hindustan coca cola-beverages_private_limited_goblej

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


Sr. No. Project Description Investment (Rs. MM)


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


Sr. No. Project Description Investment(Rs. MM)


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


Sr. No. Project Description Investment(Rs. MM)


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


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


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


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 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 )


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


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


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


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


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


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 )


17 Optimum capacity pump for pet juice line pasteurizer


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


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


UFRO SYSTEM


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




2011-2012

Water -Consumption per liter of beverage production(WUR/Water Usage Ratio)

Installation of recovery scheme - Rainmaker plant



RUN OFF WATER RECHARGE WELL

RAINWATER HARVESTING AT GOBLEJ UNIT


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