Presentation by Sumit Kedia, CEO of Sitaram Gokul Dairy Nepal.

1. Presented By
Sumit Kedia
Sita Ram Gokul Milk
Kathmandu, Nepal

3.  Established on Asadh 4, 2052 BS by Late Shankar Lal Kedia
 Located at Dudhpokhari, Kirtipur occupying around 27 Ropani of
land
 Employment to around 300 people
 Around 1.5 lakh farmers directly and indirectly benefited by the
industry
 Annually, crores of rupees being flown from factory to rural sector
 Plant Capacity more than 1 Lakh LPD and produces milk and milk
products

4.  Study conducted on SGML was from 24th August 2003 to 31st
December 2003
 Major Focus of ESPS was Cleaner Production(CP)
Objective of CP
• Minimize waste generated in the life cycle of all the products or
services
Tools of ESPS to implement CP
• Participatory approach for capacity building, organized approach
and involvement of employees at all levels of organizations

5.  Waste management aspect
1. Introduce Trigger Nozzle to the end of floor washing hoses
2. Introduce timer in water pumping house
3. Introduce high pressure jet cleaner for cleaning purpose
4. Make the facility to recycle and reuse the homogenizer
(piston) cooling water
5. Modification of CIP facility
6. Platform and conveyer installation for immediate storage and
closed feeding during reconstitution of SMP
7. Reuse of buttermilk by installation of cream pasteurizer

6.  Energy Aspect
1. Insulation of Boiler Head and proper boiler tuning
2. Conversion of pneumatic filling machine to mechanical
filling machine
3. Installation of capacitor banks to improve power factor from
0.81 to 0.98
4. Use of flat belts instead of v-belts in ammonia compressor
drives
5. Installation of TOD( Time Of Day) energy meter

7. All the findings were implemented
and we are very thankful to ESPS
for their technical and financial
support which they provided for
the completion of the findings.

14.  After we had finished with ESPS, due to
technical and financial scarcity, despite of we
wanting to do many more energy saving related
programs we could not move ahead but
somehow we came to know about EEC and the
MOU between SGML and EEC was signed on
16th September, 2012.

15.  Audit conducted on SGML was from 20-25th September, 2012
 Major Focus of EEC was Energy Audit
 The audits were carried out under the guidance of GIZ/NEEP Experts and trained Auditors
Objective of IGEA
 Brief history of production and energy use
 measurement and monitoring of plant facilities for energy consumption
 Assess energy efficiency improvement opportunities in the areas of Power Factor
Management
 Load Management
 Sizing of Electrical Motors
 Lighting Systems
 Boiler Operation
 Insulation
 Waste Heat recovery
 Diesel generator sets
 House keeping

16. The findings were categorized
under immediate, short term and
long term and the basis for this
was investment and ROI(Return
On Investment)

17.  Revising the approved electrical demand with NEA from 500KVA to 400KVA
 Operating the ETP(Effluent Treatment Plant) during low tariff peak period
 Operating ground water pump at night off peak hours
 Insulation of chilled milk pipeline
 Recovering condensate during diesel boiler operation
 Effective use of Ice Bank Tank
 Insulation of Ghee Boiling Pan
 Condensate Recovery from Cream Pasteurizer and Ghee Boiling Pan
 Installation of VFD for chilled water pump
 Installation of De-super heater at ammonia compressor discharge

18. Short Term
 Performance of boilers and measures for fuel economy (Replacement of
Oil Fired Boilers with Rice husk boiled boiler)
 Heat Recovery from DG set flue gas
 Milk Chilling and Pasteurization efficiency improvements
Long Term
 Installation of a 1KL/Day solar hot water system to generate hot water

19. Implemented
 Revised the approved demand with NEA from 500 KVA to 400 KVA
a) Saving on demand charge
 Operated ETP during low tariff period
a) Peak demand reduction and energy cost reduction
 Recovered condensate during the diesel boiler operation
a) Thermal energy saving
Under Process
 Effective use of IBT
 Installation of VFD for chilled water pump
 Installation of de-super heater
 Insulation of Ghee Boiling Pan
 Condensate Recovery from Cream Pasteurizer and Ghee Boiling Pan
 Pasteurization efficiency improvements
 Heat Recovery from DG set flue gas
 Installation of De-super heater at ammonia compressor discharge

20.  Replacement of Oil Fired Boilers with Rice husk boiled
boiler/Multi Fueled Boiler
 Installation of a 1KL/Day solar hot water system to
generate hot water
Problems Encountered to implement left out things
The reason why we could not implement left out things
was because of initial heavy investment for the
purchase and commissioning. Therefore, we are
looking forward for technical and financial support
from EEC and GIZ.

