hindustan coca cola-beverages_private_limited_goblej
DESCRIPTION
trainningTRANSCRIPT
CII13th National Award
For“Excellence In Energy Management – 2012”
Hindustan Coca-Cola Beverages Pvt. Ltd.
By Mitesh Pandya
Alok SharmaPiyush Shah
Company Details
Company Manufacturing Process
ENCON Efforts – Last 3 Year
Specific Energy Consumption / Benchmarking
Innovative Projects
CDM Projects
Involvement of Employees , Team Work In Encon ,
Monitoring & Reporting Formats and Implementation
Methodologies
ENCON ‐ Future Projects
Project Implementation as CA / PA for ISO 9001 / 14001
Utilization of Alternative Energy Source & Waste
Implementation On Energy Front Amongst Associates
( Vendors / Suppliers, Contractors, Customers etc. )
Awards & Accolades
Contents
Manufacturing Map of Coca-Cola In India
33 Manufacturing Plants
Current Manufacturing LocationsCBOs + FBOs + Co pack
Production lines (CBO & Copack)• Sparkling RGB 32
• Juice RGB 10 (2 cold fill)
• Sparkling PET 24
• Juice Hotfill 6
• Juice Tetra Pack 3
• Retail water 11
• Bulk Water 4
• Cans 1
Co-Pack9 Plants 24 Plants
CBO
Goblej Plant - Overview2nd Largest Plant In India,
Largest By 1st Jan 2013
Plant Commissioned : Year 1998
Total Plant Area : 53 Acre
Built Up Area : 23 Acre
Green Belt Area : 30 Acre
Capacity :
600 X 2 BPM RGB line
300 X 1 BPM Maaza Line
120 X 1 JPH Kinley Jar
600 X 2 BPM PET line
120X1 BPM PET line
Zero Discharge Plant
Water Neutral Plant
Process – Over View
RGB Empty Bottle Handling
& Conveying
Bottle Washing
Filling / Crowning / Capping
Water Treatment
Soft Water Treated Water
Syrup Processing
Beverage Processing
Conveying & Fulls Handling
CO2
PET Bottle Blowing & Conveying
OR
Energy Contribution
Two Areas Contributes 87%
Of The Total Power & Fuel
Cost
40%
2%5%
53%
Contribution ( MJ ) Power Sourced
HSD
Furnace Oil
Briqueete
42%
58%
Contribution ( MJ )
Electrical
Thermal
67%
20%7%
4% 2% Power-Variable
Fuel-Briq
Power-Fix
Fuel - FO
HSD - DG Set
Focus Area
Contribution ( Cost )
Plant Power Distribution
13%
13%
13%
10%7%
7%
5%5%
5%
4%
4%
3%3%
3% 2%1% 1% 1% 1% 600 BPM Pet CSD Line
HP Air CompressorETP & MVRERefrigeration600 BPM Pet Juice LineLP Air CompressorProcessLightingAHU's & Air Conditioing120 BPM Pet LineLine-1Maaza RGB LineWTP/BorwellOthersBoilerFL ChargingCold StorageRGB Line-2Admin Power
Top 9 of 25 Area Contribute To 78% of The Power Consumption
80-20 Technique
En-Con Projects In Last 3 Year
Sr. No. Year
Nos. of En-con Projects
Implemented
Investment (Rs. INR MM)
Saving (Rs. INR MM) Pay Back
(Months)
Average
1 2011-2012 19 20.7 42.6 6
2 2010-2011 13 2.7 29.3 1
3 2009-2010 13 5.4 14.1 5
Total 45 28.8 88.7 3
En-Con Projects In 2009-2010
Sr. No. Project Description Investment(Rs.MM)
Saving (Rs. MM / Annum)
Pay Back (Months)
1 Installation of 4 Ton Agro Waste Solid Fuel Boiler 3.0 10 42 Installation of PHE type condenser In place of Shell & Tube 1.1 1 10
3 Installation of New Pasteurizer for Precise Temperature Control of Maaza Beverage Nil 0.6 0
4 Installation of VFD for 40 Bar Compressor of 120 Pet CSD Line 0.6 0.5 155 Optimum capacity Rinse pumps of Line-1 & 2 bottle washer 0.13 0.4 46 Flow Meter For Monitoring of Air Consumption In Various Area 0.25 0.3 10
7 Common Cooling Tower for Raw Syrup System, Low Pressure Air Compressor & Maaza Cooling Tunnel 0.08 0.3 4
8 Automation of Maaza Line Conveyors 0.04 0.2 29 Sizing of Maaza Filling Hall Ahu with Optimization of Pulley 0.02 0.2 1
10 Installation of Exhaust Blower to remove the hot air of the oven & reduce the air conditioning load of 120 pet blowing room 0.04 0.2 2
