CII

13th National Award

For

Excellence In Energy Management 2012

Hindustan Coca-Cola Beverages Pvt. Ltd.

By
Mitesh Pandya
Alok Sharma
Piyush Shah

Contents
CompanyDetails
CompanyManufacturingProcess
ENCONEfforts Last3Year
SpecificEnergyConsumption/Benchmarking
InnovativeProjects
CDMProjects
InvolvementofEmployees,TeamWorkInEncon,
Monitoring&ReportingFormatsandImplementation
Methodologies
ENCON FutureProjects
ProjectImplementationasCA/PAforISO9001/14001
UtilizationofAlternativeEnergySource&Waste
ImplementationOnEnergyFrontAmongstAssociates
(Vendors/Suppliers,Contractors,Customersetc.)
Awards&Accolades

Manufacturing Map of Coca-Cola In

India
Current Manufacturing Locations
CBOs + FBOs + Co pack
33 Manufacturing
Plants

Production lines (CBO & Copack)

Co-Pack

9 Plants

CBO

24 Plants

Sparkling RGB
Juice RGB
Sparkling PET
Juice Hotfill
Juice Tetra Pack
Retail water
Bulk Water
Cans

32
10 (2 cold fill)
24
6
3
11
4
1

Goblej Plant - Overview

2ndLargestPlantInIndia,
LargestBy1stJan2013
PlantCommissioned:Year1998
TotalPlantArea:53Acre
BuiltUpArea:23Acre
GreenBeltArea:30Acre
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

ZeroDischargePlant
WaterNeutralPlant

Process Over View

Water Treatment

Soft Water

RGB Empty
Bottle Handling
& Conveying

Treated Water

Bottle
Washing

Syrup
Processing
CO2

OR

Beverage
Processing

PET Bottle
Blowing &
Conveying

Filling / Crowning /
Capping
Conveying & Fulls
Handling

Energy Contribution
Contribution ( MJ )

Power Sourced
40%

53%

Contribution ( MJ )
42%
Electrical

HSD
Furnace Oil

5%

2%

Contribution ( Cost )
7%

4%

Briqueete

Thermal

58%
Power-Variable

2%

Fuel-Briq

20%

Power-Fix
Focus
Area

Fuel - FO
HSD - DG Set

67%

Two Areas
Contributes 87%
Of The Total
Power & Fuel
Cost

Plant Power Distribution

3% 2%
3%
3%

1%

1%

1%

1%
13%

4%
4%

13%

5%

5%

13%
5%
7%
7%

10%

80-20
Technique

600 BPM Pet CSD Line

HP Air Compressor
ETP & MVRE
Refrigeration
600 BPM Pet Juice Line
LP Air Compressor
Process
Lighting
AHU's & Air Conditioing
120 BPM Pet Line
Line-1
Maaza RGB Line
WTP/Borwell
Others
Boiler
FL Charging
Cold Storage
RGB Line-2
Admin Power

Top 9 of 25 Area Contribute To 78% of The Power Consumption

En-Con Projects In Last 3 Year

Sr.
No.

Year

Nos. of En-con
Projects
Implemented

Average
Investment
Saving
Pay Back
(Rs. INR MM) (Rs. INR MM)
(Months)

2011-2012

19

20.7

42.6

2010-2011

13

2.7

29.3

2009-2010

13

5.4

14.1

Total

45

28.8

88.7

En-Con Projects In 2009-2010

Sr. No.

Project Description

Investment Saving (Rs. Pay Back

(Rs.MM) MM / Annum) (Months)

Installation of 4 Ton Agro Waste Solid Fuel Boiler

3.0

10

Installation of PHE type condenser In place of Shell & Tube

1.1

10

Nil

0.6

Installation of New Pasteurizer for Precise Temperature Control

of Maaza Beverage
Installation of VFD for 40 Bar Compressor of 120 Pet CSD Line

0.6

0.5

15

Optimum capacity Rinse pumps of Line-1 & 2 bottle washer

0.13

0.4

0.25

0.3

10

0.08

0.3

0.04
0.02

0.2
0.2

2
1

0.04

0.2

11

Flow Meter For Monitoring of Air Consumption In Various Area

Common Cooling Tower for Raw Syrup System, Low Pressure
Air Compressor & Maaza Cooling Tunnel
Automation of Maaza Line Conveyors
Sizing of Maaza Filling Hall Ahu with Optimization of Pulley
Installation of Exhaust Blower to remove the hot air of the oven
& reduce the air conditioning load of 120 pet blowing room
Energy Efficient CFL Light Fixtures for 120 Pet Line Halls

0.1

0.2

11

12
13

Installation of VFD for Soft Water Pump of WTP

Interlocking of Pet 600 Mixer Chilled Water Pump

0.02
0.01

0.1
0.04

4
3

5.4

14.1

4.6

7
8
9
10

Total

En-Con Projects In 2010-2011

Sr. No.

