the GreenCo parameters and those that were implemented as a result of the GreenCo initiative, are highlighted as under –

1. Energy EfficiencyWith good systems in place for setting targets and action plans, for reviewing progress of targets, for continuous monitoring and so on, HPCL, Silvassa, has shown nearly 39% reduction in its specific energy consumption. Automatic drum filling, use of oil cooled screw compressors with VFD, VFD installed kettles are a few examples of the initiatives taken.2. Renewable EnergyUse of renewable energy is important in terms of energy security and serves as one of the mitigation strategies for climate change. GreenCo emphasizes the importance of use of renewable energy and encourages companies to utilize renewable energy. The objective should be to increase the share of renewable energy keeping in mind the future requirements. HPCL Corporate has taken a target of increasing alternate energy utilisation to 500 - 600 MW. With a major focus on solar energy and wind energy, 50.5 MW of wind power has been

XIIICase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

39% reduction in specific energyconsumption

28.8% reduction in specific GHG intensity in the last three years

SAVINGS ACHIEVED BY SUBSTITUTING CONVENTIONAL ENERGY WITH RENEWABLE ENERGY

commissioned and another 50 MW is in the implementation phase. Several solar energy projects have been planned in different locations and retail outlets. To comply with the GreenCo requirements, HPCL, Silvassa at the plant level has taken the following initiatives HPCL, Silvassa Lube Oil Blending Plant has installed a 20 kW solar PV grid interactive Ü

system. With an investment of about Rupees 20 Lakhs, the solar PV system substitutes nearly 3.5% of the total electricity by catering to the administrative building’s power requirement

HPCL, Silvassa is also in the process of implementation of 20 light pipes which will Üsubstitute a good percentage of the overall electrical energy consumption of the plant

With clear action plan and resource allocation in place, HPCL, Silvassa has also identified Üpotential renewable energy projects that will be taken up in the subsequent years for implementation

Units Generated / % Substitution of CO Emissions Offset /2

Annum ConventionalEnergy Annum 38000 3.5% 37 Tonnes

3. GHG Emissions Mitigation HPCL, as a corporate, has been accounting for its carbon emissions since 2008 for the Mumbai and Vizag refineries and has also completed carbon footprint at 50 Petroleum, Oil and Lubricants (POL) locations. The following initiatives are noteworthy - HPCL, Silvassa’s commitment to minimize the carbon footprint is visible through their Ü

sustainable development policy percolated from the corporate level and the energy policy developed at the plant level

An internally developed online portal to capture carbon emissions and present emission Üdata of every location and strategic business unit of HPCL

Efforts to inventorize scope 1 and scope 2 emissions; one of the very few Corporates to Ühave inventorized their scope 3 emissions as well. Emissions from bulk dispatch, employee travel, direct customer dispatch and bulk receipts are accounted under scope 3 emissions

4. Waste ManagementHPCL, Silvassa has initiated good practices in areas of waste reduction and management. The facility has inculcated the discipline of waste inventorization and accounting. A good initiative is that, HPCL, Silvassa has set up a Phytoremediation system to treat the sewage from the plant. In the first phase, a system of 6 kL capacity is set up and the treated water will be used for irrigation. 5. Material Conservation, Recycling and RecyclabilityOptimum use of raw material is an important strategy that is required for sustainable development. Material Conservation, Recycling and Recyclability, one of GreenCo’s ten parameters, is an area where HPCL, Silvassa Lube Oil Blending Plant, has performed exceedingly well, as noted below: Appreciable internal performance improvement activities are carried out for achieving Ü

reduction in material consumption -

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Rating BenefitsHPCL, Silvassa, between July 2014 and February 2015, has taken commendable efforts to comply with the GreenCo Rating System which has led to significant improvements in its overall environmental performance. The GreenCo Rating System being a combination of Systems and Performance has driven HPCL, Silvassa to improve their existing monitoring systems and develop new ones wherever required. PolicyÜ HPCL, at the corporate level and Silvassa, at the plant level, have instituted good policies,

all of which have been driving excellence in productivity and management. Excellence in environmental performance has gained priority in HPCL, Silvassa and an act to substantiate its commitment was the introduction of specific policies namely the Energy Policy, Water Policy and Material & Resource Policy to guide and monitor its environmental activities.

Employee InvolvementÜ GreenCo has helped HPCL, Silvassa ensure that their employees play a major part in all of

their activities. While the policy remains to serve as the base, to build on their commitment and to show improved environmental performance, HPCL, Silvassa, involving their employees, has formed various groups such as the energy management cell, water management cell, etc. The members of the respective teams execute their roles and get themselves involved in various awareness and training programs to execute it better.

TargetsÜ A focused and targeted approach to excellence in environmental performance was HPCL,

Silvassa’s strategy. The plant has taken targets with respect to reduction in specific energy consumption, dependence on conventional fuels, specific water consumption, raw material and consumables consumption and so on. HPCL, Silvassa has set clear reduction targets and devise appropriate action plans to meet the set targets.

Structured Monitoring Mechanism Ü Consumption details of energy, water, waste, materials, etc. are monitored through a

structured monitoring mechanism that was incorporated by HPCL, Silvassa. These systems facilitate continuous monitoring of consumption details on a daily and a monthly basis, status of targets, projects implementation, equipment wise performance details and many more.

HPCL, Silvassa Lube Oil Blending Plant along with its proactive corporate, has initiated a number of noteworthy steps to improve its environmental footprint. Initiatives and projects already implemented by HPCL, Silvassa across the GreenCo parameters and those that were implemented as a result of the GreenCo initiative, are highlighted as under –

1. Energy EfficiencyWith good systems in place for setting targets and action plans, for reviewing progress of targets, for continuous monitoring and so on, HPCL, Silvassa, has shown nearly 39% reduction in its specific energy consumption. Automatic drum filling, use of oil cooled screw compressors with VFD, VFD installed kettles are a few examples of the initiatives taken.2. Renewable EnergyUse of renewable energy is important in terms of energy security and serves as one of the mitigation strategies for climate change. GreenCo emphasizes the importance of use of renewable energy and encourages companies to utilize renewable energy. The objective should be to increase the share of renewable energy keeping in mind the future requirements. HPCL Corporate has taken a target of increasing alternate energy utilisation to 500 - 600 MW. With a major focus on solar energy and wind energy, 50.5 MW of wind power has been

XIIICase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

39% reduction in specific energyconsumption

28.8% reduction in specific GHG intensity in the last three years

SAVINGS ACHIEVED BY SUBSTITUTING CONVENTIONAL ENERGY WITH RENEWABLE ENERGY

commissioned and another 50 MW is in the implementation phase. Several solar energy projects have been planned in different locations and retail outlets. To comply with the GreenCo requirements, HPCL, Silvassa at the plant level has taken the following initiatives HPCL, Silvassa Lube Oil Blending Plant has installed a 20 kW solar PV grid interactive Ü

system. With an investment of about Rupees 20 Lakhs, the solar PV system substitutes nearly 3.5% of the total electricity by catering to the administrative building’s power requirement

HPCL, Silvassa is also in the process of implementation of 20 light pipes which will Üsubstitute a good percentage of the overall electrical energy consumption of the plant

With clear action plan and resource allocation in place, HPCL, Silvassa has also identified Üpotential renewable energy projects that will be taken up in the subsequent years for implementation

Units Generated / % Substitution of CO Emissions Offset /2

Annum ConventionalEnergy Annum 38000 3.5% 37 Tonnes

3. GHG Emissions Mitigation HPCL, as a corporate, has been accounting for its carbon emissions since 2008 for the Mumbai and Vizag refineries and has also completed carbon footprint at 50 Petroleum, Oil and Lubricants (POL) locations. The following initiatives are noteworthy - HPCL, Silvassa’s commitment to minimize the carbon footprint is visible through their Ü

sustainable development policy percolated from the corporate level and the energy policy developed at the plant level