11 Energy Efficient CFL Light Fixtures for 120 Pet Line Halls 0.1 0.2 1112 Installation of VFD for Soft Water Pump of WTP 0.02 0.1 413 Interlocking of Pet 600 Mixer Chilled Water Pump 0.01 0.04 3
Total 5.4 14.1 4.6
En-Con Projects In 2010-2011
Sr. No. Project Description Investment (Rs. MM)
Saving (Rs. MM / Annum)
Pay Back (Months)
1 Ambient Temp.(18⁰C) Filling for Pet Csd Instead of 4⁰C Nil 24 02 Optimization of Blowing Pressure For Pet Bottles Nil 3.9 0
3 Installation of Separate Condensate Recovery Pump for Pasteurizer of Maaza RGB & Pet Line 0.5 1.1 5
4 Installation of VFD For AF Make 40 Bar Compressors 1.4 1.0 16
5 Conversion of Air Cooled Chilled Water to Water Cooled Chilled Water System For Pet 600 CSD Line 0.4 1 6
6 Installation of Variable Frequency Drive for Chilled Water Pumps for Pet 600 CSD Line & Process 0.15 0.3 7
7 VFD installation for ID & FD Fan of 4 ton briquette fired boiler 0.15 0.2 8
8 120 pet Mixer, Chilled water tanks & pumps removal & avoided the double pumping & loss of cooling 0.02 0.1 2
9 Installation of VFD for Soft Water Pumps 0.04 0.1 610 Installation of Suitable Design & Capacity Pump for Irrigation 0.04 0.1 8
11 Conversion of Delta to Star Connection for Agitator of Maaza RGB Syrup Tanks Nil 0.1 0
12 Interlocking of Air Washer's & AHU's With Filler Machine 0.02 0.1 513 On/Off System for 40 Bar Cooling Tower Fan Based on Temp. 0.01 0.03 4
Total 2.73 32.03 1
En-Con Projects In 2011-2012
Sr. No. Project Description Investment(Rs. MM)
Saving (Rs. MM / Annum)
Pay Back (Months)
1 Installation of Agro Waste Solid Fuel FBC Boiler 10 27 42 Energy Efficient Pumps Installation In Utility 2.1 3.4 7
3 Transfer of 173 TR Cooling Load From -2 ⁰C To + 6 ⁰C 0.1 2.7 0.5
4 Installation of Energy Efficient Screw Comp. 4 2.0 24
5 Supply of Cooling Water Instead of Chilled Water (6⁰C) 0.2 1.2 2
6 Installation of Energy Efficient T5 Fixture ( 216 watt ) InPlace of HPMV Lamps ( 400 Watt ) 1.2 0.9 16
7 Installation of Energy Efficient T5 Fixture (4x14 watt)Instead of Tube lights (2x36 Watt ) 1.2 0.9 16
8 Installation of Effimax for Online O2 Monitoring & ImprovedCombustion Efficiency 0.7 1 11
9 Blower Installation for Date coding air instead ocompressed air of 7 kg/cm2 (5 Lines)
f 0.4 1.0 5
10 Improvement Of Condensate Recovery Nil 0.6 0
En-Con Projects In 2011-2012
Sr. No. Project Description Investment(Rs. MM)
Saving (Rs. MM / Annum)
Pay Back (Months)
11 Improvement of Power Factor 0.1 0.6 212 Conversion of V Belts to Cogged Belts 0.2 0.5 5
13 Installation of Suitable Capacity Pump for Pet Juice Line Pasteurizer 0.1 0.3 5
14 Lighting Energy Saver Installation for Pet 600 CSd Line Lighting 0.15 0.2 9
15 Installation of VFD for Cooling Tower Pump 0.08 0.1 8
16 Chilled Water System for 120 Pet Line Blow Molding Room In Place of Dx Cooling System 0.05 0.1 6
17 Timer Provision For All The Lighting Circuit Across the Plant For Automatic On & Off 0.05 0.1 6
18 Interlocking of Ahu's & Air Washers With Running of Machine 0.03 0.1 5
19 Level Control System for UFRO Syntax Water Tank 0.02 0.1 5
Total 20.7 42.6 5.8
Specific Energy Consumption
12.112.4
12.6
13.2
11.9
12.5
13.1
2008 2009 2010 2011
Electricity Usage Ratio ( Bev of Liter / Unit )
• Continuous Improvement In Electricity & Furnace Oil Usage Ratio
• Significant Reduction In Utilization of Overall Energy Year After Year
86.5 93.7113.6
164.4
6080
100120140160180
2008 2009 2010 2011
Fuel Usage Ratio ( Bev of Liter / Unit )
0.900.86 0.83