Project Description

1
2

12

Ambient Temp.(18C) Filling for Pet Csd Instead of 4C

Optimization of Blowing Pressure For Pet Bottles
Installation of Separate Condensate Recovery Pump for
Pasteurizer of Maaza RGB & Pet Line
Installation of VFD For AF Make 40 Bar Compressors
Conversion of Air Cooled Chilled Water to Water Cooled
Chilled Water System For Pet 600 CSD Line
Installation of Variable Frequency Drive for Chilled Water
Pumps for Pet 600 CSD Line & Process
VFD installation for ID & FD Fan of 4 ton briquette fired boiler
120 pet Mixer, Chilled water tanks & pumps removal &
avoided the double pumping & loss of cooling
Installation of VFD for Soft Water Pumps
Installation of Suitable Design & Capacity Pump for Irrigation
Conversion of Delta to Star Connection for Agitator of Maaza
RGB Syrup Tanks
Interlocking of Air Washer's & AHU's With Filler Machine

13

On/Off System for 40 Bar Cooling Tower Fan Based on Temp.

3
4
5
6
7
8
9
10
11

Total

Investment Saving (Rs. Pay Back

(Rs. MM) MM / Annum) (Months)
Nil
24
0
Nil
3.9
0
0.5

1.1

1.4

1.0

16

0.4

0.15

0.3

0.15

0.2

0.02

0.1

0.04
0.04

0.1
0.1

6
8

Nil

0.1

0.02

0.1

0.01

0.03

2.73

32.03

En-Con Projects In 2011-2012

Sr. No.

Project Description

Investment Saving (Rs. Pay Back

(Rs.MM) MM / Annum) (Months)

1
2

Installation of Agro Waste Solid Fuel FBC Boiler

Energy Efficient Pumps Installation In Utility

10
2.1

27
3.4

4
7

Transfer of 173 TR Cooling Load From -2 C To + 6 C

0.1

2.7

0.5

Installation of Energy Efficient Screw Comp.

2.0

24

Supply of Cooling Water Instead of Chilled Water (6C)

0.2

1.2

Installation of Energy Efficient T5 Fixture ( 216 watt ) In

Place of HPMV Lamps ( 400 Watt )

1.2

0.9

16

Installation of Energy Efficient T5 Fixture (4x14 watt)

Instead of Tube lights (2x36 Watt )

1.2

0.9

16

Installation of Effimax for Online O2 Monitoring & Improved

Combustion Efficiency

0.7

11

Blower Installation for Date coding air instead of

compressed air of 7 kg/cm2 (5 Lines)

0.4

1.0

10

Improvement Of Condensate Recovery

Nil

0.6

En-Con Projects In 2011-2012

Sr. No.

Project Description

Investment Saving (Rs. Pay Back

(Rs. MM) MM / Annum) (Months)

11
12

Improvement of Power Factor

Conversion of V Belts to Cogged Belts

0.1
0.2

0.6
0.5

2
5

13

Installation of Suitable Capacity Pump for Pet Juice Line

Pasteurizer

0.1

0.3

14

Lighting Energy Saver Installation for Pet 600 CSd Line

Lighting

0.15

0.2

15

Installation of VFD for Cooling Tower Pump

0.08

0.1

16

Chilled Water System for 120 Pet Line Blow Molding

Room In Place of Dx Cooling System

0.05

0.1

17

Timer Provision For All The Lighting Circuit Across the

Plant For Automatic On & Off

0.05

0.1

18

Interlocking of Ahu's & Air Washers With Running of

Machine

0.03

0.1

19

Level Control System for UFRO Syntax Water Tank

0.02

0.1

20.7

42.6

5.8

Total

Specific Energy Consumption

Energy ( MJ / Ltr )

Electricity Usage Ratio ( Bev of Liter / Unit )