An internally developed online portal to capture carbon emissions and present emission Üdata of every location and strategic business unit of HPCL

Efforts to inventorize scope 1 and scope 2 emissions; one of the very few Corporates to Ühave inventorized their scope 3 emissions as well. Emissions from bulk dispatch, employee travel, direct customer dispatch and bulk receipts are accounted under scope 3 emissions

4. Waste ManagementHPCL, Silvassa has initiated good practices in areas of waste reduction and management. The facility has inculcated the discipline of waste inventorization and accounting. A good initiative is that, HPCL, Silvassa has set up a Phytoremediation system to treat the sewage from the plant. In the first phase, a system of 6 kL capacity is set up and the treated water will be used for irrigation. 5. Material Conservation, Recycling and RecyclabilityOptimum use of raw material is an important strategy that is required for sustainable development. Material Conservation, Recycling and Recyclability, one of GreenCo’s ten parameters, is an area where HPCL, Silvassa Lube Oil Blending Plant, has performed exceedingly well, as noted below: Appreciable internal performance improvement activities are carried out for achieving Ü

reduction in material consumption -

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Conversion of HDPE to PET for

packing in a phased manner

resulted in reduction of 266

MT of HDPE

XIIICase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

180 kL reduction in flushing per

annum was achieved and also

saved process time in which 6

additional batches could be

processed

Transition to nanoscale

products has proven to provide

outstanding protection against high shock loads, leading to 6 times

improved life apart from 3%

fuel savings

Compatibility matrix was developed to identify grades which could be processed in Øthe same kettle without flushing.

Reduced filling time and improved the number of processed batches in kettlesØ Bulk storage of additives by converting unused storage tanks into additive storage, Ø

thus reducing the tank charging time by 45 minutes and reduction in use of packaging material by shifting to bulk transportation

Very good efforts in optimizing the use of packaging material –Ø Incorporation of square pail design for 10L and 20L lube oil packaging resulted in ð

packaging material weight reduction Reduction of MS grease drum weight that are used for finished products resulting ð

in 31 MT reduction in material consumption and also reduced all associated costs. Reduction in carbon emissions were also achieved

Reuse of packing bags and consumables such as wooden pallets has reduced ð purchase of new packaging material

HPCL identified ways through which seals can be used for MS and HDPE barrels ð and introduced induction moulding for product seals. This initiative reduced product pilferages, thereby reducing customer complaints. HPCL received the India Star, Asia Star and World Packaging Award in 2014 for this initiative

6. Product StewardshipProduct stewardship emphasizes various aspects such as influencing consumer’s behavior, reducing toxic or hazardous substances, concept of design for environment and extended producer responsibility. HPCL, Silvassa Lube Oil Blending Plant has shown very good performance in this aspect - R&D studies to modify the manufacturing process of grease were conducted. The new Ü

manufacturing process apart from improving productivity has provided the following benefits

Reduction in Reduction in energy Rupee Savings / First pass yield process time consumption Annum improvement 40% 40% 8 Lakhs 100%

Transition to low viscosity fluids has extended the oil drain interval by two times 40,000 to Ü60,000 kilometers to 1 Lakh kilometers.

Metal free (zinc) additive technology promoted for customers in the form of hydraulic oils Üand new generation biodegradable oils

Reduction of Sulphur levels from 1500 ppm to 300 ppm between group I and group II oils Üand increase in production of group II oils by 13%

Use of XRF analyzer and auto viscosity analyzer in labs thereby completely eliminating the Üuse of toluene and hexane

HPCL, Silvassa has demonstrated excellent performance with respect to the environmental aspects; many initiatives even before the implementation of the GreenCo Rating System and multiple strategic and significant initiatives because of the GreenCo Rating System. HPCL, Silvassa is striving to achieve higher level of rating by implementing the opportunities for improvement brought out during the site visit assessment. This focused and systematic approach will lead HPCL, Silvassa towards achieving excellence in green performance.

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

The Godrej Group is one of the largest players of Home Appliances in India. In 1958, Godrej was the First Indian Company to manufacture Refrigerators and since then, it has become synonymous with the category. Godrej and Boyce Mfg. Co. Ltd., Appliance Division, Mohali manufactures Refrigerators and Compressors used in refrigerators. Godrej Appliances launched India's first 100% green refrigerator series in 2002 which was CFC, HFC and HCFC free and is the only company to have 100% green refrigerators until date.

Godrej Appliances, Mohali factory covers an area of 303,578 sq. meters with an annual production of 6 Lakh refrigerators and 13.5 Lakh compressors. GAD, Mohali has been the only GreenCo rated company to have undergone the GreenCo Rating without any intervention from any external source on training/hand holding. It is the 2nd company to be Rated GreenCo Platinum.

Jan2015

Company Profile

Godrej and Boyce Mfg. Co. Ltd., Appliance Division,

Mohali

Launch of GreenCo

On-site Assessment

Jan2015

Case Study XIV

Conversion of HDPE to PET for

packing in a phased manner

resulted in reduction of 266

MT of HDPE

XIIICase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

180 kL reduction in flushing per

annum was achieved and also

saved process time in which 6

additional batches could be

processed

Transition to nanoscale

products has proven to provide

outstanding protection against high shock loads, leading to 6 times

improved life apart from 3%

fuel savings

Compatibility matrix was developed to identify grades which could be processed in Øthe same kettle without flushing.

Reduced filling time and improved the number of processed batches in kettlesØ Bulk storage of additives by converting unused storage tanks into additive storage, Ø

thus reducing the tank charging time by 45 minutes and reduction in use of packaging material by shifting to bulk transportation

Very good efforts in optimizing the use of packaging material –Ø Incorporation of square pail design for 10L and 20L lube oil packaging resulted in ð

packaging material weight reduction Reduction of MS grease drum weight that are used for finished products resulting ð

in 31 MT reduction in material consumption and also reduced all associated costs. Reduction in carbon emissions were also achieved

Reuse of packing bags and consumables such as wooden pallets has reduced ð purchase of new packaging material

HPCL identified ways through which seals can be used for MS and HDPE barrels ð and introduced induction moulding for product seals. This initiative reduced product pilferages, thereby reducing customer complaints. HPCL received the India Star, Asia Star and World Packaging Award in 2014 for this initiative

6. Product StewardshipProduct stewardship emphasizes various aspects such as influencing consumer’s behavior, reducing toxic or hazardous substances, concept of design for environment and extended producer responsibility. HPCL, Silvassa Lube Oil Blending Plant has shown very good performance in this aspect - R&D studies to modify the manufacturing process of grease were conducted. The new Ü

manufacturing process apart from improving productivity has provided the following benefits

Reduction in Reduction in energy Rupee Savings / First pass yield process time consumption Annum improvement 40% 40% 8 Lakhs 100%

Transition to low viscosity fluids has extended the oil drain interval by two times 40,000 to Ü60,000 kilometers to 1 Lakh kilometers.

Metal free (zinc) additive technology promoted for customers in the form of hydraulic oils Üand new generation biodegradable oils

Reduction of Sulphur levels from 1500 ppm to 300 ppm between group I and group II oils Üand increase in production of group II oils by 13%

Use of XRF analyzer and auto viscosity analyzer in labs thereby completely eliminating the Üuse of toluene and hexane

HPCL, Silvassa has demonstrated excellent performance with respect to the environmental aspects; many initiatives even before the implementation of the GreenCo Rating System and multiple strategic and significant initiatives because of the GreenCo Rating System. HPCL, Silvassa is striving to achieve higher level of rating by implementing the opportunities for improvement brought out during the site visit assessment. This focused and systematic approach will lead HPCL, Silvassa towards achieving excellence in green performance.

