going green...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 temperature time...

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

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150

200

250

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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

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100

150

200

250

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TE

MP

ER

AT

UR

E

TIME

Roasting Profile


(Fast Possible)



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

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TE

MP

ER

AT

UR

E

TIME

Roasting Profile


(Fast Possible)



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

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TE

MP

ER

AT

UR

E

TIME

Roasting Profile


(Fast Possible)



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


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


Spray Drying

Powder Collection

Separate Chicory

Extraction

Compressors

ETP

UTILITIES

FO Boiler

GB Dumping

Roasting


Cooling Tower


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


2nd StageElectrical Heating

90 KW

Cond @134 C

Air @ 25 Deg

Air @ 110 Deg

Air @ 140 Deg


BEFORE

7 Bar

3 Bar134 C

165 C

Enthalpy of Vap


Cond @165 C

Air @ 25 Deg

Air @ 140 Deg


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


Spray Drying

Powder Collection

Separate Chicory

Extraction

Compressors

ETP

UTILITIES

FO Boiler

GB Dumping

Roasting


Cooling Tower


DHU

46%40% 50%80L

2014

Clarification

Aroma Stripping


Spray Drying

Powder Collection

Separate Chicory

Extraction

Compressors

ETP

UTILITIES

FO Boiler

GB Dumping

Roasting

Coffee Extraction

Cooling Tower


DHU

Multimedia Boiler

38L

46%40% 50%80L

51% 54% 55%2014

Clarification

Aroma Stripping


Spray Drying

Powder Collection

Separate Chicory

Extraction

Compressors

ETP

UTILITIES

FO Boiler

GB Dumping

Roasting


Cooling Tower


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


Spray Drying

Powder Collection

Separate Chicory

Extraction

Compressors

ETP

UTILITIES

FO Boiler

GB Dumping

Roasting


Cooling Tower


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

going green...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 temperature time...

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