First Prize

Dairy

SUMUL DAIRY
(Surat Distt. Co-operative Milk Producers Union Ltd.)
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, SUMUL Dairy was established.

Main Objective of Sumul

1. To provide a guaranteed remunerative milk market round the year for all the marketable surplus of member producers in their villages. 2. To procure milk, process it into good quality milk/milk products and market it most economically and efficiently to give maximum overall net-returns to the producers and general satisfaction to the consumers. 3. To provide essential technical inputs and services to the producers at their door-steps in an economic and efficient manner and also in a way most acceptable to them - to increase milk production and to reduce the cost of production.

SUMUL DAIRY SURAT Bajipura chilling Center

OTHER UNITS OF SUMUL Navipardi Chilling Center Uchchal Chilling Center

Nizar Chilling Center

Chalthan Cattle Feed Plant

Lahe, Shahpur Nasik Plant

`Simul is also ISO 9002, HACCP and ISO 14001 certified organization. It is also certified from Export council of India, which will help in improvement and export of surplus milk and milk product.

165

Name of Product Amul Shakti, standardized Milk Amul Gold, High Fat Milk Amul Taaza, Toned Milk Skimmed Milk, Cow milk Butter Milk, Masala chhas Ghee Paneer Flavored milk Curd Sweets Powder Butter Pasteurized chilled water

Packing Type 500 ML , 6 Litres 500 ML , 6 Litres 250 ML, 500 ML 6 Litres 500 ML Tin, Pouches Pouches. Tin Bottle, Cups (200 & 400 gm) Box Bag cartons

Production in (kg) 328301659

3293942 232651 446812 1556623 640882 749400 732720 2429000

Energy Consumption
There is a steady decline of specific energy conservation due to implementation of various energy conservation measures in last 3 years. The details are as given below: DESCRIPTION Annual milk & milk production Total electricity consumption/ annum Specific energy consumption Total thermal energy consumption / annum Specific energy consumption thermal Total manufacturing cost Total energy cost Energy cost as % of total manufacturing cost UNIT Mt Lakhs kwh Kwh/mt Million kcal Million kcal /mt Lakhs Rs. Lakhs Rs. % 2005-06 334461 91.90 27.477 13007.41 0.0389 3519.17 633.0 17.98 2006-07 329544 88.73 26.92 12856.33 0.039 4247.97 596.65 14.05 2007-08 344307 90.01 26.14 12684.2 0.0368 4780.68 668.78 13.98

166

Graphical presentation of Specific Energy Consumption of Sumul Dairy

SPECIFIC ENERGY CONSUMPTION KWH/MT
27.47
27.6 27.4 27.2 27
MKCAL/MT

SPECIFIC ENERGY CONSUMPTION MKCAL/MT

0.0389 0.039

0.039

26.92

0.0385 0.038 0.0375 0.037 0.0365 0.036 0.0355

0.0368

26.8
K W H /M T

26.6 26.4 26.2 26 25.8 25.6 25.4

2005-06 2006-07 YEAR

26.14

2007-08

2005-06

2006-07 YEAR

2007-08

% Energy Cost To Manufacturing Cost

WATER V/S MILK RATIO

0.69
18

17.98

0.69 0.685 0.68

14.05

13.98

16

0.68

14 % OF ENERGY COST 12 10

K L /M T

0.675 0.67 0.665 0.66 2005-06 2006-07

YEAR

0.67

8 6 4 2 0

2007-08

2005-06

2006-07

2007-08

Energy Conservation Commitment, Policy and Set up

Energy Policy The unit is committed to conserve the energy which is a scarce resource with the requisite consistency in the efficiency, effectiveness in the cost involved in the operation and ensuring that production quality & quantity, environment, Safety, health of people are maintained.

The Mission is to be lowest specific energy consumer in the industry we operate.

This we plan to achieve by the following: Manage efficiently the utilization of energy resources upgrade hardware & employ cleaner & more efficient Technology. Carryout regular internal & external audits to identify area for improvement. Bench-mark continuously our performance against best practices. Enrich our experience on energy conservation by exchange of ideas with other organization. Promote awareness among all members of the Sumul large family.

167

Energy Conservation Plans and Targets

S. No. Energy Conservation Measures (Planned) 2008-09 Anticipated savings Approx. investment (Rs. Lakhs) Project Commencement & Completion year Status as on 5th Oct-08

Energy Value Rs. ( specify units ) Lakhs A Electrical Project

1.