0.760.72
0.660.62
0.72
0.82
0.92
2007 2008 2009 2010 2011 2012
Energy ( MJ / Ltr )
Bench Marking Q-Spec Report ( Coca-Cola India )
25.3
24.0
23.3
22.7 22.7 22.5
21.9 21.8
21.0
23.5
26.0
Consistently Achieving 1st
Rank In HCCBL – India, Since
Last 1 Year
Electricity Usage Ratio ( Beverage of Litre / Unit )
Road Map To Be Best In Class0.66
0.40
0.110.10
0.05
0.00
0.20
0.40
0.60
0.80Energy Usage Ratio ( MJ / Liter )
Ref. Screw Compressor18 Degree FillerEnergy Efficient PumpsPet 600 Csd Block Line to Eliminate Rinser & Conv.Screw Type Air Compressors In Place of Recip. Comp.Energy Efficient Lighting
Captive Power GenerationRecovery From HP AirFlash Steam Heat RecoveryDe-Humidifier In Place of Air Conditioning SystemDe-Super Heater for Ref. SystemHeat Recovery From Raw Syrup
RGB & Pet Line Conveyors AutomationInterlocking of Ahu’s & PumpsDate Coding Blowers Interlocking With LinesScada System for Tracking Utility ParametersVFD Installations
Innovative Project 1 : Optimization of Blowing Pressure Of Pet Bottles From 30 to 26 Kg/cm2
Project Name: Project #: Project Start/End Dates:
PET blowing pressure & 40 bar air compressor power optimization. NA-PH-xxx From 13.01.10 To 15.5.10
Project Lead: Piyush Shah Executive Sponsor: Rajeev ChawlaTeam Members: Project Costs: (include required capital, expenses)
[1]Mahesh Kore [2]Parthiv [3] Dilipkumar [4] Rizwan [5] Bhavik [6] Hemendra [7] Ajay [8]Manoj Pal [9] Viral
- Capital: - Expenses:
INR 1.8 Mn
Mission/Project Overview:
Optimization of PET blowing pressure & Unload power of 40 bar air compressor to achieve energy efficiency.
- KPI's: Optimization of PET blowing pressure from 30 kg/cm2 to 26 kg/cm2 & VFD Installation for 40 bar air compressor- Visual Mgmt Tools being implemented:PET blown bottle quality reports, Blow moulding machine recipe, Log sheet of 40 bar compressor
Objectives: (include beginning & ending KPI's) Net Benefits:To optimize the PET blowing pressure and optimization of 40 bar air compressor unload power. Annual savings of INR 1.8 Mn
In Scope: OE Tools to be used: Out of Scope:
PET Blow Moulding Machine & 40 Bar Air Compressor. DMAIC Method, Yield Graph, Process Capability Chart
Assumptions: Risks & Constraints:
Based on feedback of Dasna plant successful trials. Higher reduction of blowing pressure may affect quality of pet bottle.
Project Milestones: Dependencies:
1.PET bottle blowing at lower pressure ( 26 kg/cm2 ) & study the parameters of same - 15/1/2010 2.Validation of QA results for reduced blowing pressure - 1/2/2010 3.Training of PET blow moulding operators, chemist, 40 bar operator. 4. VFD Installation for 40 bar air compressor
Production & QA Department
Project Lead Time: (Total time required to implement) Other Key Stakeholders & Areas Affected:8 week [1] Finance Dept [2] Plant OperationApprovals:Project Lead: PIYUSH SHAH Date:Area Lead: MR. RAJEEV CHAWLA Date:Finance: MR. SAMEER AGRAWAL Date:Executive Sponsor/Steering Committee: MR. RAJEEV CHAWLA Date:
The critical quality impacted by blowing pressure parameters
were identified as height, brimful volume, wall thickness and
stress cracking
Compressor Receiver Dryer Filter
Blow Molds 3 – Way Valve
BottlesBlowingPreforms
Process Flow. . . Gaining Process Understanding
D M A I C
Innovative Project 1 : Optimization of Blowing Pressure of Pet Bottles From 30 to 26 Kg/cm2
30 kg/cm2
Blowing pressure optimized for
600ml bottle from 30 to 26 kg/cm2
40 bar air compressor loading &
unloading setting changed to 27 & 29
kg/cm2.