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

The Godrej Group is one of the largest players of Home Appliances in India. In 1958, Godrej was the First Indian Company to manufacture Refrigerators and since then, it has become synonymous with the category. Godrej and Boyce Mfg. Co. Ltd., Appliance Division, Mohali manufactures Refrigerators and Compressors used in refrigerators. Godrej Appliances launched India's first 100% green refrigerator series in 2002 which was CFC, HFC and HCFC free and is the only company to have 100% green refrigerators until date.

Godrej Appliances, Mohali factory covers an area of 303,578 sq. meters with an annual production of 6 Lakh refrigerators and 13.5 Lakh compressors. GAD, Mohali has been the only GreenCo rated company to have undergone the GreenCo Rating without any intervention from any external source on training/hand holding. It is the 2nd company to be Rated GreenCo Platinum.

Jan2015

Company Profile

Godrej and Boyce Mfg. Co. Ltd., Appliance Division,

Mohali

Launch of GreenCo

On-site Assessment

Jan2015

Case Study XIV

GreenCo Rating BenefitsGodrej and Boyce Mfg. Co. Ltd., Appliance Division, Mohali led by a proactive corporate, has taken a lot of environmental sustainability initiatives. Identified areas for improvement during the execution of GreenCo rating at their Shirwal unit were also implemented at Mohali unit due to similar operational aspects, which has helped GAD Mohali to further improve its environmental performance. The activities initiated as a result of the implementation of the GreenCo Rating System are described below - 1. Energy EfficiencyThrough consistent efforts and several initiatives, Godrej Appliance Mohali has shown a good specific energy consumption reduction trend of 23.6% over a period of four years. The GreenCo assessment brought out various opportunities for improvement and some of the major improvement actions taken are described below - Developed energy index for equipment and identified energy intensive zonesÜ Process wise benchmarking was done for injection moulding, powder coating and Ü

vacuum forming. Benchmarking of Injection Moulding (IM) and Vacuum Forming process was done with other industries with similar processes. GAD, Mohali included the following for the process benchmarking -

Manufacturers supplying components to the appliances industryØ Manufacturers of auto components and other engineering companiesØ Conducted energy audits at suppliers' end and monitored savings achieved by suppliers Ü

through implementation of energy saving projects Implementation of energy scorecard at the shop floor to improve operational efficiency Ü

through performance comparison of equipments& operators

2. Water ConservationFraming aspirational targets and executing them was one of the suggested improvement areas. GAD, Mohali revised its target of achieving water neutral status to 2015-16 from 2020. The activities that were executed are highlighted - Developed zone wise water index to ensure improved monitoringÜ Monitoring of water leakages from underground pipelines by installing pressure gauges Ü

and valves in closed loop Enhanced use of water efficient gadgets in washrooms and reduction of pressure of all Ü

water taps Reuse of DM water in cooling towers from compressor leak testing tankÜ

Reduction in 106,402

kWh/month of energy

consumption at the suppliers' end

equivalent to ` 851,216 per month

Annual Recurring Savings achieved

after implementation of

OFIs identified from Shirwal Plant

GreenCo assessment &

improved systems is `15 Million

XIVCase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

SEC REDUCTION TREND

3. Renewable Energy and Greenhouse Gas Emission reductionRenewable energy has been an area of focus for GAD, Mohali and the major projects executed and activities planned are mentioned below – Solar heating for quality laboratories saving 42,939units of electricity Ü Use of solar energy for purchase, finance & HR department computers Ü Target to increase RE share by 60% in the next three yearsÜ Use of battery operated clamp forklift in place of diesel forkliftÜ Use of producer gas generated from bio-mass for ovenÜ The excellent efforts put into the use of renewable energy and improving energy efficiency

has resulted in reduced GHG emissions. 4. Waste Management & Material ConservationGAD, Mohali has excellent systems in place to monitor its waste management and material conservation activities. Some of its activities in these areas are highlighted Use of ETP sludge and hanger burning ash for brick manufacturingÜ Reuse of foam pieces from rejected refrigeratorsÜ Paper cartons, plastic bagsand polyethylene replaced with recyclable and reusable plastic Ü

cartons Use of pulp and paper packaging for refrigerators and compressors in places of EPS sheetsÜ5. Green Supply Chain GAD, Mohali aims to extend its sustainability initiatives in its supply chain and adopts a cluster approach for suppliers. In addition to the implementation of concepts such as 5S, my machine concept, quality &productivity improvement, GAD, Mohali has incorporated several Green concepts in the cluster approach. Highlighted below is some of GAD, Mohali’s initiatives - Development of green sourcing policy and green procurement guidelines Ü Development of e-buy portal for all co-ordination and communication with suppliersÜ Conducted environmental performance survey for suppliersÜ Identification and implementation of methods for indigenization or localization of Ü

imported components 100% RoHS compliant material procurementÜ 105 critical suppliers covered under the mapping & monitoring exercise for Ü

Energy/Water/Waste/Toxicity 6. Product Stewardship GAD, Mohali has taken all possible measures to ensure the quality of its products throughout the supply chain. Initiatives taken in areas of product stewardship and LCA are mentioned below - First refrigerator manufacturer in India to introduce 100% CFC, HFC, HCFC free Ü

refrigerators way back in 2002. GAD, Mohali has switched over to HC refrigerant which has zero ODS and a GWP of 3

Achieved 100% RoHS compliance for all products and processesÜ Developed product take back policyÜ Manufacturing and usage of high EER compressorsÜ Improvement in insulation properties to reduce losses during operationÜ Proposed to use Vacuum Insulated Panels for refrigerator manufacturingÜ Developed customer satisfaction index. Customer survey is conducted through third Ü

party and improvement actions are taken based on the feedback

Reduction in specific water consumption

from 98 litres per appliance in

2006-07 to 48 litres per

appliance in 2013-14

Percentage share of renewable energy is 30% and target to

achieve 60% by 2017

Reduction of 22% GHG Scope 1, Scope 2 and

Scope 3 emission reduction

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Rating BenefitsGodrej and Boyce Mfg. Co. Ltd., Appliance Division, Mohali led by a proactive corporate, has taken a lot of environmental sustainability initiatives. Identified areas for improvement during the execution of GreenCo rating at their Shirwal unit were also implemented at Mohali unit due to similar operational aspects, which has helped GAD Mohali to further improve its environmental performance. The activities initiated as a result of the implementation of the GreenCo Rating System are described below - 1. Energy EfficiencyThrough consistent efforts and several initiatives, Godrej Appliance Mohali has shown a good specific energy consumption reduction trend of 23.6% over a period of four years. The GreenCo assessment brought out various opportunities for improvement and some of the major improvement actions taken are described below - Developed energy index for equipment and identified energy intensive zonesÜ Process wise benchmarking was done for injection moulding, powder coating and Ü

vacuum forming. Benchmarking of Injection Moulding (IM) and Vacuum Forming process was done with other industries with similar processes. GAD, Mohali included the following for the process benchmarking -

Manufacturers supplying components to the appliances industryØ Manufacturers of auto components and other engineering companiesØ Conducted energy audits at suppliers' end and monitored savings achieved by suppliers Ü

through implementation of energy saving projects Implementation of energy scorecard at the shop floor to improve operational efficiency Ü

through performance comparison of equipments& operators

2. Water ConservationFraming aspirational targets and executing them was one of the suggested improvement areas. GAD, Mohali revised its target of achieving water neutral status to 2015-16 from 2020. The activities that were executed are highlighted - Developed zone wise water index to ensure improved monitoringÜ Monitoring of water leakages from underground pipelines by installing pressure gauges Ü

and valves in closed loop Enhanced use of water efficient gadgets in washrooms and reduction of pressure of all Ü

water taps Reuse of DM water in cooling towers from compressor leak testing tankÜ