Replacement of 125 HP Star 81457 Delta starters with 190 amp Soft starter for powder plant delivery fan.

4.48

5.0

Commissioned

2.

Replacement of less efficient 217261 butter milk pasteurizer with high regeneration new butter milk Pasteurizer. (As per suggestion of PCRA audit recommendation.) Replacement of old 3.5 hp motor 7292 with new 3.0 hp motor.

11.95

10

Commissioned

3.

0.40

1.8

Commissioned

4.

Replacement of Tank room milk 84715 tank manual agitator system with PLC automation system.

4.74

Commissioned

5.

Replacement with new double 26280 headed mechanical Ghee packing machine in place of pneumatic machine.

1.44

4.81

Commissioned

6.

Installation of PUF Panel in 35770 incubation room of curd section.

2.0

Commissioned

168

S. No.

Energy Conservation Measures (Planned) 2008-09

Anticipated savings

Approx. investment (Rs. Lakhs)

7.

Energy Value ( units ) Installation of Soft starter for 10 43444 small motors.

Rs. Lakhs 2.39

3.0

Project Commencement & Completion year Status as on 5th Oct-08 Commissioned

8.

Milk heating for UHT from 6-35 C 18105 by hot water recovered from ammonia PHE. With electrical saving in condenser load. (Electrical saving). Installation of Paneer whey 26280 cooling system by incoming milk from 75 to 30 C & simultaneous heating of milk from 6-35 C by improving regeneration. (Electrical saving). Installation of natural ventilation 6424 system.

1.01

0.46

Commissioned

9.

1.44

0.5

Commissioned

10.

0.359

3.6

Commissioned

11.

Substation automation in Sumul.

1.5

Commissioned

12.

Replacement of old IBT agitator 325828 with Grundfos make IBT agitator for power saving. Replacement of new boiler feed 35841 water pump. Installation of common 250 KVA 60590 automatic voltage stabilizers for lighting load (AS PER ENERGY AUDIT REPORT).

17.92

20

Commissioning

13.

1.97

Under Commissioning Under installation & commissioning

14.

3.39

5.0

169

S. No.

Energy Conservation Measures (Planned) 2008-09

Anticipated savings

Approx. investment (Rs. Lakhs)

Energy Value ( units ) 15. Installation of PLC in Ghee Tin filling machine. Replacement of 30 kl pasteurizer 79409 with high energy efficient milk pasteurizer. Replacement of crate washer old 21722 pumps with new pump. Replacement of old thermocol 43800 insulation with PUF Panel in butter clod store. Replacement of pneumatic milk 163520 filling cylinder by magnetic type. Hydro flow system for ETP plant. 28928

Rs. Lakhs -

Project Commencement & Completion year Status as on 5th Oct-08 Order placed

16.

4.37

15

Under Inquiry

17.

1.19

10

Under Inquiry

18.

2.45

15

Under Inquiry

19.

9.15

Under Inquiry

20.

1.62

0.83

Under Inquiry

21.

Installation of vfd for milk transfer 39099 to pouch packing machine in packing section. Generation of power at ETP 182500 through Bio-methanization. Capacity 100 KVA TOTAL 1528265

2.19

5.0

Under Inquiry

22.

9.12

35.0

Under Inquiry

83.579

156.5

Environment and Safety

A) Water Effluent The major effluent in dairy is the flushing of milk pipelines with Caustic & Acid which comes to the Effluent Treatment Plant. Our plant comprised anaerobic treatment followed by aerobic system, while making use of all the existing units. With the addition of UASB system, there will be a potential for reusing a valuable byproduct of the plant i.e. Biogas. Due to the conservation of process water at various stages of milk processing, the effluent generation came down from 700 to 500 M3 / Day.

170

For that, unit has upgraded our Effluent Treatment Plant with recycling plant to reduce pollution load as well as to reduce water consumption by using ETP reused water.
GPCB Analysis data ( BOD)
30 25 20 15 10 5 0
ril .0 Ap

GPCB Analysis data ( COD)

permicible limit 100

GPCB Analysis data ( SS)

100 80 60 40 20 0
ri l .

premicible limit 30
23 20 23 14 13 11

permicible limit 100

32 36 42 26 8 22 32

V alue

BOD

COD

17

18

08

.07

.0

07

07

07

c. 0

ay

ne

ly.

g.

b.

.0 7

y .0

ly . 0

c .0

b .0

Ap

r i l.

07

07

07

08

Ma

ne

g.