Quality parameter found within range
Process capability checked & achieved
for critical quality parameters.
Parameters Change Before After
Blowing Pressure 30 26
Pre Blowing Pressure 15 12
Pre Blowing Angle 62 58
Layer Temperatures ( 1 to 9 )
Based On Weight Distribution
Quality Parameter Acceptable RangeBrimful 623.34 +/- 5 MLBase Weight 5 to 5.5 GMUpper Shoulder Weight 10 to 11 GMLabel Panel Weight 11 to 12 GMWall Thickness - Minimum 0.3 MMGate Area - Minimum 1.3 MMBase Clearance - Minimum 3.5 MM
Stress Crack Test No Crack For 20 Minute
Improvement in 40 bar compressor power consumption from 101
Kwh to 85 Kwh
Innovative Project 1 : Optimization of Blowing Pressure of Pet Bottles From 30 to 26 Kg/cm2
D M A I C
Process Controls . . . Sustaining The Gains
Recipe changes saved on blowing machine, old recipe removed
Check process capability for critical quality parameters at regular interval.
Process parameters specification chart display on the machine.
Process parameters locked – Access to change limited to authorized
person.
Error Proofing Done To Ensure That Process Runs In Control
Innovative Project 1 : Optimization of Blowing Pressure of Pet Bottles From 30 to 26 Kg/cm2
D M A I C
2010 2011 2012 Saving
Prod - Cs Units Ratio Prod - Cs Units Ratio Prod - Cs Units Ratio 2011 vs 2010
2012 vs 2011
45,34,453 13,33,663 3.4 89,89,147 20,43,100 4.4 44,59,774 8,45,354 5.3 -29% -20%
Saving :
2011 Vs. 2010 : Rs. 3.9 Million
2012 Vs. 2011 : Rs. 1.2 Million
Comparison Of Power Consumption : 2010 - 2011 - 2012
Innovative Project 1 : Optimization of Blowing Pressure of Pet Bottles From 30 to 26 Kg/cm2
Objective : Optimization of PET blowing pressure
Target : 600 ml PET bottle blowing @ 26 kg/cm2
Achieved: Optimization of blowing pressure @ 26 kg/cm2
Target Savings : INR 1.8 MM Per annum
Saving Achieved: INR 3.9 MM Per annum
Project Summary
Innovative Project 1 : Optimization of Blowing Pressure of Pet Bottles From 30 to 26 Kg/cm2
Innovative Project 2 : Transfer of 173 TR Cooling LoadFrom -2 Degree To + 6 Degree Chilling System
Glycol supply to process at
-2⁰C
Glycol return from process at
+1⁰C
Chilled water to process at
+6⁰C
Chilled water return from process at +10⁰C
Ready Syrup at 25⁰C
Raw Syrup (Flow Rate
5KLPH) Temp.(45⁰C)
Before After
Innovative Project 2 : Transfer of 173 TR Cooling LoadFrom -2 Degree To + 6 Degree Chilling System
Annual Saving of INR 2.65 MM Per Annum
Parameters Raw Syrup5 KL System
Raw Syrup10 KL
System
120 Pet Line
Chiller Total
Raw Syrup/Chilled Water Flow Rate (LPH) 5000 10000 25000 40000Raw Syrup/Chilled Water Inlet Temp. (⁰C) 45 50 15Raw Syrup/Chilled Water Outlet Temp. (⁰C) 25 25 8Cooling Used ( TR Per Hour ) 33 83 58 174Power Consumption Per Hour(-2⁰C System) 38 95 67 200Power Consumption Per Hour(+6⁰C System) 28 70 49 148
Annual Power Saving ( Kwh ) 74405 161210 130208 365823Annual Saving ( Rs. ) 5,39,435 11,68,775 9,44,010 26,52,220Investment ( Rs. ) 30,000 40,000 30,000 1,00,000Pay Back Period ( Months ) 1 0.4 0.4 0.5
Chilled water to PHE at 07⁰C
Before After
Chilled Water Supply @ 40m /hr