Reduction in 106,402

kWh/month of energy

consumption at the suppliers' end

equivalent to ` 851,216 per month

Annual Recurring Savings achieved

after implementation of

OFIs identified from Shirwal Plant

GreenCo assessment &

improved systems is `15 Million

XIVCase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

SEC REDUCTION TREND

3. Renewable Energy and Greenhouse Gas Emission reductionRenewable energy has been an area of focus for GAD, Mohali and the major projects executed and activities planned are mentioned below – Solar heating for quality laboratories saving 42,939units of electricity Ü Use of solar energy for purchase, finance & HR department computers Ü Target to increase RE share by 60% in the next three yearsÜ Use of battery operated clamp forklift in place of diesel forkliftÜ Use of producer gas generated from bio-mass for ovenÜ The excellent efforts put into the use of renewable energy and improving energy efficiency

has resulted in reduced GHG emissions. 4. Waste Management & Material ConservationGAD, Mohali has excellent systems in place to monitor its waste management and material conservation activities. Some of its activities in these areas are highlighted Use of ETP sludge and hanger burning ash for brick manufacturingÜ Reuse of foam pieces from rejected refrigeratorsÜ Paper cartons, plastic bagsand polyethylene replaced with recyclable and reusable plastic Ü

cartons Use of pulp and paper packaging for refrigerators and compressors in places of EPS sheetsÜ5. Green Supply Chain GAD, Mohali aims to extend its sustainability initiatives in its supply chain and adopts a cluster approach for suppliers. In addition to the implementation of concepts such as 5S, my machine concept, quality &productivity improvement, GAD, Mohali has incorporated several Green concepts in the cluster approach. Highlighted below is some of GAD, Mohali’s initiatives - Development of green sourcing policy and green procurement guidelines Ü Development of e-buy portal for all co-ordination and communication with suppliersÜ Conducted environmental performance survey for suppliersÜ Identification and implementation of methods for indigenization or localization of Ü

imported components 100% RoHS compliant material procurementÜ 105 critical suppliers covered under the mapping & monitoring exercise for Ü

Energy/Water/Waste/Toxicity 6. Product Stewardship GAD, Mohali has taken all possible measures to ensure the quality of its products throughout the supply chain. Initiatives taken in areas of product stewardship and LCA are mentioned below - First refrigerator manufacturer in India to introduce 100% CFC, HFC, HCFC free Ü

refrigerators way back in 2002. GAD, Mohali has switched over to HC refrigerant which has zero ODS and a GWP of 3

Achieved 100% RoHS compliance for all products and processesÜ Developed product take back policyÜ Manufacturing and usage of high EER compressorsÜ Improvement in insulation properties to reduce losses during operationÜ Proposed to use Vacuum Insulated Panels for refrigerator manufacturingÜ Developed customer satisfaction index. Customer survey is conducted through third Ü

party and improvement actions are taken based on the feedback

Reduction in specific water consumption

from 98 litres per appliance in

2006-07 to 48 litres per

appliance in 2013-14

Percentage share of renewable energy is 30% and target to

achieve 60% by 2017

Reduction of 22% GHG Scope 1, Scope 2 and

Scope 3 emission reduction

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Godrej Locking Solutions and Systems has been a symbol of trust and security for 116 years. It has set several benchmarks in the locks industry since its establishment in 1857. The company offers 5 levels of security from conventional mechanical locking system with basic security system to elite technologies like “Godrej EWA” characterized by its spring less principle and with each key offering 30 lakh Crore combinations i.e. as unique as the human DNA.

Godrej's Good & Green envisions the following by 2020 a Ensure employability by training one million rural and urban

youth in skilled employmentb Achieve zero waste, carbon neutrality, water positive status

and generate 30% of energy needs from renewable sourcesc Generate a third of revenue from green products

Godrej Locking Solutions and Systems was rated GreenCo Gold in March 2015.

Company Profile

Godrej and Boyce Mfg. Co. Ltd., Locking Solutions & Systems

Vikhroli

Case Study XV

Sep'13-Mar'15

Implementa�onof Sugges�ons

Iden�fied

On-siteAssessment

Mar2015

Sep2013

GreenCoSilver

Aug2012

Launch ofGreenCo

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Godrej Locking Solutions and Systems has been a symbol of trust and security for 116 years. It has set several benchmarks in the locks industry since its establishment in 1857. The company offers 5 levels of security from conventional mechanical locking system with basic security system to elite technologies like “Godrej EWA” characterized by its spring less principle and with each key offering 30 lakh Crore combinations i.e. as unique as the human DNA.

Godrej's Good & Green envisions the following by 2020 a Ensure employability by training one million rural and urban

youth in skilled employmentb Achieve zero waste, carbon neutrality, water positive status

and generate 30% of energy needs from renewable sourcesc Generate a third of revenue from green products

Godrej Locking Solutions and Systems was rated GreenCo Gold in March 2015.

Company Profile

Godrej and Boyce Mfg. Co. Ltd., Locking Solutions & Systems

Vikhroli

Case Study XV

Sep'13-Mar'15

Implementa�onof Sugges�ons

Iden�fied

On-siteAssessment

Mar2015

Sep2013

GreenCoSilver

Aug2012

Launch ofGreenCo

REDUCTION DUE TO INTEGRATED MANUFACTURING

REDUCTION IN WASTE GENERATION THROUGH VALUE ENGINEERING PROJECTS

GreenCo Rating Benefits During the GreenCo assessment several improvement opportunities were brought out. Over a period of two years, the plant has implemented the following initiatives:

1. Renewable Energy Renewable energy plays a major role in meeting the energy demand of the country, conserving natural resources and mitigating climate change impacts through reduction of GHG emissions. Godrej Locks has a target to source 16% of its total energy needs at Vikhroli campus from a Ü

4 MW solar farm. 2. Waste Management and Material Conservation Several value engineering and yield improvement projects were implemented in the die casting and press shop departments to reduce solid waste generation. Some examples include -

Number of cavities in storewel plate Reduction in specific waste and cover reduced from 4 to 2. generation from 634 gm to 121 gm. Improvement in bar cutting fixture Reduction in waste generation by 32%

3. Green Supply Chain The plant has taken the following initiatives in greening the supply chain – EMS Survey on the web portal to rate suppliersÜ 59 suppliers have been covered under this surveyØ Training programs to improve the green rating of suppliers Ü Reduce, reuse and recycle projects have been initiated in packaging at the suppliers' endÜ Integrated manufacturing set up under one roof has resulted in reduction as shown below Ü Converted hexavalent zinc plating process to trivalent passivation at suppliers endÜ

Reduction in Reduction in Reduction in distance Chemicals CO2 emissions travelled (km) consumption per annum 970 to 650 13% 7,521 kg

Effective monitoring for milk-run optimization has resulted in 49.7 MT of CO reduction 2Ü annually

XVCase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Several value engineering

projects such as use of alternate material have

resulted in material savings of

1580 kg per annum and

significant cost savings

5. Life Cycle Assessment Life cycle assessment is a tool used to understand and quantify the environmental impacts of a product over the entire life cycle from cradle to grave. Godrej Locks has done commendable work in completing the life cycle assessment of a Ü

safe deposit lock The hot spots identified for improvement are bolt, base plate and cover plate. The Ü

recommendations after the LCA study are as follows – Reduction of compressed air consumptionØ Reduction in scrap generation Ø The safe plate sub-assembly has the maximum scrap lossesð Use of renewable energy sourcesØ Sourcing of recycled materials Ø Redesigning of lock componentsØ Light weighting of lock by use of high strength steel. Redesign of components using ð

materials like high grade plastic components. The safe deposit lock bolt material has been changed. This has reduced the Ü

component weight by 10.5 gm per lock and eliminated usage of lead The plant has also conducted LCA study of 7 lever navtal lock. Alternate material for Ü

the lock bolt, key and shackle guide has resulted in huge material savings.