13.2
13.1
12.5

12.4

0.90

0.86

0.82

12.6

0.83
0.76

0.72

12.1

11.9

0.72
0.66

0.62
2008

2009

2010

2011

Fuel Usage Ratio ( Bev of Liter /

Unit )
180
160
140
120
100
80
60

0.92

164.4

86.5

93.7

2008

2009

2007

2008

2009

2010

2011

2012

Continuous Improvement In
Electricity & Furnace Oil
Usage Ratio

113.6

2010

2011

Significant Reduction In
Utilization of Overall Energy
Year After Year

Bench Marking
Q-Spec Report ( Coca-Cola India )
Electricity Usage Ratio ( Beverage of Litre / Unit )
26.0
25.3

Consistently
Achieving 1st
Rank In HCCBL
India, Since
Last 1 Year

24.0
23.5

23.3
22.7

22.7

22.5
21.9

21.0

21.8

Road Map To Be Best In Class

0.80

0.66

0.11
0.10

0.60

Energy Usage Ratio ( MJ / Liter )

0.05

0.40

0.40
0.20
0.00

Ref. Screw Compressor

18 Degree Filler
Energy Efficient Pumps
Pet 600 Csd Block Line to
Eliminate Rinser & Conv.
Screw Type Air Compressors
In Place of Recip. Comp.
Energy Efficient Lighting

Captive Power Generation

Recovery From HP Air
Flash Steam Heat Recovery
De-Humidifier In Place of Air
Conditioning System
De-Super Heater for Ref.
System
Heat Recovery From Raw
Syrup

RGB & Pet Line Conveyors

Automation
Interlocking of Ahus & Pumps
Date Coding Blowers
Interlocking With Lines
Scada System for Tracking
Utility Parameters
VFD Installations

Innovative Project 1 : Optimization of Blowing Pressure Of

Pet Bottles From 30 to 26 Kg/cm2
Project Name:

Project #:

PET blowing pressure & 40 bar air compressor power optimization.

Project Lead:
Team Members:

Piyush Shah

Project Start/End Dates:

NA-PH-xxx

From 13.01.10 To 15.5.10

Executive Sponsor:
Rajeev Chawla
Project Costs: (include required capital, expenses)
- Capital:

[1]Mahesh Kore
[2]Parthiv
[3] Dilipkumar
[4] Rizwan
[5] Bhavik
[6] Hemendra
[7] Ajay
[8]Manoj Pal
[9] Viral

- Expenses:

INR 1.8 Mn

Mission/Project Overview:
- KPI's:
Optimization of PET blowing pressure & Unload power of 40 bar air
compressor to achieve energy efficiency.

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
Net Benefits:

Objectives: (include beginning & ending KPI's)

To optimize the PET blowing pressure and optimization of 40 bar air
Annual savings of INR 1.8 Mn
compressor unload power.
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)

8 week
Approvals:
Project Lead:
PIYUSH SHAH
Area Lead:
MR. RAJEEV CHAWLA
Finance:
MR. SAMEER AGRAWAL
Executive Sponsor/
MR. RAJEEV CHAWLA
Steering Committee:

Other Key Stakeholders & Areas Affected:

[1] Finance Dept [2] Plant Operation
Date:
Date:
Date:
Date:

Innovative Project 1 : Optimization of Blowing Pressure of

Pet Bottles From 30 to 26 Kg/cm2

Process Flow
. . . Gaining Process Understanding
Compressor

30 kg/cm2

Preforms

Receiver

Dryer

Blow Molds

Blowing

Filter

3 Way Valve

Bottles

The critical quality impacted by blowing pressure parameters

were identified as height, brimful volume, wall thickness and
stress cracking
D

Innovative Project 1 : Optimization of Blowing Pressure of

Pet Bottles From 30 to 26 Kg/cm2
Blowingpressureoptimizedfor
600mlbottlefrom30to26kg/cm2
40baraircompressorloading&
unloadingsettingchangedto27&29
kg/cm2.

