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First Prize

Dairy

HERITAGE FOODS LIMITED

Hyderabad (Telangana)

Unit Profile

Hertage Foods Limited, Uppal Dairy Plant Commissioned in the year 2006 with a

rated capacity of 0.6 LLPD and was subsequently expanded to 0.74 LLPD in 2007,

1.1 LLPD in 2010 and 1.5 LLPD in 2012.

Presently, Heritage Milk and Milk Products have market presence in Andhra Pradesh,

Telangana, Karnataka, Tamilnadu, Kerala, Maharashtra, Odisha and Delhi.

Energy Consumption

Energy is the biggest component of the operational costs in the Dairy Industry. The

Unit has taken this as a challenge to reduce its energy cost. The energy

conservation drive got a good momentum when the Unit declared Energy

Management Policy in 2012.

Description Unit 2012-13 2013-14 % Reduction

Specific Electrical Energy kWh/Ton 61.99 48.25 22.17

Specific Thermal energy million kCal/Ton 0.05921 0.05289 10.67

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Energy Conservation Measures Taken

1. Installation of Ammonia Chiller

Ammonia chiller installed in return chilled water

line from processing to reduce the temperature

by 3 °C which reduces the load on IBT (PHE

system of cooling is more effective as the

ammonia and return chilled water passes

through plate by plate which increases the

contact surface tremendously and leads to

instant exchange of heat).

Electricity saving : 2.409 Lakh kWh/yr

Cost saving : Rs 19.36 Lakh/yr

2. Centrifuge for installation for Oil fired Boiler

Centrifuge has been installed for Pre-Filtration of

furnace oil to Boiler which ultimately reduced

nozzle choking and efficiency of Burner have

been improved.

The steam generation per liter of Furnace Oil

have been improved which saved an annual of

7% of Furnace Oil.

Furnace Oil saving : 16.74 kL/yr

Cost saving : Rs. 8.41 Lakh/yr

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3. Installation of Pre-Heater for pre-heating the Curd Milk

Pre heating of curd milk with OHT soft water has

double impact both on FO & Electrical energy.

Due to preheating the inlet temp. of curd milk to

the curd past. Increased to 17 °C against 5 °C

which saves 8.46 kL of Furnace oil.

On the other hand the OHT soft water cooled to

15 °C which used in RSM (Reconstitution

skimmed milk) preparation and in cream past for cooling cream after regeneration.

Electricity savings : 0.401 Lakh kWh/yr

FO saving : 8.46 kL/yr

Cost saving : Rs. 7.48 Lakh/yr

4. Arrangement of Cyclic timers for Milk silo agitator motors

15 nos. of Cyclic timers were arranged for

packing milk Silo’s for operating with cyclic

intervals of 10 minutes span with which we can

save electricity of 161 Units per day.

Agitator running hrs per day has been reduced.

Maintenance cost also reduced accordingly.

Electricity savings : 0.57 Lakh kWh/yr

Cost saving : Rs. 4.65 Lakh/yr

5. Downsizing of ETP Air blower pulleys

Due to water conservation measures and GMP

practices implemented, the water quantity and

COD reduced by 25% & 38% respectively. As

dissolve oxygen in aeration tank is found more,

the blower pully has down sized, which results

in reduction of RPM of Blower.

With the above modifications the electricty

consumption was reduced by 21%.

Electricity savings : Rs. 0.401 Lakh kWh/yr

Cost saving : Rs 3.22 Lakh/yr

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6. Condensate recovery from CIP Tanks

In CIP section the direct steam injection to

generate hot water is replaced with SS pumpkin

type coils.

Due to this the heating time reduced to half and

the collected condensate is used as a boiler feed

water.

Furnace oil savings : 8.10 kL/yr

Cost saving : Rs 4.07 Lakh/yr

ENERGY POLICY

The Unit is committed in Energy Management Performance on a continual basis

through

• Continuous up gradation of technology, systems and service to optimize the

energy cost.

• Monitor and control the Energy consumption effectively.

• Providing Resources to achieve measurable objectives whenever necessary.

• Educate and motivate all the people concerned through effective

communication and recognition

• From time to time identify the energy saving potential for reduction of energy

consumption.

• Conducting energy conservational studies & energy audits through internal &

external professional.

• To Establish bench mark Energy standards in dairy industry.