21. In this competitive world , it is very necessary to cut your costs in
order to survive and utility section contributes to a significant
amount of the total cost. Therefore, energy audit is an excellent
factor for financial gain as well as the good feeling that comes
from doing something that benefits the planet.
Successful Energy Management sustains savings and integrates
projects with
 Understanding energy use
 Operation and management
 Behavioral changes
 Tracking and bench marking energy use
 Communicating to the employees

22.  Make energy a priority
 Assign responsibility
 Set a goal
 Look beyond first Cost
 Get with the program
 This audit relates to other industries also in terms of environment
friendly and energy saving the final outcome which is reduction in
production cost of any industry and conservation of energy for our
future generations. For example:
 ETP (Effluent Treatment Plant)
 Boiler
 Refrigeration system
 Air Compressor
 Electricity
 Solar power

23. Findings
Almost all the industries are using water in some or the other
form & the used water is thrown in nearby streams and localities
without any treatment and the results is pollution.
Results
SGML is very proud to say that our processed water is being treated through
our state of the art ETP plant and this is how we are conserving the nature and
we are reusing the treated water.

24. Global warming has become
a major concern in the
National and international
community therefore in the
farm level and industry
level it needs to be
controlled

25. Findings:
 The cost of production
becomes very high on using
diesel /furnish oil.
Results:
 To reduce cost of production
multi fuel boiler has become
the need of the hour.

26. Findings:
 As most of the food industries use
Refrigeration system. In our case
installation of de super heater at
ammonia compressor discharge
was lacking, IBT system was not
converted to PHE system.
Results:
 We are under process for
implementing these thing & if
other industries also can follow the
same , it will be very beneficial.

27. Findings:
 we was running compressor
on high pressure & facing
pipe line leakage problem.
Results:
 We reduced working
pressure & which in turned
to solve leakage problem &
reduce running hours.

28. Findings:
The demand with NEA was higher than
needed also power factor was low
Results:
 Reduces the KVA demand and installed the
capacitor as per requirement to increase
power factor

29. Finding:
 Though the solar is clean and
renewable source of energy
applicable for many application
such as heating, lighting, water
pumping etc, we are not using it.
Results:
 We are planning to install solar
lighting system and solar hot water
system

30.  We have become so mean that we try to prove ourselves
in the society by exploiting the nature and we also try to
pamper our children by giving them better
education, shelter and food it is there right but what if all
forms of non renewable energy is exhausted.
 We do not mind if our children misuse electricity, water
and fuel but friends we need to save non renewable
energy and promote the use of renewable energy(solar
energy, harvest raindrop,
 Therefore the need of the hour is as in Kyoto protocol
summit the whole world came together to reduce the
emission of green house gas and carbon footprint
 in similar way the whole world has to come together to
save non renewable energy(fossil fuel, natural gas oil and
coal) and to promote the use of renewable energy
(sun,wind,rain and tides)
 Few initiatives by Sitaram Gokul milks in conserving
nature
 1) has implemented the use of effluent treatment plant
 2)has promoted the use of cotton bag instead of plastic
bag with consumers in market.
 under process initiations to save energy
 1) to generate electricity by solar for light purpose as well
as production purpose

31. “our elder generation spent dark nights but we
see bright lights let us conserve energy to keep
away future generations in dark frights”
“natural resources are not our property we have
borrowed it from our future generations energy
is life use it wisely”

32. Effluent Treatment
Plant

35. In the end we are thankful to EEC (an
autonomous center functioning under
FNCCI) and we are looking forward for
TECHNICAL AND FINANCIAL
SUPPORT from EEC AND GIZ for
implementing the desired energy audit
results conducted in Sitaram Gokul Milks.