Cooling Water Supply @ 55m /
hr
Process water flowrate 55m /hr
Chilled water from PHE @ 12⁰C
Cooling Water From PHE At 36⁰C
Cooling water to PHE at 32⁰C
Innovative Project 3 : Supply of Cooling Water In Placeof Chilled Water ( 6 Degree )
Annual Saving of INR 1.15 MM Per Annum
Parameters Before Chilled Water
After Cooling Water
Process Water Flow Rate 25000 25000Process Water Temp. - Inlet to PHE (⁰C) 42 42Process Water Temp. - Outlet from PHE (⁰C) 36 36Cooling Used (TR Per Hour) 49.6 49.6Specific Power Consumption for Chilled Water System & Cooling Tower Water System 0.9 0.2
Power Consumption Per Hour (Kwh) 44 12Per Hour Power Saving (Kwh) 31.7Annual Running Hours 5000Annual Power Saving (Kwh) 158651Annual Saving ( Rs. ) 11,50,218Investment ( Rs. ) 2,00,000Pay Back Period ( Months ) 2.1
Innovative Project 3 : Supply of Cooling Water In Placeof Chilled Water ( 6 Degree )
Innovative Project 4 : Elimination of Compressed Air With Air Blower
Air Blow Is Required Before Date Coding On Glass Bottles
Before After
Compressed Air @ 3 Bar
Air Blower @ 0.8 Bar
Annual Saving of INR 1.00 MM Per Annum
Innovative Project 4 : Elimination of Compressed Air With Air Blower
Air Requirement for Air Knife of Date Coding Machine ( CFM ) 25
Running Load of 7 Bar Air Compressor With Cooling Tower ( KW ) 6.5
Connected Load of Air Blower Motor ( KW ) 2.2
Running load of Air Blower 1.9
Power Saving Per Hour ( KW ) 4.6
Running Hour of All Lines ( 5 Lines ) 30000
Annual Power Saving ( Kwh ) 138000
Annual Power Saving ( Rs. ) 10,00,500
Investment ( Rs. ) 4,00,000
Pay Back Period ( Months ) 4.8
Carbon Emission Reduction
Parameter Value
Briquette Used ( Kg ) 30,93,500
Briquette Cost ( Rs ) 1,70,14,250
Equivalent Furnace Oil (Ltrs.) 10,31,167
Equivalent Furnace Cost (Rs) 4,43,40,167
Saving ( Rs. ) 2,73,25,917
Reduction In Co2 Emission Equivalent To 1031 KL Of Furnace Oil
Project Name : Installation of 8 Ton Capacity Agro Waste FBC Boiler
Carbon Emission Reduction
Reduction In Co2 Emission Equivalent To 24.7 KL Of Furnace Oil
Parameter Value
Briquette Used ( Kg ) 30,93,500
Reduction of Briquette Cons.(Kg) 74,244
Equivalent Furnace Oil (Ltrs.) 24,748
Equivalent Furnace Cost( Rs) 10,64,164
Saving (Rs.) 10,64,164
Project Name : Installation of On line O2 Analyzer
4% Reduction In Excess Air In Flue Gas Leads to 2.4% Improvement In Boiler Efficiency
Carbon Emission Reduction
Reduction In Co2 Emission Equivalent To 17 KL Of Furnace Oil
Project Name : Installation of Precise Temperature Control System InPasteurizer To Control Temp. Overshoot For Reduction of Steam Consumption
Carbon Emission Reduction
73%
89%95%
27%
11%5%
0%
25%
50%
75%
100%
2010 2011 2012
Agro Waste
Fossil Foil ( HSD, Furnace Oil )
Reduction In Fossil Fuel Contribution From 27% to 5%With Increase In Overall Energy Utilization
Involvement of Employees, Team Work In Encon, Monitoring & Reporting Formats & Implementation Methodologies
Team Member Responsibility
Piyush Shah Coaching The Team For Energy Management.
AbhishekSikligar
Power Monitoring & Improvement of Electrical Energy In Utility.