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Second Prize

Dairy

SURAT DISTRICT CO-OPERATIVE MILK PRODUCERS

UNION LIMITED, SUMUL DAIRY

Surat (Gujarat)

Unit Profile

Surat District has been a Pioneer in India in channeling trade in Cotton and

Milk through co-operatives. Before SUMUL stepped in, traditional Private Milk

Traders were dominant in the area. Dairying on the other hand, was never

popular with tribal (a major rural population in the district) as practically no

infrastructure existed for milk marketing in their talukas, inaccessibility to their

villages as well as taboos regarding keeping of buffaloes prevented the entire

population of tribal from considering dairying as a source of income. To salvage the

poor producers from the clutches of these Private Traders, Organization and

integration of procurement, processing and marketing of milk and milk products by

the producers themselves on a sound co-operative line was essential; this would

also ensure elimination of middlemen, equitable distribution of benefits to Rural Milk

Producers and indirectly to urban milk consumers as well. Being a producers owned

organization, it eliminated the middlemen and minimized the overhead costs giving

the maximum overall net-returns to its producer members from their milk

production enterprises.

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Energy Consumption

There is a steady decline of specific energy conservation due to implementation of

various energy conservation measures in last 2 years. The details are as given

below:

DESCRIPTION UNIT 2012-13 2013-14

Annual Milk & Milk Production MT 470407 492490

Total Electricity Consumption / Annum Lakh kWh 110.142 111.950

Specific Energy Consumption kWh / MT 23.41 22.73

Total Thermal Energy Consumption / Annum million kCal 21995.57 21106.56

Specific Energy Consumption – Thermal million kCal / MT 0.0467 0.0428

Summary of Annual Saving in Energy Conservation 2013-14

Section Investment (Lakh Rs)

Annual Saving (Lakh Rs)

Electrical 106.57 89.40

Thermal 45.88 177.21

TOTAL 152.45 266.61

Energy Conservation Measures Taken

Electrical Points

1. Installation of Soft Starter in place of Conventional starters up to 10 HP Motors.

2. Installation of Low Speed 2 HP Agitator in place of 7.5 HP Agitator for Milk Silos

– 4 Nos.

3. Installation of Ammonia based milk cold storage in place of Frion Based at Main

gate area.

4. Installation of VFD for Milk pouch filling Direct from Milk Silo in place of VMST –

2 Nos.

5. To Reduce the Chilled water supply pressure from 3.5 Bar to 3.2 Bar for

supplying the Chilled water in plant area.

6. Energy Saving for Crate Washing & Crate conveyor by installation of High

Speed Milk Conventional Machine – 1 Line.

7. Energy Saving for Pouch Machines by Installation of High Speed (Speed: 9600

Pouches / Hr.) Milk Pouch Packing Machine in place of Conventional Machine

(Speed: 5400 Pouches / Hr.) – 5 Nos.

8. Installation of 30 HP VFD in place of Star Delta Starter for Blower of Aeration

Tank at ETP.

9. Installation of Energy Efficient Grundfoss make 20 HP Pump in place of 30 HP

Pump at Boiler Feed Water.

10. Installation of VFD on Air Blower motor of Burner at Boiler.

11. Installation of LED Lowbay Lighting Fixtures in place of 250 Watt Conventional

fixtures for plant lighting – 35 Nos.

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12. Installation of VFD in place of Star Delta Starter on 40 HP Motor for Alfa Laval

Butter Churn Machine.

13. Installation of Energy Efficient Grundfoss make 7.5 HP Pump in place of 12.5

HP for Under Ground Tank Return Pump.

14. Installation of VFD in place of DOL starter for Booster Pump of Milk Pasteurizer

– 2 Nos.

15. Installation of Energy Efficient Grundfoss make 3 HP Pump in place of 5 HP for

Chilled Water Circulation in Pouch Machines.

16. Installation of 45 Watt LED Street light fixtures in place of 150 Watt for Campus

lighting – 30 Nos.

17. Reduce the Running hour for Chilling the Milk by Installation of energy Efficient

Chiller for GOA plant.

18. Installation of 33 Watt LED light Fixtures in place of 72 Watt for Office lighting

– 30 Nos.

Thermal Points

1. Reducing the Set-point of Germfree Chemical from 59 Deg C to 45 Deg C for

Process CIP System.

2. Installation of Packaged Plant Room System (PPRS) to supply hot water in

place of Direct heating for Dahi Section.

3. Installation of Packaged Plant Room System (PPRS) to supply hot water in

place of Direct heating for UHT Section.

4. Installation of VFD for Milk Pouch filling Direct from Milk silo in place of VMST –

2 Nos.

5. Energy Saving for Crate Washing & Crate Conveyor by installation of High

Speed Milk Pouch packing machine in place of Conventional Machines – 1 Line.

6. Prevention of thermal losses by adopting LRB insulation in place of Glass wool

for 1.5”, 2”, 2.5” & 3” hot water supply lines.

7. Installation of Economizer in Boiler for Recovery of heat & pre-heating of Feed

water.

8. Recovery of Flash Steam of 10 TPH Boiler.

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ENERGY POLICY