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

REDUCTION DUE TO INTEGRATED MANUFACTURING

REDUCTION IN WASTE GENERATION THROUGH VALUE ENGINEERING PROJECTS

GreenCo Rating Benefits During the GreenCo assessment several improvement opportunities were brought out. Over a period of two years, the plant has implemented the following initiatives:

1. Renewable Energy Renewable energy plays a major role in meeting the energy demand of the country, conserving natural resources and mitigating climate change impacts through reduction of GHG emissions. Godrej Locks has a target to source 16% of its total energy needs at Vikhroli campus from a Ü

4 MW solar farm. 2. Waste Management and Material Conservation Several value engineering and yield improvement projects were implemented in the die casting and press shop departments to reduce solid waste generation. Some examples include -

Number of cavities in storewel plate Reduction in specific waste and cover reduced from 4 to 2. generation from 634 gm to 121 gm. Improvement in bar cutting fixture Reduction in waste generation by 32%

3. Green Supply Chain The plant has taken the following initiatives in greening the supply chain – EMS Survey on the web portal to rate suppliersÜ 59 suppliers have been covered under this surveyØ Training programs to improve the green rating of suppliers Ü Reduce, reuse and recycle projects have been initiated in packaging at the suppliers' endÜ Integrated manufacturing set up under one roof has resulted in reduction as shown below Ü Converted hexavalent zinc plating process to trivalent passivation at suppliers endÜ

Reduction in Reduction in Reduction in distance Chemicals CO2 emissions travelled (km) consumption per annum 970 to 650 13% 7,521 kg

Effective monitoring for milk-run optimization has resulted in 49.7 MT of CO reduction 2Ü annually

XVCase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Several value engineering

projects such as use of alternate material have

resulted in material savings of

1580 kg per annum and

significant cost savings

5. Life Cycle Assessment Life cycle assessment is a tool used to understand and quantify the environmental impacts of a product over the entire life cycle from cradle to grave. Godrej Locks has done commendable work in completing the life cycle assessment of a Ü

safe deposit lock The hot spots identified for improvement are bolt, base plate and cover plate. The Ü

recommendations after the LCA study are as follows – Reduction of compressed air consumptionØ Reduction in scrap generation Ø The safe plate sub-assembly has the maximum scrap lossesð Use of renewable energy sourcesØ Sourcing of recycled materials Ø Redesigning of lock componentsØ Light weighting of lock by use of high strength steel. Redesign of components using ð

materials like high grade plastic components. The safe deposit lock bolt material has been changed. This has reduced the Ü

component weight by 10.5 gm per lock and eliminated usage of lead The plant has also conducted LCA study of 7 lever navtal lock. Alternate material for Ü

the lock bolt, key and shackle guide has resulted in huge material savings.

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Tamil Nadu Newsprint and Papers Limited (TNPL), promoted by the Government of Tamil Nadu, was established in the year 1979 to produce Newsprint, Printing and Writing paper (PWP) using bagasse as the primary raw material. TNPL produces 400,000 tonnes of uncoated printing & writing paper per annum, accounting to approximately 10% of the total production of Printing and Writing Paper (PWP) in the country.

TNPL has perfected the technology of manufacturing newsprint, printing and writing paper from bagasse, a waste product of the sugar industry. This is an outstanding innovation. TNPL procures bagasse from sugar mills in exchange of steam. This is a unique system practiced successfully for the last 30 years. TNPL is the largest producer of paper from bagasse and uses about 1 million tonnes of depithed bagasse for producing the Printing & Writing Paper. TNPL produces wide portfolio of high quality non-surface sized and surface sized papers which are best suited for hi-tech printing machines. TNPL was rated in June 2015.GreenCo Gold

Company Profile

Tamil Nadu Newsprintand Papers Limited

Kagithapuram

Case Study XVI

June14-May 15

Implementa�onof Sugges�ons

Iden�fied

On-siteAssessment

June2015

May2014

FeasibilityStudy

May2014

Registra�onfor feasibility

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Tamil Nadu Newsprint and Papers Limited (TNPL), promoted by the Government of Tamil Nadu, was established in the year 1979 to produce Newsprint, Printing and Writing paper (PWP) using bagasse as the primary raw material. TNPL produces 400,000 tonnes of uncoated printing & writing paper per annum, accounting to approximately 10% of the total production of Printing and Writing Paper (PWP) in the country.

TNPL has perfected the technology of manufacturing newsprint, printing and writing paper from bagasse, a waste product of the sugar industry. This is an outstanding innovation. TNPL procures bagasse from sugar mills in exchange of steam. This is a unique system practiced successfully for the last 30 years. TNPL is the largest producer of paper from bagasse and uses about 1 million tonnes of depithed bagasse for producing the Printing & Writing Paper. TNPL produces wide portfolio of high quality non-surface sized and surface sized papers which are best suited for hi-tech printing machines. TNPL was rated in June 2015.GreenCo Gold

Company Profile

Tamil Nadu Newsprintand Papers Limited

Kagithapuram

Case Study XVI

June14-May 15

Implementa�onof Sugges�ons

Iden�fied

On-siteAssessment

June2015

May2014

FeasibilityStudy

May2014

Registra�onfor feasibility

XVICase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Rating BenefitsTNPL, Kagithapuram has taken commendable efforts to comply with the GreenCo Rating System which has led to several improvements in its overall environmental performance. Initiatives and projects already implemented by TNPL across the GreenCo parameters and those that were implemented as a result of the GreenCo initiative, are highlighted –

1. Energy EfficiencyTNPL has been constantly improving their technology into latest energy efficient and environment friendly ones. The plant has implemented several major improvement projects in 2008 through their Mill Development Program (MDP). As part of MDP, TNPL has installed: 300 TPD modern hard wood fibre line with super-batch cookingÜ Oxygen delignfication and Elemental Chlorine Free (ECF) bleaching sequenceÜ 500 TPD ECF chemical bagasse bleach plant to replace the conventional chlorine based Ü

bleach plants operated in bagasse fibre line

2. Renewable EnergyTNPL has a strong commitment from the top management to enhance the use of Renewable Energy. The plant has implemented various onsite and offsite renewable energy projects - Wind farms of 35.6 MW capacity Ü Recovery boiler that utilizes various bio mass based / derived fuels such as fresh pith, Ü

screw pith, lagoon sludge, wood bark, wood dust, black liquor solids, and agro fuels Installation of Bio-methanation plant for recovery of methane from process waste waterÜ

3 Bio gas (40 m /day) from kitchen wasteÜ

3. Water ConservationSome of TNPL's water conservation activities are highlighted - Dedicated water management team Ü Metering of water consumption at individual sections Ü DCS based online monitoring systemsÜ 14% reduction in specific water consumption Ü Rain water harvesting system implemented throughout the plant and colony. ÜGreenCo has given a new direction for TNPL to focus on sustainable water management activities beyond the fence.

4. GHG Emissions MitigationSome of the notable efforts taken by TNPL for GHG mitigation and carbon neutral approach are - 43% of the overall energy requirement through bio based fuelsÜ Refrigeration using vapor absorption machines Ü Wind farms of 35.6 MW capacity Ü Carbon emission offset by pulp wood plantation through captive plantation and Ü farm forestry schemes Onsite PCC plant that uses CO from flue gas of cement kiln2Ü

5. Waste Management and Material ConservationTNPL uses the non-hazardous solid waste generated in its operations as alternate fuels or as raw material - Organic solids waste namely pith and chipper dust are used as fuel in boilerÜ Primary sludge from ETP is used for cardboard manufacturingÜ Lime sludge and fly ash are converted into high grade cement through a 600 TPD cement Ü

manufacturing plant abutting the mill premises. It is the first-of-its-kind in the pulp and paper industry.