Nimish Nikam Monitoring & Control of Efficient Air Generation & Distribution System.
Hemendra Rawat
Monitoring & Improvement of HP Air Usage Ratio
Vaibhav Deshpande
Monitoring & Improvement of Refrigeration System Operation
Rahul Saxena Automation & Electrical Energy Improvement on RGB Lines
SaurabhTrivedi
Automation & Electrical Energy Improvement on Pet Lines
Hemul Joshi Monitoring & Improvement of Condensate Recovery & Fuel Yield
Manish Singh Provide Support for Automation Activity on Pet Lines
Sachin Parashar
Provide Support for Automation Activity on RGB Lines
RajneeshSharma
Monitoring & Control ETP & WTP Operation As Well As Support for Process Optimization.
Cross Function Team Continuously Working on Energy Conservation Through Operational Excellence For Sustainance
Involvement of Employees, Team Work In Encon, Monitoring & Reporting Formats & Implementation Methodologies
Employees Involvement System
Training : ON Energy Conservation & Environmental Awareness
Audit : Internal & External Energy Audit
Improvement Project : Promoting More & More Energy Conservation
Projects and Rewarding The Project Team
Workshop : Participation In Energy Conservation Workshop
Review : Daily, Weekly, Fortnightly & Monthly Review of Action Plan /
Projects, Further Planning
Display : Temperature & Pressure Set Points, Loading / Unloading Set points
Periodic Circulation of Do’s and Don’ts For The Effective Use of Energy
Most of The Energy Projects Are Executed By Inter Departmental Team
Team work
Sr. No. Proposal Source Of En-
Con Idea YearExtent of
ManpowerInvolved
ImplementationProgress
Investment ( Rs. MM)
Saving Potential ( Rs. MM
Per Annum )
AchiSav
( Rs.
eved ing
MM )
1 Interlock of air blower with labeller machine start & stop Supervisor 2011 2 Implemented Nil 0.02
2 Provision separate lighting circuit for LT room lights Workmen 2011 2 Implemented Nil 0.02
3 Installation of VFD for chilled water pump of pet 600 csd line
Middle Management 2011 4 Implemented 0.1 0.15
4 VFD installation for AF make 40 bar air compressors
Top Management 2011 5 Implemented Nil 1
5Installation of centrifugal pump In place of submersible pump for Irrigation water pump
Supervisor 2011 5 Implemented 0.04 0.06
6 Level control system for UF RO tank Workmen 2011 3 Implemented 0.01 0.03
7 Conversion of V belts to Coggeed belts
Top Management 2011 4 Implemented 0.2 0.25
8 Installation of air regulator for Maaza rgb line crowner air Supervisor 2011 2 Implemented 0.005 0.04
9SS pipeline in place of pu pipe in pet 600 cip room due to atmosphere condition
Workmen 2012 4 Implemented 0.08 0.1
Sr. No. Proposal Source Of En-
Con Idea YearExtent of
Manpower Involved
ImplementationProgress
Investment ( Rs. MM)
Saving Potential ( Rs. MM Per Annum
)
Achieved Saving
( Rs. MM )
10 Installation of limit switch & interlocking with door air curtain Supervisor 2012 3 Implemented 0.1 0.12
11 Timer installation for switching of the ware house lights in day time Workmen 2012 4 Implemented 0.1 0.12
12 VFD & Pressure Transmitter installation for cooling tower pump
Middle Management 2012 3 Implemented 0.1 0.12
13 Rain maker day tank piping modification to avoid double pumping Supervisor 2012 4 Implemented 0.04 0.08
14 Ventury trap installation in place of conventional trap
Top Management 2012 4 Implemented 0.2 0.2
15 Installation of motion & occupancy sensors for plant less movement area Supervisor 2012 Under
Consideration 0.5 0.7
16 Installation of On line O2 Monitoring system ( Effimax 2000 )
Middle Management 2012 5 Implemented 0.7 0.8
17 Optimum capacity pump for pet juice line pasteurizer
Middle Management 2012 6 Implemented 0.1 0.25
18 Solar Lighting Top Management 2013 Under