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

Qualityparameterfoundwithinrange
Processcapabilitychecked&achieved
forcriticalqualityparameters.
Quality Parameter

Acceptable Range

Brimful
Base Weight
Upper Shoulder Weight
Label Panel Weight
Wall Thickness - Minimum
Gate Area - Minimum
Base Clearance - Minimum

623.34 +/- 5 ML
5 to 5.5 GM
10 to 11 GM
11 to 12 GM
0.3 MM
1.3 MM
3.5 MM
No Crack For 20
Minute

Stress Crack Test

Improvement in 40 bar compressor power consumption from 101

Kwh to 85 Kwh
D

M A I

Innovative Project 1 : Optimization of Blowing Pressure of

Pet Bottles From 30 to 26 Kg/cm2

Process Controls
. . . Sustaining The Gains
Recipechangessavedonblowingmachine,oldreciperemoved
Checkprocesscapabilityforcriticalqualityparametersatregularinterval.
Processparametersspecificationchartdisplayonthemachine.
Processparameterslocked Accesstochangelimitedtoauthorized
person.

Error Proofing Done To Ensure That Process Runs In Control

D

M A I

Innovative Project 1 : Optimization of Blowing Pressure of

Pet Bottles From 30 to 26 Kg/cm2

Comparison Of Power Consumption : 2010 - 2011 - 2012

2010
Prod - Cs

Units

2011
Ratio Prod - Cs

Units

2012
Ratio Prod - Cs

Units

Saving
Ratio

45,34,453 13,33,663 3.4 89,89,147 20,43,100 4.4 44,59,774 8,45,354 5.3

Saving :
2011 Vs. 2010 : Rs. 3.9 Million
2012 Vs. 2011 :

Rs. 1.2 Million

2011 vs 2012 vs
2010
2011

-29%

-20%

Innovative Project 1 : Optimization of Blowing Pressure of

Pet Bottles From 30 to 26 Kg/cm2

Project Summary

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

Innovative Project 2 : Transfer of 173 TR Cooling Load

From -2 Degree To + 6 Degree Chilling System
Before

After
Raw Syrup
(Flow Rate
5KLPH)
Temp.(45C)

Glycol
return from
process at
+1C

Glycol
supply to
process at
-2C

Chilled water return

from process at +10C

Ready Syrup
at 25C

Chilled water
to process at
+6C

Innovative Project 2 : Transfer of 173 TR Cooling Load

From -2 Degree To + 6 Degree Chilling System
Parameters

Raw Syrup
5 KL System

Raw Syrup 120 Pet

10 KL
Line
System
Chiller
10000
25000
50
15

Total

Raw Syrup/Chilled Water Flow Rate (LPH)

Raw Syrup/Chilled Water Inlet Temp. (C)

5000
45

Raw Syrup/Chilled Water Outlet Temp. (C)

25

25

Cooling Used ( TR Per Hour )

33

83

58

174

Power Consumption Per Hour(-2C System)

38

95

67

200

28

70

49

148

74405

161210

130208

365823

5,39,435

11,68,775

30,000
1

40,000
0.4

Power Consumption Per Hour(+6C

System)
Annual Power Saving ( Kwh )
Annual Saving ( Rs. )
Investment ( Rs. )
Pay Back Period ( Months )

40000

9,44,010 26,52,220
30,000
0.4

1,00,000
0.5

Annual Saving of INR 2.65 MM Per Annum

Innovative Project 3 : Supply of Cooling Water In Place

of Chilled Water ( 6 Degree )
Before

Cooling Water
From PHE At 36C

After

Cooling Water
Supply @ 55m/
hr
Cooling water to
PHE at 32C
Chilled water from
PHE @ 12C

Chilled Water
Supply @
40m/hr

Chilled water to PHE at 07C

Process water
flowrate 55m/hr

Innovative Project 3 : Supply of Cooling Water In Place

of Chilled Water ( 6 Degree )
Parameters

Process Water Flow Rate

Process Water Temp. - Inlet to PHE (C)
Process Water Temp. - Outlet from PHE (C)
Cooling Used (TR Per Hour)
Specific Power Consumption for Chilled Water System &
Cooling Tower Water System
Power Consumption Per Hour (Kwh)
Per Hour Power Saving (Kwh)
Annual Running Hours
Annual Power Saving (Kwh)
Annual Saving ( Rs. )
Investment ( Rs. )
Pay Back Period ( Months )