.0

Ap

.0

g.

ne

ay

ly .

c.

b.

r .0

Ju

De

Au

Ju

Ap

Fe

Ju

r .0

Ju

Ju

De

Ju

Au

Fe

Ap

Month

Month

B) Air Emission Analysis The major source of air emission in Sumul is through Boiler, DG set, Hot air generator stacks. The unit is constantly using natural gas a source of fuel which is eco friendly.
Stack Analysis (SO2) data of 07-08
permicible limit 100

20

50 40

Stack Analysis (NOx) data of 07-08

permicible limit 50
200
162.5

Details of SPM of 07-08

permicible limit 200
146.3 148.1 5 137.9 1 32 1 33 122 137.3 134.55 128.36 135.5

Au

Month

De

Fe

07

Ap

07

r. 0

100 80 60 40 20

96 84

75

69 52 43

V alue

88

82

COD

18

SS

SPM

S O 2 v alu e

N O x v a lu e

162

10 4.35 4.31 4.51 3.45 3.4

8.5

7.75

6.6

6.5

20 10 0

SO2
Oct. Nov. Dec. Jan. Feb. Mar.

11.65 12.7 11.85 10.7 9.85 11.15 12.6 11.75 10.95 10.8 10.15 11.25

Nox

100 50

0 Apr. May. Jun. Jul. Aug. Sep.

Apr. May. Jun.

Jul.

Aug. Sep. Oct.

Nov. Dec.

Jan.

Feb. Mar.

Month

Month

Value

9.2

30

150

0
Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec. Jan. Feb. Mar.

Month

Plantation
Sumul Dairy has planted Rs. 2.825 Lakhs of plant in 369 villages of Surat District as part of forestation.

Celebration of Energy Conservation Day

Sumul has celebrated Energy Conservation Day on 14th Dec-2007. Employees from top to bottom level have participated. Banners, posters are placed at various places in plants. Training program was conducted at floor level.

171

Second Prize

Dairy

HERITAGE FOODS (INDIA) LIMITED

Chittoor Distt. (Andhra Pradesh)

Unit Profile
Heritage Foods (India) Limited is one of the fastest growing enterprises in Dairy Industry in South India. The Main Dairy Plant, Gokul was commissioned in 1996 with a rated capacity of 1.5 LLPD and was subsequently expanded to 2.5 LLPD in 2007. Presently, Heritage Milk and Milk products have prominent market presence in Andhra Pradesh, Karnataka, Kerala, Tamilnadu and Maharashtra.

GOKUL PLANT

172

Energy Consumption
There has been a steady increase in the milk handled and decrease in the energy consumption since the establishment of Energy Management policy implementation in 2005. Last 3 years Specific energy consumption figures are shown below, which depicts continual reduction in energy consumption over last 2 years due to our sustained efforts to conserve with the implementation of various energy conservation measures and ideas to increase efficiency of all its our operations.

Description Electrical energy Thermal Energy Total Manufacturing Cost Total Energy cost Energy as % of Total cost of production

Unit KWh / Tonne M Kcal / Tonne Rs. Lakhs Rs. Lakhs %

2005-06 52.93 0.0984 367.71 160.62 43.68

2006-07 52.32 0.0890 440.12 177.85 40.41

2007-08 44.75 0.0730 570.63 248.18 43.49

SPECIFIC POWER CONSUMPTION

54

SPECIFIC THERMAL ENERGY CONSUMPTION

0.12
52

0.1 M KCal / Tonne

KWh / Tonne 50 48 46 44 42 40 2005-06 2006-07 YEAR 2007-08

0.08 0.06 0.04 0.02 0 2005-06 2006-07 YEAR 2007-08

Energy Conservation Commitment, Policy and Set up

Heritage Foods (India) Limited, Main Dairy Plant, Gokul visualized the importance of Energy Conservation and taken measures accordingly in forming the core team and conducted several brain storming sessions section wise by creating awareness and to identify the areas to concentrate.

