GOING GREEN !MYSORE BEVERAGES FACTORY
WE REMAIN COMMITTED TO OUR STRATEGY
We Will Develop New Ways of Doing Business with the
Aim of Doubling the Size of Our Company While Reducing
Our Environmental Impact
VISION
A BRAND OF SUSTAINABILITY
Double the Productivity
Highly visible point of difference for consumers, and a clear indicator of Unilever’s
sustainability credentials
MYSORE FACTORY UNIT
GREEN CO JOURNEY11• WFE Installation
• Spraying Pattern Optimization• Agro-waste Boiler Installation
• WFE Installation• Spraying Pattern Optimization• Agro-waste Boiler Installation
• Flash Steam and Condensate Recovery• Screw Based Air Compressor Installation• Heat Recovery from ICC Column• VAM Chiller
• Flash Steam and Condensate Recovery• Screw Based Air Compressor Installation• Heat Recovery from ICC Column• VAM Chiller
2010
2012
2013
2014
• IE3 Motors Installation • Jet Aerators to Replace surface aerators• Spent Water Recycling• Condensate Recovery Phase 2• Vacuum Pump Water recirculation by cooling• Westphalia Sludge Recycling • Recycling ETP treated water through RO
• IE3 Motors Installation • Jet Aerators to Replace surface aerators• Spent Water Recycling• Condensate Recovery Phase 2• Vacuum Pump Water recirculation by cooling• Westphalia Sludge Recycling • Recycling ETP treated water through RO
• IE3 Motors Phase 2• LED Lighting Phase 1• Online In-house Spent Burning• MMB Uptime Improvement• Spray Drier Efficiency Improvement• 3D TRASAR for Cooling Tower Optimization• VFD and Interlocks for Energy Optimization• Planetary Gear Boxes• Lighting Timers
• IE3 Motors Phase 2• LED Lighting Phase 1• Online In-house Spent Burning• MMB Uptime Improvement• Spray Drier Efficiency Improvement• 3D TRASAR for Cooling Tower Optimization• VFD and Interlocks for Energy Optimization• Planetary Gear Boxes• Lighting Timers
Green-Co “Silver” Rating• Registration for rating with Green-Co CII
Godrej GBC• Training Program by CII Godrej GBC• Submission of Green-Co Rating Assessment
documents• Preliminary Assessment and Site Visit• Submission of recommendations
2015
2016
• Modulation unit in Roaster• Cooling tower optimization• Liquor distribution optimization• Electrical heater elimination in DHU• Extraction steam economy improvement• MMB conveyor breakdown reduction• Express feeder• Tank drain collection system• ESP installation• Steam turbine installation• Solar power usage• Solar water heater for canteen
• Modulation unit in Roaster• Cooling tower optimization• Liquor distribution optimization• Electrical heater elimination in DHU• Extraction steam economy improvement• MMB conveyor breakdown reduction• Express feeder• Tank drain collection system• ESP installation• Steam turbine installation• Solar power usage• Solar water heater for canteen
Clarification
Aroma Stripping
Thermal Concentration
Spray Drying
Powder Collection
Separate Chicory
Extraction
Compressors
ETP
UTILITIES
FO Boiler
GB Dumping
Roasting
Coffee Extraction
Multimedia Boiler
Cooling Tower
Liquor Transfer
Pumps
DHU
Process OverviewWhat Are my Top Opportunities ?
40%2014
ROASTER – PROCESS OVERVIEW
98196 KJ/Batch
Theoretical and Bare minimum Energy needed to roast one
batch of beans to 198 degrees
Specific Heat of Dry Coffee Bean @ 10% Moisture
1.67 KJ/Kg/K
Source - http://www.home-barista.com/tips/heat-capacity-of-dry-coffee-and-brew-temperature-profiles-t11433.html
924616 KJ/Batch
Practically Achieved
THEORITICAL ROASTING CONSUMPTION
CIRCLES – AN INCLUSIVE APPROACH !
PARETO ANALYSIS – ENERGY LOSS
1. 400 degree exhaust temp due to Catalyzer (VOC)
10% efficiency loss !
2. Idle running of burner during charging/discharging
3. Regular Startup and Shutdown due to inventory levels
4. Higher Surface Temperature
PAIN POINTS !