Consideration 15 7.5
Team work
Monitoring & Reporting System
Parameter Monitoring & Reporting Frequency
Critical KPI Tracking ( Receiver Air Pressure, Product Temp. Set Point, Blowing Pressure Set Point ) Every Shift
Condensate Recovery Every Shift / Daily / MonthlySpecific Power Consumption Tracking for Higher Power Consuming Area’s Daily / Monthly / Yearly
Identification of Gap In Electrical Consumption of Different Area ( Standard Vs. Actual ) Daily
Boiler Efficiency DailyElectricity Usage Ratio, Fuel Usage Ratio Daily / Monthly / YearlyDG Efficiency Daily / Monthly / YearlyIdentification of Air & Steam Leak & Corrections WeeklyMonitoring of Steam Traps Working FortnightlyReview of Energy Improvement Action Plan MonthlyReview of Power & Fuel Usage Ratio & Cost With Zonal Supply Chain Head Monthly
Free Air Delivery Check for Air Compressors Quarterly
Energy Monitoring & Reporting Formats
Specific Power Consumption Norms For High Impact Area…….. Daily Tracking, Gap Identification & Corrections
HP Air LP Air
Target 5.5 ( Crate Pet Unit )
5.5 ( Crate Pet Unit )
Date Daily MTD Daily MTD1-Feb 2.4 5.0 10.0 18.92-Feb 5.2 5.1 18.6 18.8
Energy Monitoring & Reporting Formats
Gap Identification Betn Std. Vs. Actual Power Consumption…….. Daily Tracking & Corrections
Date RGB1 (KWH)
RGB1 %Opp.
RGB2 (KWH)
RGB2 % Opp
HS PET 1 CSD
(KWH)
HS PET 1 CSD % Opp.
1-Apr-12 331 21% 0 0% 640 12%
2-Apr-12 231 13% 0 0% 0 0%
Sequence PurposeBench Mark Gap IdentificationAudit ( Internal / External ) Identify Potential Saving To Close GapAnalysis Evolution or ProjectExecution ImprovementMonitoring System SubstanceOnline Suggestion Value Creation
Energy Monitoring & Implementation Methodology
Benchmarking
Audit
AnalysisExecution
Monitoring
Innovation
Step-1: Categorization
Step-2 : Data Collection
Step-3 : 80:20 Technique
Step-4 : DMAIC
Approach
SIX SIGMA APPROACH FOR PROJECT
En-Con : Future Projects
Sr. No. Project Description Investment
( Rs. MM )S
( Rs.MM aving Per Annum )
Pay Back ( Months )
1 Solar Lighting 25 25 122 Captive Power Generation 4.5 4.5 12
3 Installation of Energy Efficient Lighting In Raw Syrup, Ready Syrup, RGB Line-2 & Other Areas 1.5 3 7
4 Installation of Energy Efficient Pumps 1.2 1.8 8
5 Installation of PHE For Heat Recovery for Hot Syrup To Product Water 0.5 1.5 4
6 Air Recovery System To Recover Blowing Machine Exhaust Air To Low Pressure Air 0.03 1.0 0
7 Recovery Of Flash Steam For Pet Juice Line Pasteurizer 1 0.9 13
8 Desuperheater @ KC9 - Use For Boiler Feed Water Tank Water Heating 0.8 0.9 11
9 Automation of Lighting With Occupancy & Movement Sensors 0.6 1 9
10 Ring Main System For Low Pressure ( 7 Bar ) Air ToOptimize The Receiver Pressure
0.15 0.5 4
11 Insulation of Bottle Washers Soak Compartment 0.3 0.5 712 Flash Steam Recovery - Maaza RGB Pasteurizer 0.5 0.5 13
En-Con : Future Projects
Sr. No. Project Description Investment
( Rs. MM ) ( Rs. MSaving M Per Annum)
Pay Back ( Months )
13 Insulation Effectiveness using thermal Imager & correction across the plant 0.2 0.4 6
14 Ring Main System For High Pressure ( 40 Bar ) Air To Optimize The Receiver Pressure 0.1 0.3 4
15 Mech Seal Type Efficient Vacuum Pump In Place Of Gland Type Vacuum Pumps For RGB Line-1 & 2 0.2 0.3 8
16 Installation of DI Pipe Line For Gravity Flow Of Raw Water To Avoid The Double Pumping 0.15 0.2 10
17 Installation of Variable Frequency Drive For Maaza Filling Hall Air Washer Blower 0.1 0.2 8
18 Heat Recovery From Bottle Washer Hydro Water For Warmer Water Heating 0.1 0.2 8
19 Nitrile Rubber Insulation For Cold Lines 0.1 0.2 8
20 Installation of Variable Frequency Drives For Raw Syrup Air Washer Blower 0.08 0.1 7