173

Energy Conservation Team Structure

General Manager (O)

Plant Manager / Energy Manager

Energy Conservation Core Team consists of Maintenance Engineer Electrical Engineer Utilities Incharge Quality Representative The above team activities - Brain storming - Identify the area / Investment & ROI

Implementation team Executive Supervisor Executing the designed activity as per plan

Monitoring team Executive Supervisor Fitter Monitoring and analyzing the output and feedback to core team

174

Energy Conservation Achievements

During the period 2007-2008, The Unit implemented 13 major Energy saving Ideas through Brain Storming Sessions conducted in Energy cell and in Energy Conservation awareness classes. Annual Savings of Rs. 18.99 lakhs was achieved with an investment of Rs. 8.06 lakhs only. It has resulted in Percentage Reduction of 14.469% in Electrical Energy and 17.98% in Thermal Energy. Achievement of energy savings per year basis Electricity Project description (Lakhs (kWh) Replaced raw effluent pump of 5HP capacity with Energy Efficient 2HP pumps Replaced CBMM rotopump 5HP capacity with Energy efficient VFD driven 1HP rotopump Instead of Cooling tower for Cream Pasteurizer water connection taken from ATM sump. 0.20 F.Oil (KL) Total (fuel) in Mkcal) Fuels* Investment incurred on Total the project savings (Rs. Lakhs) in (Rs. Lakhs) 0.69 0.30

0.26

0.93

1.50

0.06

0.19

0.00

Condensate recovery tanks provided. One tank for the pasteurizers condensate and one tank for the condensate of Khoa pan and Paneer vats Replaced 10KL and 3KL 0.16 pasteurizers Hot water pumps of 3.5HP with Energy Efficient pumps 2.0HP Multi purpose vat jacket Chilled 0.55 water taken back to IBT and chiller arranged to reduce temp. from 85 degrees 50 degrees with soft water. The heated soft water used for bottle cleaning Installed Condensed milk chiller, there by reducing the temperature of condensed milk from 55 degrees to 10 degrees and preheating the skim milk going to powder plant. IBT make up water with the Chilled water getting from Cream silo during heating cream from 8 degrees to 13 degrees 0.56

12.0

119.70

2.86

0.25

0.58

0.81

4.0

39.90

2.88

1.50

8.0

79.64

3.88

1.67

0.04

0.13

0.00

175

Splash steam from all the steam traps recovered by connecting them to hot water tub and used as boiler feed. By following sequence of operations, minimized the Ammonia compressor running hours. In 2006-07 per hour of Compressor 7534lts milk handled and in 2007-08 8063 lts handled. 391hours of KC6 compressor reduced By elevating the Silo avoided 2HP pump for the FCBT of Curd Pasteurizer Arranged Electro Magnetic Water Flow meters in CIP section and monitored efficiently the qty. of water per object CIP (achieved 5000Lts/ Day hot water saving) Replaced the IBT agitators motors 10HP 2 numbers with Energy Efficient 7.5HP motors Sub Total

5.0

49.88

1.19

0.25

0.57

2.01

0.00

0.09

0.31

0.50

10.0

99.75

2.38

0.48

0.27

0.96

0.80

2.76

38.98

388.87

18.99

8.06

Energy Conservation Plans and Targets

Anticipated savings in Energy Value (specify units) --1.095 Lakh Kwh 27141.5 M Kcal --3.9 10.0 1000 Mkcal 2.3 5 2009 Dec'2008 Rs. Lakhs

Energy Conservation Measures (Planned) 6 tons Multi Fuel Fluidized bed boiler planned (Coal) in place of Furnace Oil fired boilers Prechiller for returned chilled water Pasteurizers Hot water source to be changed from Steam Battery system to PHE system

Approx. investment (Rs.lakhs)

Project Commencement & Completion year

248.0

62.0

March'2009

176

Environment and Safety

1. A Safety committee is constituted with employees working at Different levels which meet periodically to analyse all aspects of Employees health & safety during work. The safety committees recommendations are being implemented to improve the working conditions & safety of all. 2. A good ETP system consisting of USAB reactor and Aerator tanks treat our plant water very efficiently and this water is being used for the development of green belt around the plant

177

Certificate of Merit

Dairy

KOLAR MILK UNION LIMITED

Kolar (Karnataka)

Unit Profile
Kolar District Co-operative Milk Producers Union is registered under Co-operative Societies act after bifurcation from Bangalore District Co-operative Milk Producers Union on 23/03/1987. The area of operation is restricted to Kolar and Chikkaballapur Districts having 2919 villages of 11 revenue Taluks.