WWBLA – HEAT ENERGY LOSSES
K1
K2
K3
K4
ENERGY LOSS THROUGH SURFACE
Dismantling Of Old Drum Damaged Refractory
& Flame Tube
Repair of Refractory
& Flame Tube
Installation Of New DrumI am Ready To Roast
RESTORATION OF BASIC CONDITION
Challenges Faced• Alignment and rotation assembly is very critical – 1 week
training by OEM• Proprietary equipment, unforeseen issues will lead to major
delays – Inventory of possible issues and spares kept ready• Leakages due to inappropriate fixing – Detailed drawings
prepared with tolerances and method statement prepared
HIGH STACK LOSS
0
50
100
150
200
250
-1.5 0.5 2.5 4.5 6.5 8.5 10.5 12.5 14.5 16.5 18.5
TE
MP
ER
AT
UR
E
TIME
Roasting Profile
Exhaust Damper
Heat Recovery
Rate of Heating
CONSPROS• Energy Saving• Low BCT
• Charring Potential• Non Uniform Roasting
Charging 1st StageHeating
(Fast Possible)
2nd StageHeating(Steady)
Quenching Discharging Drum Heating
Fixed Damper 40%, Optimized over full duration
HIGH STACK LOSS
BEFORE AFTER
� Automated Damper which is Controlled
By Drum temperature
� More Recovery of Heat Energy
� Less Diesel Consumption
�Fixed Position of Exhaust Damper
� Less Heat Energy Recovery
� More Combustion through Burner
0
50
100
150
200
250
-1.5 0.5 2.5 4.5 6.5 8.5 10.5 12.5 14.5 16.5 18.5
TE
MP
ER
AT
UR
E
TIME
Roasting Profile
Charging 1st StageHeating
(Fast Possible)
2nd StageHeating(Steady)
Quenching Discharging Drum Heating
Exhaust Damper
20%
Exhaust Damper
40%
KAIZEN 1- AUTOMATION OF DAMPERK1
Challenges Faced• Additional equipment added – Included part of PM and
calibration schedule• Improper operation by damper – Feedback loop for positions
given• Increased complexity of operation – Detailed OJT, OPLs
prepared, SCADA connected• Beans quality impact – new parameters standardized post
trials
K1
IDLE RUNNING OF BURNER
0
50
100
150
200
250
-1.5 0.5 2.5 4.5 6.5 8.5 10.5 12.5 14.5 16.5 18.5
TE
MP
ER
AT
UR
E
TIME
Roasting Profile
Charging 1st StageHeating
(Fast Possible)
2nd StageHeating(Steady)
Quenching Discharging Drum Heating
Burner Loading – 90% (fixed)
Idle Time
� Constant Diesel Flow and Air
� Incomplete combustion
� More Clinker Formation
BEFORE
KAIZEN 2 – MODULATION UNIT IN BURNER
0
50
100
150
200
250
-1.5 0.5 2.5 4.5 6.5 8.5 10.5 12.5 14.5 16.5 18.5
TE
MP
ER
AT
UR
E
TIME
Roasting Profile
Charging 1st StageHeating
(Fast Possible)
2nd StageHeating(Steady)
Quenching Discharging Drum Heating
Burner Loading – 65%
Idle Time
� Constant Diesel Flow and Air
� Incomplete combustion
� More Clinker Formation
BEFORE
�New Burner Can Modulate
Diesel Flow Based on Air
� Better Combustion
� Diesel Saving and Better roast in turn
AFTER
30%
KAIZEN 2 – MODULATION UNIT IN BURNERK2
Challenges Faced• Additional clinker formation – separate modulation unit for
air to ensure correct air to fuel ratio• High smoke generation during quenching – ID fan adjusted
to ensure –ve pressure• Higher cycle time – automated damper position optimized
with trials• Special spares – inventory created for key high lead time
spares
K2
K1
IDLE RUNNING
Roaster 1 Roaster 2
Green
Beans
Hopper
BEFORE AFTER
� Separate Green Bean Charging Hopper For both the
Roasters
� Diesel Wastage Due to idle Running is reduced
� Loading time of Roasters is reduced �One Green Bean Charging Hopper for Both the Roasters
� One Roaster Used to run Idle when charging to the other
Roaster
Roaster 1 Roaster 2
Green
Beans
Hopper
Green
Beans
Hopper
Starving and
Stopped
No
Starving
KAIZEN 3 – GREEN BEANS CHARGING SYSTEMK3
Roaster 1 Roaster 2
Roasted
Beans
Hopper
Roasted
Beans
Hopper
IC Silos CC Silos
Roaster 1 Roaster 2
Roasted
Beans
Hopper
Roasted
Beans
Hopper