Before
Chilled Water

After
Cooling Water

25000
42
36
49.6

25000
42
36
49.6

0.9

0.2

44

12
31.7
5000
158651
11,50,218
2,00,000
2.1

Annual Saving of INR 1.15 MM Per Annum

Innovative Project 4 : Elimination of Compressed Air

With Air Blower
Before

Compressed Air
@ 3 Bar

After

Air Blower @ 0.8

Bar

Air Blow Is Required Before Date Coding On Glass Bottles

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

Annual Saving of INR 1.00 MM Per Annum

Carbon Emission Reduction

Project Name : Installation of 8 Ton Capacity Agro Waste FBC
Boiler
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

Carbon Emission Reduction

Project Name :

Installation of On line O2 Analyzer

4% Reduction In Excess Air In Flue Gas Leads to 2.4%

Improvement In Boiler Efficiency
Parameter
Briquette Used ( Kg )

Value
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

Reduction In Co2 Emission Equivalent To 24.7 KL Of

Furnace Oil

Carbon Emission Reduction

Project Name : Installation of Precise Temperature Control System In
Pasteurizer To Control Temp. Overshoot For
Reduction of Steam Consumption

Reduction In Co2 Emission Equivalent To 17 KL Of

Furnace Oil

Carbon Emission Reduction

100%

75%

95%

89%

Agro Waste

73%

Fossil Foil (
HSD, Furnace Oil )

50%

25%

27%
11%

5%

0%
2010

2011

2012

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.

Abhishek
Sikligar

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

Saurabh
Trivedi

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

Rajneesh
Sharma

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 :ONEnergyConservation&EnvironmentalAwareness
Audit :Internal&ExternalEnergyAudit
ImprovementProject :PromotingMore&MoreEnergyConservation
ProjectsandRewardingTheProjectTeam

Workshop :ParticipationInEnergyConservationWorkshop
Review :Daily,Weekly,Fortnightly&MonthlyReviewofActionPlan/
Projects,FurtherPlanning

Display :Temperature&PressureSetPoints,Loading/UnloadingSetpoints
PeriodicCirculationofDosandDontsForTheEffectiveUseofEnergy

Most of The Energy Projects Are Executed By Inter

Departmental Team

Team work
Sr.
No.

1
2
3
4
5
6
7
8
9

Proposal

Saving
Extent of
Potential Achieved
Source Of EnImplementation Investment
Year Manpower
( Rs. MM Saving
Con Idea
Progress
( Rs. MM)
Involved
Per ( Rs. MM )
Annum )

Interlock of air blower with labeller

Supervisor 2011
machine start & stop
Provision separate lighting circuit
Workmen
2011
for LT room lights
Installation of VFD for chilled water
Middle
2011
pump of pet 600 csd line
Management
VFD installation for AF make 40
Top
2011
bar air compressors
Management
Installation of centrifugal pump In
place of submersible pump for
Supervisor 2011
Irrigation water pump
Level control system for UF RO
Workmen
2011
tank
Conversion of V belts to Coggeed
Top
2011
belts
Management
Installation of air regulator for
Supervisor 2011
Maaza rgb line crowner air
SS pipeline in place of pu pipe in
pet 600 cip room due to
Workmen
2012
atmosphere condition

Implemented

Nil

0.02

Implemented

Nil

0.02

Implemented

0.1

0.15

Implemented

Nil

Implemented

0.04

0.06

Implemented

0.01

0.03

Implemented

0.2

0.25

Implemented

0.005

0.04

Implemented

0.08

0.1

Team work
Sr.
No.

Proposal

Installation of limit switch &

interlocking with door air curtain
Timer installation for switching of the
11
ware house lights in day time
VFD & Pressure Transmitter
12
installation for cooling tower pump
10

13

Rain maker day tank piping

modification to avoid double pumping

14

Ventury trap installation in place of

conventional trap

15

Installation of motion & occupancy

sensors for plant less movement area

Source Of EnCon Idea

Supervisor

2012

Implemented

0.1

0.12

Workmen

2012

Implemented

0.1

0.12

Middle
Management

2012

Implemented

0.1

0.12

Supervisor

2012

Implemented

0.04

0.08

Top
Management

2012

Implemented

0.2

0.2

Supervisor

2012

Under
Consideration

0.5

0.7

Installation of On line O2 Monitoring

system ( Effimax 2000 )
Optimum capacity pump for pet juice
17
line pasteurizer

Middle
Management
Middle
Management

18 Solar Lighting

Top
Management

16

Saving
Achieved
Extent of
Implementation Investment Potential ( Rs.
Saving
Year Manpower
Progress
( Rs. MM) MM Per Annum
( Rs. MM )
Involved
)

2012

Implemented

0.7

0.8

2012

Implemented

0.1

0.25

Under
Consideration

15

7.5

2013

Monitoring & Reporting System

Parameter

Critical KPI Tracking ( Receiver Air Pressure, Product Temp.