Energy Consumption
With the implementation of various energy conservation measures in the dairy unit, there is significant reduction in energy consumption and also considerable decline of specific energy consumption. Due to the sustained efforts to conserve energy and with the implementation of various energy conservation measures and novel ideas to increase efficiency of equipments, the declining trend of specific energy consumption in last three years is shown below. Description Specific Electrical energy Specific Thermal energy Total turn over Total Manufacturing cost Total Energy bill Energy as % of Total cost of production Unit Kwh/Tonne Mkcal/Tonne Lakhs Lakhs Lakhs % 2005-06 43.71 0.0648 30583.6 3035 333.95 11 2006-07 38.52 0.0548 29837.42 2410 361.54 15 2007-08 36.10 0.0486 35780.65 3131 360.14 11.5

178

* Though there is a remarkable decline in specific thermal & electrical energy the total energy bill is at higher side due to the increase in the prices of furnace oil, diesel and also power tariff rates.

Specific Electrical Energy Consumption 2007-08

50 45 40 35 30 25 20 15 10 5 0

43.71

38.52

2005-06

2006-07 Kwh/Tonne

2007-08

Specific Thermal Energy Consumption 2007-08

0.07 0.0648 0.06 0.05 0.04 0.03 0.02 0.01 0 2005-06 2006-07 MKCal/Tonne 2007-08

0.0548

0.0486

36.1

179

Energy Policy

Kolar District Co-operative Milk Producers Societies Union Ltd.,

ENERGY POLICY We continuously strive to effectively improve the overall operations and management systems by adopting cost effective advanced technologies and by educating and motivating the workforce to achieve maximized qualitative production with least energy consumption and safeguarding environment and natural resources.

ENERGY CONSERVATION CELL

Energy Committee Chairman (General Manager)

Energy Manager (Manager Engineering) Energy Team Coordinator

DMs (Eng)

DMs (Prod)

AMs (Eng)

AMs (Prod)

Technical Officers

Technical Officers

Energy Conservation Cell

180

Energy Conservation Plans and Targets

In this regard few energy conservation projects were planned, discussed in detail to be taken up in the year 2008-09. 1. 225 TR De-Super Heater The unit is replacing the existing 75 TR De-Super Heater with 225 TR De Super Heater, to conserve more thermal energy and to run the refrigeration plant efficiently. Unit has estimated savings to an extent of Rs. 25 Lakhs/Year, with an investment of Rs 24 Lakhs.

2. Installation of energy saver for lighting system. The lighting load of Kolar dairy is 70 KWH. The energy savings by installing energy savers is Rs 2.00 Lakhs with an investment of Rs 2.75 Lakhs.

3. Improvement of Power factor from 0.93 to 0.99 By providing additional power capacitors unit is able to increase power factor from 0.93 to 0.99, there by decreasing the electrical load on the system. The total cost of providing additional capacitors is Rs 60,000 only and expected savings is Rs 1.2 Lakhs per annum.

4. Replacement of Slip ring induction motors At present 100 HP capacity of type slip ring induction motors are connected to 4 No's KC-3 ammonia compressors. Unit has planned to replace higher capacity slip ring induction motor with lesser capacity (75 HP) high torque squirrel cage induction motor, which consumes less electrical energy. The cost of 75 HP induction motor is Rs 6.0 Lakhs and expected savings is Rs.5Lakhs/annum 5. Replacement of 7.5 HP reciprocating type boiler feed water pump. The boiler is fed through 7.5 HP capacity reciprocating type boiler feed water pump. Unit has planned to replace it with 5 HP capacity vertical type boiler feed water pump at a cost of Rs 85,000; the estimated savings is Rs 62,000 per annum. The proposal is under process.

181

Certificate of Merit

Dairy

MOTHER DAIRY
Gandhi Nagar, (Gujarat)

Unit Profile
Mother Dairy, Gandhinagar (MDG) is a unit of Gujarat Cooperative Milk Marketing Federation (GCMMF) Ltd., which markets its products under the brand name of AMUL & SAGAR. The earlier milk processing facility in Gujarat was totaling around 37 lac liters per day (LLPD) as against the expected procurement totaling 45 LLPD in 1994-95. Thus it was decided to put up the most modern, PLC based automated dairy processing plant with in-built capability to produce milk products matching to the best quality standards and handle the surplus 10 LLPD of milk. MDG was commissioned in September 1994 by L & T with assistance of APV, Westfalia & Niro. The dairy processes fresh milk to the tune of 10 LLPD. The dairy initially had Liquid Milk, Pouch Filling, Butter Oil plant & Milk Powder Plant. To keep pace with changing time Pouch filling Expansion Project, Mozzarella Cheese plant, UHT plant & Ice Cream plant were installed subsequently. Recently unit has increased its Milk Processing Capacity from 10 LLPD to 25 LLPD. It is estimated that in the year 2010, MDG would receive 35 LLPD of milk. To meet these requirements, unit has expanded its milk handling capacity by installing 100 MTPD milk powder plant. The plant is a state-of-art in terms of civil structural engineering and most modern process technology and automation. In the 2nd phase of expansion, there would be another 100 MTPD milk powder plant. As flow of milk became intermittently incessant, it was decided to convert milk into other milk products such as Ghee, Butter oil, Milk powders, Ice Cream, UHT milk, Cheese, UHT Softy Mix, UHT Chocolate milk. The other product portfolios apart from milk and milk products are Pizza and Parathas. The plant is professionally managed and has adopted world-class quality management systems and similar initiatives like ISO 9001:2000, ISO 22000:2005, HACCP, ISO 14001:2004, Total Productivity Maintenance, Six Sigma, Total Energy Management, etc. Mother Dairy, Gandhinagar is conscious about Energy Conservation, since its inception. It is the first dairy in India to install VAM (Vapour Absorption Machine) & WHRB (Waste Heat Recovery Boiler), as energy conservation measure.