IC Silos CC Silos IC Silos CC Silos
BEFORE AFTER
Diverter
Diverter
Diverter Diverter
� Separate Transportation Routes For both the
Roasters
� Diesel Wastage Due to idle Running is reduced
� Loading time of Roasters is reduced
� Only One Transportation Route For both the Roasters
� One Roaster Used to run idle if beans from other Roaster
Is getting transferred
� Diesel Wastage Due to idle Running
Stopped
Starvation
No Unnecessary
Stoppages
No Starvation
KAIZEN 4 – SEPARATE TRANSPORTATION SYSTEMK4
K1
K3
K4
K2
0
10
20
30
40
50
60
70
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec YTD
ROASTER HSD/Ton of IC
YTD 2014 YTD 2015 2014 2015
RESULT VERIFICATION
Energy Consumption reduced – 4085 GJ/Year
Carbon emission reduced – 307 Tons/Year
HSD saved – 95 KL/Year
Annual savings – 38 Lacs
Investment – 20 Lacs
BENCHMARKING, INNOVATION AND REPLICABILITYInstant coffee processing is closely guarded and very limited public information is available.This is done basis internal benchmarking and available data through various sources
• Coffee roasting is highly guarded industrial secret in terms of available designs, solutions etc.• Highly controlled process in terms of instant coffee quality• Operational and technical experience of operators in bringing better control over process• Achieved better efficiency than the equipment designed for• Reducing consumption of high CO2 contributing HSD
Highly replicable across equipments with variable heating requirements
40%
Clarification
Aroma Stripping
Thermal Concentration
Spray Drying
Powder Collection
Separate Chicory
Extraction
Compressors
ETP
UTILITIES
FO Boiler
GB Dumping
Roasting
Coffee ExtractionMultimedia Boiler
Cooling Tower
Liquor Transfer Pumps
DHU
2014
46%38L
40%2014
Clarification
Aroma Stripping
Thermal Concentration
Spray Drying
Powder Collection
Separate Chicory
Extraction
Compressors
ETP
UTILITIES
FO Boiler
GB Dumping
Roasting
Coffee ExtractionMultimedia Boiler
Cooling Tower
Liquor Transfer Pumps
DHU
1st StageSteam Heating
2nd StageElectrical Heating
90 KW
Cond @134 C
Air @ 25 Deg
Air @ 110 Deg
Air @ 140 Deg
Steam @ 3 bar – 134 C
25 Deg140 Deg
Expensive source of heat and high carbon foootprint
UNDERSTANDING DHU OPERATION
TRAINING TO OPERATORS ON BASICS OF THERMODYNAMICS
Enthalpy of VapTsatPsat
1st StageSteam Heating
2nd StageElectrical Heating
90 KW
Cond @134 C
Air @ 25 Deg
Air @ 110 Deg
Air @ 140 Deg
Steam @ 3 bar – 134 C
BEFORE
7 Bar
3 Bar134 C
165 C
Enthalpy of Vap
1st StageSteam Heating
Cond @165 C
Air @ 25 Deg
Air @ 140 Deg
Steam @ 7 bar – 165 C
AFTER
Electrical Heater
Eliminated
Replication – SD DHU
KAIZEN – STEAM HEATING IN DHUK10
Horizontal Replication potential – Evaluate the Optimum steam pressure requirements
Challenges Faced• Steam coil failures – Steam coil designed for 11 Bar pressure• Higher steam consumption – upgraded traps, pipelines• Inefficient steam consumption due to low latent heat – pressure
optimized to suit temperature and cost.• DHU performance impact due to change in system – monitoring of
key parameters – reaction air pressure, temp
SCHEMATIC DIAGRAM power
PERFORMANCE MONITORING SHEET
KPI MONITORING SHEET
STEAM MONITORING SHEET Emission Monitoring
ONLINE MONITORING
Regular Monitoring of Results
Energy Consumption reduced – 1512 MWh/Year
Carbon emission reduced – 1200 Tons/Year
Annual savings – 80 Lacs
Investment Made – 15 Lacs
BENCHMARKING, INNOVATION AND REPLICABILITY
• Electrical heater part of design for high reaction air temp• Questioning the design through basics of thermodynamics• Shifting to greener and cheaper source of energy
Highly replicable across equipments where HSD/electricity is used ad cheaper greener steam is available