Set Point, Blowing Pressure Set Point )
Condensate Recovery
Specific Power Consumption Tracking for Higher Power
Consuming Areas
Identification of Gap In Electrical Consumption of Different
Area ( Standard Vs. Actual )
Boiler Efficiency
Electricity Usage Ratio, Fuel Usage Ratio
DG Efficiency
Identification of Air & Steam Leak & Corrections
Monitoring of Steam Traps Working
Review of Energy Improvement Action Plan
Review of Power & Fuel Usage Ratio & Cost With Zonal
Supply Chain Head
Free Air Delivery Check for Air Compressors

Monitoring & Reporting

Frequency

Every Shift
Every Shift / Daily / Monthly
Daily / Monthly / Yearly
Daily
Daily
Daily / Monthly / Yearly
Daily / Monthly / Yearly
Weekly
Fortnightly
Monthly
Monthly
Quarterly

Energy Monitoring & Reporting Formats

Target
Date
1-Feb
2-Feb

HP Air

LP Air

5.5 ( Crate Pet

Unit )
Daily
MTD
2.4
5.0
5.2
5.1

5.5 ( Crate Pet

Unit )
Daily MTD
10.0
18.9
18.6
18.8

Specific Power Consumption Norms For High Impact Area

.. Daily Tracking, Gap Identification & Corrections

Energy Monitoring & Reporting Formats

Date

RGB1 RGB1 % RGB2

(KWH) Opp. (KWH)

RGB2 %
Opp

HS PET 1
HS PET 1 CSD
CSD
% Opp.
(KWH)

1-Apr-12 331

21%

0%

640

12%

2-Apr-12 231

13%

0%

0%

Gap Identification Betn Std. Vs. Actual Power Consumption

.. Daily Tracking & Corrections

Energy Monitoring & Implementation

Methodology
SIX SIGMA APPROACH FOR PROJECT
Benchmarking

Monitoring

Step-1:
Categorization
Audit

Innovation

Step-2 : Data
Collection
Step-3 : 80:20
Technique

Execution

Sequence
Bench Mark
Audit ( Internal / External )
Analysis
Execution
Monitoring System
Online Suggestion

Analysis

Purpose
Gap Identification
Identify Potential Saving To Close Gap
Evolution or Project
Improvement
Substance
Value Creation

Step-4 :
DMAIC
Approach

En-Con : Future Projects

Investment
Saving
Pay Back
Sr.
Project Description
( Rs. MM ) ( Rs.MM Per Annum ) ( Months )
No.
1 Solar Lighting
25
25
12
2 Captive Power Generation
4.5
4.5
12
Installation of Energy Efficient Lighting In Raw
1.5
3
7
3
Syrup, Ready Syrup, RGB Line-2 & Other Areas
4 Installation of Energy Efficient Pumps
1.2
1.8
8
Installation of PHE For Heat Recovery for Hot Syrup
0.5
1.5
4
5
To Product Water
Air Recovery System To Recover Blowing Machine
0.03
1.0
0
6
Exhaust Air To Low Pressure Air
Recovery Of Flash Steam For Pet Juice Line
1
0.9
13
7
Pasteurizer
Desuperheater @ KC9 - Use For Boiler Feed Water
0.8
0.9
11
8
Tank Water Heating
Automation of Lighting With Occupancy &
0.6
1
9
9
Movement Sensors
Ring Main System For Low Pressure ( 7 Bar ) Air To
10
0.15
0.5
4
Optimize The Receiver Pressure
11 Insulation of Bottle Washers Soak Compartment
0.3
0.5
7
12 Flash Steam Recovery - Maaza RGB Pasteurizer
0.5
0.5
13

En-Con : Future Projects

Sr.
No.