6. Green Supply ChainSome of the examples of green procurement and green supply chain practices initiated by the plant are mentioned below - Post-consumer and pre-consumer material waste paper procured for deinked pulp Ü

production Sourcing Forest Stewardship Council (FSC) certified wood of TNPL farm forestry andÜ

captive plantation scheme IE 2 and IE 3 energy requirements specified in the purchase requisition from the vendorsÜ Low VOC and no VOC paints are preferred and is mentioned in the contract specified to Ü

the vendors LED/ CFL bulbs procured as a replacement of conventional bulbsÜ Various logistics optimization techniques are being adapted apart from the green

procurement initiatives.

8. Product StewardshipTNPL is working with Government departments, educational institutions and other organizations, to source waste paper for their deinked pulp production. TNPL makes a special product named 'GREENPAL' which is completely made of bagasse Ü

and recycled paper ECF bleaching is adopted in the process to reduce the AOX levels; it has reduced the Ü

negative environmental impact TNPL participates in many non-binding, voluntary initiatives and programs which are Ü

aimed at reducing the environmental impact of the process or products. FSC, EPCI are a few examples.

Various energy efficiency

initiatives have resulted in 10%

reduction in specific electrical

energy consumption and 8% reduction in specific thermal

energy consumption

43% of the overall energy

consumption at TNPL is from

renewable energy sources

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

XVICase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Rating BenefitsTNPL, Kagithapuram has taken commendable efforts to comply with the GreenCo Rating System which has led to several improvements in its overall environmental performance. Initiatives and projects already implemented by TNPL across the GreenCo parameters and those that were implemented as a result of the GreenCo initiative, are highlighted –

1. Energy EfficiencyTNPL has been constantly improving their technology into latest energy efficient and environment friendly ones. The plant has implemented several major improvement projects in 2008 through their Mill Development Program (MDP). As part of MDP, TNPL has installed: 300 TPD modern hard wood fibre line with super-batch cookingÜ Oxygen delignfication and Elemental Chlorine Free (ECF) bleaching sequenceÜ 500 TPD ECF chemical bagasse bleach plant to replace the conventional chlorine based Ü

bleach plants operated in bagasse fibre line

2. Renewable EnergyTNPL has a strong commitment from the top management to enhance the use of Renewable Energy. The plant has implemented various onsite and offsite renewable energy projects - Wind farms of 35.6 MW capacity Ü Recovery boiler that utilizes various bio mass based / derived fuels such as fresh pith, Ü

screw pith, lagoon sludge, wood bark, wood dust, black liquor solids, and agro fuels Installation of Bio-methanation plant for recovery of methane from process waste waterÜ

3 Bio gas (40 m /day) from kitchen wasteÜ

3. Water ConservationSome of TNPL's water conservation activities are highlighted - Dedicated water management team Ü Metering of water consumption at individual sections Ü DCS based online monitoring systemsÜ 14% reduction in specific water consumption Ü Rain water harvesting system implemented throughout the plant and colony. ÜGreenCo has given a new direction for TNPL to focus on sustainable water management activities beyond the fence.

4. GHG Emissions MitigationSome of the notable efforts taken by TNPL for GHG mitigation and carbon neutral approach are - 43% of the overall energy requirement through bio based fuelsÜ Refrigeration using vapor absorption machines Ü Wind farms of 35.6 MW capacity Ü Carbon emission offset by pulp wood plantation through captive plantation and Ü farm forestry schemes Onsite PCC plant that uses CO from flue gas of cement kiln2Ü

5. Waste Management and Material ConservationTNPL uses the non-hazardous solid waste generated in its operations as alternate fuels or as raw material - Organic solids waste namely pith and chipper dust are used as fuel in boilerÜ Primary sludge from ETP is used for cardboard manufacturingÜ Lime sludge and fly ash are converted into high grade cement through a 600 TPD cement Ü

manufacturing plant abutting the mill premises. It is the first-of-its-kind in the pulp and paper industry.

6. Green Supply ChainSome of the examples of green procurement and green supply chain practices initiated by the plant are mentioned below - Post-consumer and pre-consumer material waste paper procured for deinked pulp Ü

production Sourcing Forest Stewardship Council (FSC) certified wood of TNPL farm forestry andÜ

captive plantation scheme IE 2 and IE 3 energy requirements specified in the purchase requisition from the vendorsÜ Low VOC and no VOC paints are preferred and is mentioned in the contract specified to Ü

the vendors LED/ CFL bulbs procured as a replacement of conventional bulbsÜ Various logistics optimization techniques are being adapted apart from the green

procurement initiatives.

8. Product StewardshipTNPL is working with Government departments, educational institutions and other organizations, to source waste paper for their deinked pulp production. TNPL makes a special product named 'GREENPAL' which is completely made of bagasse Ü

and recycled paper ECF bleaching is adopted in the process to reduce the AOX levels; it has reduced the Ü

negative environmental impact TNPL participates in many non-binding, voluntary initiatives and programs which are Ü

aimed at reducing the environmental impact of the process or products. FSC, EPCI are a few examples.

Various energy efficiency

initiatives have resulted in 10%

reduction in specific electrical

energy consumption and 8% reduction in specific thermal

energy consumption

43% of the overall energy

consumption at TNPL is from

renewable energy sources

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

ITC's Paperboards and Specialty Papers Division is India's largest, technologically advanced and most eco-friendly, paper and paperboards business. The business caters to a wide spectrum of packaging, graphic, communication, writing, printing and specialty paper requirements through its four world-class manufacturing units at Bhadrachalam, Tribeni, Kovai and Bollaram.

The ITC, PSPD, Kovai unit with 100,000 TPA capacity focuses entirely on recycled boards, servicing requirements for both greyback and whiteback recycled boards. ITC, as a corporate is carbon positive for 9 consecutive years, water positive for 12 years in a row and solid waste recycling positive for the last 7 years . To demonstrate i t s commitment towards environmental sustainability, ITC Kovai's another major step is its venture into the GreenCo Rating System. Its courageous step forward and continuous efforts, has earned ITC Limited, PSPD, Unit – Kovai the distinction of being the First Company in the Pulp and Paper Sector GreenCo Platinum to be rated .

Company Profile

ITC Limited, Paperboards and Specialty Papers Division

Case Study XVII

April 14-May 15

Implementa�onof Sugges�ons

Iden�fied

On-siteAssessment

June2015

April2014

FeasibilityStudy

March2014

Registra�onfor feasibility

Unit - Kovai

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

ITC's Paperboards and Specialty Papers Division is India's largest, technologically advanced and most eco-friendly, paper and paperboards business. The business caters to a wide spectrum of packaging, graphic, communication, writing, printing and specialty paper requirements through its four world-class manufacturing units at Bhadrachalam, Tribeni, Kovai and Bollaram.

The ITC, PSPD, Kovai unit with 100,000 TPA capacity focuses entirely on recycled boards, servicing requirements for both greyback and whiteback recycled boards. ITC, as a corporate is carbon positive for 9 consecutive years, water positive for 12 years in a row and solid waste recycling positive for the last 7 years . To demonstrate i t s commitment towards environmental sustainability, ITC Kovai's another major step is its venture into the GreenCo Rating System. Its courageous step forward and continuous efforts, has earned ITC Limited, PSPD, Unit – Kovai the distinction of being the First Company in the Pulp and Paper Sector GreenCo Platinum to be rated .

Company Profile

ITC Limited, Paperboards and Specialty Papers Division

Case Study XVII

April 14-May 15

Implementa�onof Sugges�ons

Iden�fied

On-siteAssessment

June2015

April2014

FeasibilityStudy

March2014

Registra�onfor feasibility

Unit - Kovai

XVIICase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Rating BenefitsITC Limited, PSPD, Unit Kovai, between April 2014 and February 2015, has taken commendable efforts to comply with the GreenCo Rating System which has led to significant improvements in its overall environmental performance. Initiatives and projects already implemented by ITC PSPD, Kovai across the GreenCo parameters and those that were implemented as a result of the GreenCo initiative, are highlighted as under –

PolicyÜ ITC-PSPD, Kovai unit has framed a Green Policy, which commits to monitor and continuously

improve against set targets on various environmental parameters. It also ensures continuous capability building in employees, suppliers and vendors in order to achieve international benchmarks in an environmentally sustainable manner. All GreenCo areas are addressed in the policy and the policy specifies and highlights areas of concern with respect to each of them.