• Horizontal Replication for DHU B by Sep -16
46%38L
40%2014
Clarification
Aroma Stripping
Thermal Concentration
Spray Drying
Powder Collection
Separate Chicory
Extraction
Compressors
ETP
UTILITIES
FO Boiler
GB Dumping
Roasting
Coffee ExtractionMultimedia Boiler
Cooling Tower
Liquor Transfer Pumps
DHU
46%40% 50%80L
2014
Clarification
Aroma Stripping
Thermal Concentration
Spray Drying
Powder Collection
Separate Chicory
Extraction
Compressors
ETP
UTILITIES
FO Boiler
GB Dumping
Roasting
Coffee Extraction
Cooling Tower
Liquor Transfer Pumps
DHU
Multimedia Boiler
38L
46%40% 50%80L
51% 54% 55%2014
Clarification
Aroma Stripping
Thermal Concentration
Spray Drying
Powder Collection
Separate Chicory
Extraction
Compressors
ETP
UTILITIES
FO Boiler
GB Dumping
Roasting
Coffee ExtractionMultimedia Boiler
Cooling Tower
Liquor Transfer Pumps
DHU
38L
Good Green Governance Award
2016
Specification concept
Detailed Design
Basic Design
No. Date Source Priority Problem/ Action Date Action Cause Result Feedback destinationFeedback
Details
A B Request C D E F
1 5 2
All motos associated with
Roaster 1 were running in
Full load in star delta
connection.The speed of
the motors were not
controlled. It was difficult
to trace out the wiring
during trouble shooting or
maintanence.
Installation of VFD(variable
frequency drives) helped in
controlling the speed,
frenquency of the motors.
1 2
Transmission losses are
avoided, energy and cost
savings
3Murugajothi.
N
1. This machine only
3.Design Department (Inhouse)
4.Design Department (External)
5.User Department 3.This machine subsequent and
similar models
5.Modify material shape 7.Improve operatability
as Possible 3.Modify control models 4.Improve maintanability
3.Reference Requested circuitry 3. Fabrication error 5.Improve cost
4.Modify surface / heat effectiveness
treat 4. Specification change 6.Improve Safety
2.Fabrication Department (External) Mandatory mechanism 2.Increased Capacity
2.Incorporation as far 2.Modify action / function 2. Design error 2.This machine/subsequent 3.Improve Reliability
1.Increased Process
1. Fabrication department (Inhouse) 1.Incorporation 1. Modify structure / 1. Planning error Capability
F. Feedback details
Accepting Department : Instrumentation and Process
Person Resp Remarks
Key
A. Information Source B. Priority C. Action D. Cause E. Feedback destination
Destination Section : Motor control panel
MP Sheet - ACTION / FEEDBACK TO EQUIPMENT DESIGN
Prepared by: N.Murugajothi
Equipment : Roaster 1 Utility / Engineering Section :
At the time of :
BEFORE
AFTER
MP Sheets
Generated
STANDARDIZATION
46%40% 50%80L
51% 54% 55%2014
Clarification
Aroma Stripping
Thermal Concentration
Spray Drying
Powder Collection
Separate Chicory
Extraction
Compressors
ETP
UTILITIES
FO Boiler
GB Dumping
Roasting
Coffee ExtractionMultimedia Boiler
Cooling Tower
Liquor Transfer Pumps
DHU
38L
46%40% 50%80L
51% 54%2014 2015 & 16
55% 85%2016
57%
Full IN-HOUSE SPENT BURNING
62%
ESP INSTALLATION
67%
STEAM TURBINE INSTALLATION
83%
OFF-SITE/ON SITE SOLAR
85%
Roaster Exhaust recovery
WAY FORWARD
38L
46%40% 50%80L
51% 54%2014 2015
55% 85%2016
Biomasss Thermic Fluid Heater for HSD Elimination
97% • High Capacity Steam Turbine for excess electricity
• Electricity generation through Bio gas• Excess Solar panels in the coconut farm• Additional trees for sequestering carbon
2017
WAY FORWARD
Unilever Declares Ambition to go carbon positive by 2030 !
38L
A BRAND OF SUSTAINABILITY
Double the Productivity
Highly visible point of difference for consumers, and a clear indicator of Unilever’s
sustainability credentials