21 Automation of RGB & Pet Lines Conveyors & Pumps ToStop During Non Production Time
0.01 0.1 1
22 Interlocking of Pet Juice Line Pumps For Auto Stop & Start 0.01 0.1 1
Total 37.13 42.32 10
Environmental Initiatives
Green Belts & Tree Plantation --- Across The Plant
Our Commitment to Conserve Water
4 R’s for conservationReduce: Creating Awareness & Reducing Wastage Reuse: Recovering & ReusingRecycle: Recovering & ReprocessingRecharge: Rain Water Collection & Recharge Bore Wells
4 R Implementation
Recharge• Rain water
Harvesting
Recycle• Bottle washer• Tertiary Treatment• Vacuum Pump
Recirculation
Recharge• Create awareness• Bottle washer• Backwashing
Reuse• Crate washing• Floor Cleaning• Toilet• Garden
Continuous Reduction In Water Usage Ratio, 100% Improvement In 4 Years
Water Usage Ratio ( Liter of Beverage Per Liter )
3.38
2.97
2.39
1.90
1.6
1.40
1.80
2.20
2.60
3.00
3.40
3.80
2008 2009 2010 2011 2012
Our Commitment to Conserve Water
Year Environmental Aspect Action Environmental Impact/Improvement
2010-2011
Water-consumption per liter of beverage production ( WUR/Water Usage Ratio)
1.Switch over from ground water source to surface water.2.Installation of Decaustizer.
Water consumption reduced from 2.97 per liter of beverage to 2.39 liter
Our Commitment to Conserve Water
UFRO SYSTEM
Year Environmental Aspect Action Environmental Impact/Improvement
2011-2012
Water-consumption per liter of beverage production(WUR/Water Usage Ratio)
Installation of UFRO Scheme in Effluent treatment plant to meet requirement of utilities
Water consumption reduced from 2.97 per liter of beverage to 1.9 liter
Our Commitment to Conserve Water
Year Environmental Aspect Action Environmental Impact/Improvement
2011-2012
Water -Consumption per liter of beverage production(WUR/Water Usage Ratio)
Installation of recovery scheme - Rainmaker plant
Water consumption reduced from 1.9 per liter of beverage to 1.55 liter
Our Commitment to Conserve Water
RUN OFF WATER RECHARGE WELL
RAINWATER HARVESTING AT GOBLEJ UNIT
Our Commitment to Conserve Water
Water Neutral Plant
Renewable Energy Utilization
Utilization of Agro Waste In Place of Fossil Fuel
Waste Utilization
Process Waste Water From Bottle Washing & CIP Is Being Treated Through The State of Art Plant Consisting Pretreatment ( Aeration, Membrane Bio-Reactor), Post Treatment ( Reverse Osmosis), MVRE, Crystallizer and Centrifuge
The Treated Water Quality Meets IS 14543 & IS 10500 Standards
Replication of Best Practices
Sr. No. Best Practice / Replication Associates
1 V Belts to Cogged Belts Conversion Hindustan Coca-Cola -Bangalore
2 Filling of Sparkling Beverage at Temperature of 18 Degree In Place of 4 Degree KHS - Germany
3 Blowing & Filling - Block Machine For Pet Bottles In Place of Separate Machine Sidel - France
4 Energy Efficient ( T5 ) Lights Installation Philips - India5 Use of Energy Efficient Bearings For Motors SKF - India6 Wind Driven Exhaust Fans For Plant Sheds Ratna Construction
7 No Air Conditioning System For Blowing Machine Room With The Installation of De-Humidifier KHS - Germany
8 Energy Audit of Pumps & Installation of Energy Efficient Pumps Grundfos - India9 Installation of High efficiency Vacuum Pumps For Filling Machine PPI - India
10 Power Standardization Template Energy Manager Group -HCCBPL
11 Energy Audit Devki Engg.
12 Ventury Trap Installation Instead of Conventional Bucket / Float Traps
Zenith Marketing / GEM Trap
Certifications
ISO 18001:2007ISO 14001:2004
ISO 22000:2005 PAS 220:2008
Awards
Reduction of Water Foot Print By Rain Maker / Waste Water Treatment Plant – Global Category
Innovation Award From International Water Association
Thanks