Target SettingÜ ITC-PSPD, Kovai has a clear methodology of setting targets; average of the best achieved

figures for each operational parameter is calculated against the average of the entire annual figure for each operational parameter. Targets are set based on this approach and sensitivity analysis is done to chart out action plans.

Employee Involvement Ü ITC-PSPD, Kovai has demonstrated good strategies for employee involvement. Employee

involvement is executed by the lean manufacturing structure wherein various teams such as the pillar teams, process and asset care teams, area effectiveness teams and steering board members participate and contribute to overall employee involvement and capacity building.

A 'pocket guide on GreenCo' explaining the system & its requirements and ITC Kovai's performance in each of the parameters printed in English and in the local language, was distributed to all employees.

1. Energy EfficiencyITC-PSPD, Kovai has proved that energy has always been a priority for ITC by exhibiting good performance with respect to energy efficiency. The % reduction in specific power consumption and specific steam consumption and the savings achieved is illustrated below –

% reduction in specific Units saved in the last Rupee saved in the last power consumption three years three years 6.2% 7.419 Million Units 32.9 Million Rupees % reduction in specific Tons of lignite saved in Rupee saved in the last steam consumption the last three years three years 7.7% 3018.8 tons of lignite 9.1 Million Rupees

Ü Dedicated group of members constituting the energy management cell with their roles and responsibilities clearly defined contribute to ITC's excellent energy performance

Excellent equipment wise, section wise and department wise energy efficiency Ü monitoring

2. Renewable EnergyITC-PSPD, Kovai has demonstrated its commitment to use renewable energy through the following initiatives

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Targets such as 100% utilization of wind power generated and maximizing use of bio fuels Ü are highlighted in ITC-PSPD, Kovai's renewable energy policy

Nearly 44.3% of the overall energy requirement of ITC-PSPD, Kovai is met through Ü renewable energy sources

Renewable energy system Savings Wind energy (7.5 MW) substituting conventional energy 26.2% substitution Use of bio fuels 30.1% substitution (avg. of the last three years) 48 solar street lights 200 units per annum Solar water heaters for canteen 9,612 kg of LPG per annum Solar light pipes 45,000 units per annum

3.Waste Management and Material ConservationITC-PSPD, Kovai has been helping ITC turn solid waste recycling positive for the past 7 years, by consuming more paper waste generated than is generated internally. This is done by collecting waste from households and institutions and recycling it at this facility. 100% of ITC Kovai's waste is recycled or handled by authorized recyclersÜ Fly ash generated is used 100% for making fly ash bricksØ Reject plastic from collected waste paper is sent to cement plants for co-processingØ Options of making oil from plastic are being exploredð ETP primary sludge is reused in the filler layer and also for manufacture of sundry Ø

boards Canteen waste and ETP bio sludge is vermicompostedÜ Clear Y-O-Y targets for all areas of focus, activity chart, action plan and resource allocation Ü

are mapped to reduce raw material consumption

4. Green Supply ChainITC-PSPD, Kovai has done commendable work in greening its supply chain. ITC has made sure to focus on greening its upstream and downstream supply chain activities. Some of the activities carried out internally are as highlighted below –Ü Emphasis is laid on green procurement through its green purchase policyØ Environmental performance is included as an important criteria in vendor selection Ø

and evaluation Methodology to identify critical vendors with environmental performance, quantity, Ø

alternate availability and distance being considered as evaluation parameters Very clear targets to expand and improve these activities to all identified critical Ø

vendors Some of the activities carried out externally are as highlighted below –Ü Excellent awareness creation and training programs with good training material Ø

developed Visit to supplier premises and conduct supplier audits and reviews to monitor Ø

implementation of environmental improvement activities Very good initiatives carried out in supplier premises on systems, energy, water, etc. Ø

and clear targets in place to extend these initiatives to all critical suppliers and vendors.

26.5% reduction in specific GHG

intensity in last 3 years

SUBSTITUTION AND SAVINGS FROM USE OF RENEWABLE ENERGY

Reduction in imports by 38%

through building a supplier base that

is in closer proximity

XVIICase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

GreenCo Rating BenefitsITC Limited, PSPD, Unit Kovai, between April 2014 and February 2015, has taken commendable efforts to comply with the GreenCo Rating System which has led to significant improvements in its overall environmental performance. Initiatives and projects already implemented by ITC PSPD, Kovai across the GreenCo parameters and those that were implemented as a result of the GreenCo initiative, are highlighted as under –

PolicyÜ ITC-PSPD, Kovai unit has framed a Green Policy, which commits to monitor and continuously

improve against set targets on various environmental parameters. It also ensures continuous capability building in employees, suppliers and vendors in order to achieve international benchmarks in an environmentally sustainable manner. All GreenCo areas are addressed in the policy and the policy specifies and highlights areas of concern with respect to each of them.

Target SettingÜ ITC-PSPD, Kovai has a clear methodology of setting targets; average of the best achieved

figures for each operational parameter is calculated against the average of the entire annual figure for each operational parameter. Targets are set based on this approach and sensitivity analysis is done to chart out action plans.

Employee Involvement Ü ITC-PSPD, Kovai has demonstrated good strategies for employee involvement. Employee

involvement is executed by the lean manufacturing structure wherein various teams such as the pillar teams, process and asset care teams, area effectiveness teams and steering board members participate and contribute to overall employee involvement and capacity building.

A 'pocket guide on GreenCo' explaining the system & its requirements and ITC Kovai's performance in each of the parameters printed in English and in the local language, was distributed to all employees.

1. Energy EfficiencyITC-PSPD, Kovai has proved that energy has always been a priority for ITC by exhibiting good performance with respect to energy efficiency. The % reduction in specific power consumption and specific steam consumption and the savings achieved is illustrated below –

% reduction in specific Units saved in the last Rupee saved in the last power consumption three years three years 6.2% 7.419 Million Units 32.9 Million Rupees % reduction in specific Tons of lignite saved in Rupee saved in the last steam consumption the last three years three years 7.7% 3018.8 tons of lignite 9.1 Million Rupees

Ü Dedicated group of members constituting the energy management cell with their roles and responsibilities clearly defined contribute to ITC's excellent energy performance

Excellent equipment wise, section wise and department wise energy efficiency Ü monitoring

2. Renewable EnergyITC-PSPD, Kovai has demonstrated its commitment to use renewable energy through the following initiatives

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

Targets such as 100% utilization of wind power generated and maximizing use of bio fuels Ü are highlighted in ITC-PSPD, Kovai's renewable energy policy

Nearly 44.3% of the overall energy requirement of ITC-PSPD, Kovai is met through Ü renewable energy sources

Renewable energy system Savings Wind energy (7.5 MW) substituting conventional energy 26.2% substitution Use of bio fuels 30.1% substitution (avg. of the last three years) 48 solar street lights 200 units per annum Solar water heaters for canteen 9,612 kg of LPG per annum Solar light pipes 45,000 units per annum

3.Waste Management and Material ConservationITC-PSPD, Kovai has been helping ITC turn solid waste recycling positive for the past 7 years, by consuming more paper waste generated than is generated internally. This is done by collecting waste from households and institutions and recycling it at this facility. 100% of ITC Kovai's waste is recycled or handled by authorized recyclersÜ Fly ash generated is used 100% for making fly ash bricksØ Reject plastic from collected waste paper is sent to cement plants for co-processingØ Options of making oil from plastic are being exploredð ETP primary sludge is reused in the filler layer and also for manufacture of sundry Ø

boards Canteen waste and ETP bio sludge is vermicompostedÜ Clear Y-O-Y targets for all areas of focus, activity chart, action plan and resource allocation Ü

are mapped to reduce raw material consumption

4. Green Supply ChainITC-PSPD, Kovai has done commendable work in greening its supply chain. ITC has made sure to focus on greening its upstream and downstream supply chain activities. Some of the activities carried out internally are as highlighted below –Ü Emphasis is laid on green procurement through its green purchase policyØ Environmental performance is included as an important criteria in vendor selection Ø

and evaluation Methodology to identify critical vendors with environmental performance, quantity, Ø

alternate availability and distance being considered as evaluation parameters Very clear targets to expand and improve these activities to all identified critical Ø

vendors Some of the activities carried out externally are as highlighted below –Ü Excellent awareness creation and training programs with good training material Ø

developed Visit to supplier premises and conduct supplier audits and reviews to monitor Ø

implementation of environmental improvement activities Very good initiatives carried out in supplier premises on systems, energy, water, etc. Ø

and clear targets in place to extend these initiatives to all critical suppliers and vendors.