182

Energy Consumption
Mother Dairy, Gandhinagar has witnessed a steady decline in specific energy consumption as a result of implementation of various energy conservation measures as ongoing practice. Figure showing the usage of Total Energy in comparison to Total Cost of Manufacturing, clearly reveals continual improvement due to our strong and consistent efforts during the last two years. Also the annual energy savings achieved as a ratio of annual sales turnover is highly remarkable, as shown in the figure. DESCRIPTION Total Manufacturing Cost Total Energy Cost Energy Cost as % of Total Manufacturing Cost UNIT Rs. Lakhs Rs. Lakhs % 2005-06 123124.79 2088.07 2.74 2006-07 88703.72 1553.02 1.75 2007-08 76103.40 1957.57 1.59

DESCRIPTION Actual Energy Savings achieved Annual Sales Turnover Energy Savings Achieved

UNIT Rs. Lakhs Rs. Lakhs %

2005-06 93.92 834 0.1062

2006-07 155.88 896 0.1740

2007-08 335.97 1124 0.2989

183

Energy Conservation Commitment, Policy and Set up

Mother Dairy, Gandhinagar has visualized importance of energy conservation and had made sincere efforts in achieving the same. Mother Dairy is committed to make continual improvements in energy conservation. For this Total Energy Management (TEM) team is established at Mother Dairy. The team is led by General Manager and it is delineated below. The team works in close co-ordination to achieve our Energy Policy objectives. The energy conservation initiatives are reviewed periodically and new projects are identified.

Energy Conservation Achievements

During the period 2005-2006 to 2007-2008, the unit implemented, 48 energy saving ideas generated. Annual savings of Rs. 616.74 lakhs was achieved as against the investment of Rs. 438.85 lakhs. Major projects implemented for Energy Conservation during the period 2007-2008 1. Installation of Vapour Absorption Machine (VAM) and Waste Heat Recovery Boiler (Trend-setter Project)

02 Nos. of Vapor Absorption M/C are installed those are utilized to produce the Chilling Effect from the Hot Water of all 04 Gas Engines. This concept of using VAM for chilling of hot water (a major requirement in dairy) is first done by MDG

02 Nos. of Waste Heat Recovery Boilers are installed those are utilized to produce Steam from Exhaust Gas from all Engines. Plant is getting 1.5TPH steam from each WHRB.

Investment:

Rs. 345.46 lakh

Saving:

Rs. 300.04 lakh

184

2. Installed new burner for air heater in old powder plant Replaced burner of air heater of powder plant to achieve best O2 level of 2.8% 3.0% to save gas consumption of around 10%.

Investment: Gas Saving: Saving:

Rs. 11 lakh 1.1 lakh SCM Rs. 14.02 lakh

3. Replaced conventional Chock with electronics ballast in Tube light fittings Replaced Conventional Chock in tube light fittings by new Electronics ballast.

Investment:

Rs. 1.77 lakh

Electricity Saving:

0.24 lakh KWH

Saving:

Rs. 1.08 lakh

Environment and Safety

Basically the unit being a food processing industry, considerable thrust has been given to implementation of HACCP which is currently in place and is being upgraded for the purpose of obtaining, ISO 22000:2005. Since the internal operations are being covered by HACCP, the waste residues are considerably brought down and the leftover waste discharges are sufficiently treated as per the requirements of water-air pollution control Act. There is a plan to use the effluent for industrial cleaning purpose after secondary treatment.

185