13
14
15
16
17
18
19
20
21
22

Project Description

Insulation Effectiveness using thermal Imager &

correction across the plant
Ring Main System For High Pressure ( 40 Bar ) Air To
Optimize The Receiver Pressure
Mech Seal Type Efficient Vacuum Pump In Place Of
Gland Type Vacuum Pumps For RGB Line-1 & 2
Installation of DI Pipe Line For Gravity Flow Of Raw
Water To Avoid The Double Pumping
Installation of Variable Frequency Drive For Maaza
Filling Hall Air Washer Blower
Heat Recovery From Bottle Washer Hydro Water For
Warmer Water Heating
Nitrile Rubber Insulation For Cold Lines
Installation of Variable Frequency Drives For Raw
Syrup Air Washer Blower
Automation of RGB & Pet Lines Conveyors & Pumps To
Stop During Non Production Time
Interlocking of Pet Juice Line Pumps For Auto Stop &
Start
Total

Investment
Saving
( Rs. MM ) ( Rs. MM Per Annum)

Pay Back
( Months )

0.2

0.4

0.1

0.3

0.2

0.3

0.15

0.2

10

0.1

0.2

0.1

0.2

0.1

0.2

0.08

0.1

0.01

0.1

0.01

0.1

37.13

42.32

10

Environmental Initiatives
Green Belts & Tree Plantation --- Across The Plant

Our Commitment to Conserve Water

4 Rs for conservation
Reduce: Creating Awareness & Reducing Wastage
Reuse: Recovering & Reusing
Recycle: Recovering & Reprocessing
Recharge: Rain Water Collection & Recharge Bore Wells
Recharge
Rain water
Harvesting

Recycle
Bottle washer
Tertiary Treatment
Vacuum Pump
Recirculation

4R
Implementation

Reuse
Crate washing
Floor Cleaning
Toilet
Garden

Recharge
Create awareness
Bottle washer
Backwashing

Our Commitment to Conserve Water

Water Usage Ratio ( Liter of Beverage Per Liter )
3.80
3.40

3.38
2.97

3.00
2.60

2.39

2.20

1.90

1.80

1.6

1.40
2008

2009

2010

2011

2012

Continuous Reduction In Water Usage Ratio, 100%

Improvement In 4 Years

Our Commitment to Conserve Water

Year

20102011

Environmental Aspect

Water-consumption per liter of

beverage production
( WUR/Water Usage Ratio)

Action
1.Switch over from
ground water source to
surface water.
2.Installation of
Decaustizer.

Environmental
Impact/Improvement
Water consumption
reduced from 2.97 per
liter of beverage to 2.39
liter

Our Commitment to Conserve Water

Year

20112012

Environmental Aspect

Action

Water-consumption per liter of

beverage
production(WUR/Water Usage
Ratio)

Installation of UFRO
Scheme in Effluent
treatment plant to meet
requirement of utilities

UFRO SYSTEM

Environmental
Impact/Improvement
Water consumption
reduced from 2.97 per
liter of beverage to 1.9
liter

Our Commitment to Conserve Water

Year

20112012

Environmental Aspect

Action

Environmental
Impact/Improvement

Water -Consumption per liter of

Water consumption
Installation of recovery
beverage
reduced from 1.9 per liter
production(WUR/Water Usage scheme - Rainmaker
of beverage to 1.55 liter
plant
Ratio)

Our Commitment to Conserve Water

RAINWATER HARVESTING AT GOBLEJ UNIT

RUN OFF WATER

RECHARGE WELL

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.
1
2
3
4
5
6
7
8
9

Best Practice / Replication

V Belts to Cogged Belts Conversion
Filling of Sparkling Beverage at Temperature of 18 Degree In
Place of 4 Degree
Blowing & Filling - Block Machine For Pet Bottles In Place of
Separate Machine
Energy Efficient ( T5 ) Lights Installation
Use of Energy Efficient Bearings For Motors
Wind Driven Exhaust Fans For Plant Sheds
No Air Conditioning System For Blowing Machine Room With The
Installation of De-Humidifier
Energy Audit of Pumps & Installation of Energy Efficient Pumps
Installation of High efficiency Vacuum Pumps For Filling Machine

10 Power Standardization Template

11 Energy Audit
Ventury Trap Installation Instead of Conventional Bucket / Float
12
Traps

Associates
Hindustan Coca-Cola Bangalore
KHS - Germany
Sidel - France
Philips - India
SKF - India
Ratna Construction
KHS - Germany
Grundfos - India
PPI - India
Energy Manager Group HCCBPL
Devki Engg.
Zenith Marketing / GEM
Trap

Certifications
ISO 14001:2004

ISO 18001:2007

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