26.5% reduction in specific GHG

intensity in last 3 years

SUBSTITUTION AND SAVINGS FROM USE OF RENEWABLE ENERGY

Reduction in imports by 38%

through building a supplier base that

is in closer proximity

XVIICase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

6. Product Stewardship ITC's flagship programme, Wellbeing out of Waste (WOW) initiative is one of the best Ü

examples for product take back and recycling WOW is aimed at addressing efficient waste management and source segregation of Ø

waste The WOW movement has spread across Hyderabad, Chennai, Bengaluru, Cochin, Ø

Coimbatore, Trichy, Erode, Madurai, Vijayawada, Rajahmundry and Guntur, enjoying the support of over

3 million citizensð 500,000 school childrenð 350 corporatesð more than 1,000 commercial establishments ð around 200 industriesð ITC PSPD's FSC® certification is one more indicator of its continued pursuit for Ü

sustainability and commitment for a better tomorrow. ITC-PSPD's all four units are FSC | certified

7. Life Cycle AssessmentITC-PSPD, Kovai has conducted LCA study for its Coated Board Grey Back (CBGB) paperboard and it was conducted by PE International. The study concluded that the major environmental impact in terms of the global warming Ü

potential was highest during the manufacturing phase followed by the transportation phase and upstream phase.

ITC-PSPD, Kovai has charted out an action plan aiming to reduce the environmental Üimpact created by their product throughout its life cycle.

ITC also has targets to execute Life Cycle Assessment studies for its other major product Üthe Coated Board White Back paperboard and reassessment targets for both these products

ITC Limited, PSPD, Unit Kovai has d e m o n s t r a t e d e x c e l l e n c e i n environmental sustainability and the GreenCo Platinum is to substantiate its performance; many significant initiatives taken even before the implementation of the GreenCo Rating System and multiple strategic and significant initiatives executed because of the GreenCo Rating System. This focused and systematic approach will enable ITC-PSPD, Kovai to remain as one of the global leaders in the pulp and paper industry.

XVIICase Study

Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre

6. Product Stewardship ITC's flagship programme, Wellbeing out of Waste (WOW) initiative is one of the best Ü

examples for product take back and recycling WOW is aimed at addressing efficient waste management and source segregation of Ø

waste The WOW movement has spread across Hyderabad, Chennai, Bengaluru, Cochin, Ø

Coimbatore, Trichy, Erode, Madurai, Vijayawada, Rajahmundry and Guntur, enjoying the support of over

3 million citizensð 500,000 school childrenð 350 corporatesð more than 1,000 commercial establishments ð around 200 industriesð ITC PSPD's FSC® certification is one more indicator of its continued pursuit for Ü

sustainability and commitment for a better tomorrow. ITC-PSPD's all four units are FSC | certified

7. Life Cycle AssessmentITC-PSPD, Kovai has conducted LCA study for its Coated Board Grey Back (CBGB) paperboard and it was conducted by PE International. The study concluded that the major environmental impact in terms of the global warming Ü

potential was highest during the manufacturing phase followed by the transportation phase and upstream phase.

ITC-PSPD, Kovai has charted out an action plan aiming to reduce the environmental Üimpact created by their product throughout its life cycle.

ITC also has targets to execute Life Cycle Assessment studies for its other major product Üthe Coated Board White Back paperboard and reassessment targets for both these products

ITC Limited, PSPD, Unit Kovai has d e m o n s t r a t e d e x c e l l e n c e i n environmental sustainability and the GreenCo Platinum is to substantiate its performance; many significant initiatives taken even before the implementation of the GreenCo Rating System and multiple strategic and significant initiatives executed because of the GreenCo Rating System. This focused and systematic approach will enable ITC-PSPD, Kovai to remain as one of the global leaders in the pulp and paper industry.

The Confedera�on of Indian Industry (CII) works to create and sustain an environment conducive to the development of Ind ia , partner ing industry, Government, and civil society, through advisory and consulta�ve processes.

CII is a non-government, not-for-profit, industry-led and industry-managed organiza�on, playing a proac�ve role in India's development process. Founded in 1895, India's premier business associa�on has over 7400 members, from the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 100,000 enterprises from around 250 na�onal and regional sectoral industry bodies.

CII charts change by working closely with Government on policy issues, interfacing with thought leaders, and enhancing efficiency, compe��veness and business opportuni�es for industry through a range of specialized services and strategic global linkages. It also provides a pla�orm for consensus-building and networking on key issues..

Extending its agenda beyond business, CII assists

industry to iden�fy and execute corporate ci�zenship programmes. Partnerships with civi l society organiza�ons carry forward corporate ini�a�ves for integrated and inclusive development across diverse domains including affirma�ve ac�on, healthcare, educa�on, livelihood, diversity management, skill development, empowerment of women, and water, to name a few.

In its 120th year of service to the na�on, the CII theme of 'Build India – Invest in Development, A Shared Responsibility,' reiterates Industry's role and responsibility as a partner in na�onal development. The focus is on four key enablers: Facilita�ng Growth and C o m p e � � ve n e s s , P ro m o � n g I n f ra s t r u c t u re Investments, Developing Human Capital, and Encouraging Social Development.

With 64 offices, including 9 Centres of Excellence, in India, and 7 overseas offices in Australia, China, Egypt, France, Singapore, UK, and USA, as well as ins�tu�onal partnerships with 300 counterpart organiza�ons in 106 countries, CII serves as a reference point for Indian industry and the interna�onal business community.

CII - Sohrabji Godrej Green Business CentreSurvey No. 64, Kothaguda Post, Near HITEC City,Hyderabad - 500 084. India.Tel : +91 40 44185111. Fax : +91 40 44185189www.greenbusinesscentre.com

For further informa�on,kindly contact :N. MuthusezhiyanPrincipal CounsellorEmail : n.muthu@cii.in

CII-Sohrabji Godrej Green Business Centre (CII-Godrej GBC) was established in the year 2004, as CII's Developmental Ins�tute on Green Prac�ces & Businesses, aimed at offering world class advisory services on conserva�on of natural resources.

The Green Business Centre in Hyderabad is housed in one of the greenest buildings in the world and through Indian Green Building Council (IGBC) is spearheading the Green Building movement in the country. The Green Business Centre was inaugurated by His Excellency

Dr. A. P. J. Abdul Kalam, the then President of India on 14 July 2004.The Services of Green Business Centre include- Energy Management, Green Buildings, Green Companies, Renewable Energy, GHG Inventoriza�on, Green Product Cer�fica�on, Waste Management and Cleaner Produc�on Process.

CII-Godrej GBC works closely with the stakeholders in facilita�ng India emerge as one of the global leaders in Green Business by the year 2022.

About CII - Sohrabji Godrej Green Business Centre (CII-Godrej GBC)

ABOUT CII