Excellence in Water Management
                                                          @
                               ...
Mfg Process & Water IPO

                                                                                                 ...
Resource Conservation Strategy


                                                                              Idea Cam ps...
Water Kaizen


                                                                                                           ...
Monitoring & Review system

                                                                                    Repor ting...
Initiatives : Floor Cleaning machine (2006)


                                                                            ...
Initiatives : Optimization of Water pressure




                       • Redu ction of Water pr essur e : 1.5 to 0.9 Kgs/...
Initiatives : Cooling Water for seal cooling
                                                   of Vacuum pumps

         ...
Initiatives : Sprinkler & Drip Irrigation




                                         Sprinkler i n use                  ...
Performance delivered



                                                                                                 ...
Waste Water Treatment - Facility

                                                                                        ...
Waste Water Generation



                                                                                                ...
Way forward…



                       Installation of s ub me ters at ide ntifie d areas
                       Conductin...
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Excellence in Water Management at GlaxoSmithKline Consumer Healthcare Limited, Rajahmundry

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This is a presentation from GlaxoSmithKline, one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008

The awards are in 2 categories, Within the Fence for work done on minimizing the organisations

water footprint, and Beyond the Fence for work done in the community around the industry.

This presentation was in the "Within the Fence" category.

We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.

Published in: Education, Business, Technology
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Excellence in Water Management at GlaxoSmithKline Consumer Healthcare Limited, Rajahmundry

  1. 1. Excellence in Water Management @ GlaxoSmithKline Consumer Healthcare Ltd Rajahmundry E HS V isio n To achiev e Site Profile Compet it ive Busi ness advant age t hrough Lead ership and Exc el l enc e in EHS Rajahmundry G SKCH, India Ø Indian br anch of G lax oSmithKlin e plc U .K. Ø Manufactur ing sites at Nabha, Rajahmu ndr y and Sonepat A bout Rajahm undr y Ø Commer cial pr oduction star ted in 1973 ww w.gsk.com Ø Capa city Installed – 24 KT Ø Pr oduct Portfolio: Hor licks, Cho co late Hor licks, Boost Cho cob last Ø Employees ~ 1500 (In cl. co ntr actor employees) 12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.01
  2. 2. Mfg Process & Water IPO HORLIC KS - Man ufacturin g p rocess flow diagr am Malted Barely Wh e t Glu te n a W heat F lour IS P Mash ing Malt Ext ract Raw water Mas h s e aration p Waste water Sa lts & Min e rals Hu sk w ashi ng Milk rece tion p Steam Weak Wort Condensat e Milk Pas teurizat ion W ort hol ding CCP - 1 Milk h oldin g Filter ed water Evaporat ion - 1 st st age n d s tag O ily Vit amin (A,D ,E ),K Milk s ta ndard iz tion a Condens er Evaporat ion 2 e SMP Chill water F ood Trans fer for sp read ing on trays FCS Dry Vit amin Hot water Oven dryi ng ( B- Comp lex & C) Trays s crap ping P ART - B CCP - 2 Grind ing I on r con tamin at ion Mixing P acking i n Drums Water Out flow Waste Water • Utilities Recycl e • Other Fu nctio ns • Manufactur ing Condensat e Reuse Cond ens er water Reuse , Recycl e Hot water Reuse , Recycl e Gr o u n d W a t e r f o m Bo r e r we l s Rechargin g of grou nd Co o li n g & Do m e s ti c P r o d u c ti o n water B o il er f ed e R a i n w a te r E f f lu e n t Tr e a t e n t P l n t m a Me t h a n e Ga s Us e d i n c a n t e e n f o r f o o dp r e p a r t i n a o 3 R (Zero Discharge) - 100% Compliance har es t i g v n pi t R e so ur ce T r at e e d W at e s or e r t d W a te r r e u s e d f or gar eni ng d su b st i t u t i on i n l goon a ( R e p la c in g LP G ) R e u se R echar e of g Fi h s c ul ur t e wa t e r t o R e so ur ce gr ound B i o - di v er si t y co n ser va t i on 12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.02
  3. 3. Resource Conservation Strategy Idea Cam ps, Sugg estion box es/JDIs EHS Kaizens & Plan for Pr ojec ts Exc ellenc e Top Down GMS – India Baselining & Bottom up Stra teg y Benc hmar king Innovatio n & EHS program & Collaboratio n pr ocedur es at sit e Cor por at e Functiona l & pr ogram s Indiv idual objectives Employee Engagement Training & E ducation Visual displ ays/ Controls Idea Camp s Competitio ns – Posters/Slog an s Suggestion Boxes Just Do Its Aware ness ca mpai gn Rew ards & Recognition / Spirit Aw ards Site Director o bserv ing the entries i n Slogan Co mpe titi on Rewar d to Em plo ye e 12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.03
  4. 4. Water Kaizen Brainstormi ng sessio n on water c ons erv ation • Basel ining t he Curr ent p erformance. Process follow ed • Studied cons umptio n patter n for la st 1 y ear • Identifi ed cros s functio nal team • Co nducted Kaize n eve nt on 21st Sep’0 6 • End hose co ntrol systems put in u se • Replaci ng ra w water p oints wit h treate d one s • Providi ng pu sh typ e cocks in toilets Key Result Areas • Leak/ spil l contro l clamp s • Rational ization of was h po ints (6 3 to 48) – nee d base d • 48 UDE’s Ide ntified • Impl ement ed all Quick wi n so lution s in Benefits 3 month s Soluti on ide nti ficati on for • Water consu mptio n is reduce d by 30% the op portuni ties pe r T OP Community Involvement Students witnessing a Slide from ‘Con necti ng Little demonstration during the session Hearts’ on wate r conservation Imbi bed EHS concepts in 1550 young “ Ignited Minds ” Site Director administering oath to Conserve Natu ral Resources 12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.04
  5. 5. Monitoring & Review system Repor ting Water Consumption Format for monitoring Spec ifi c water consumption Format for monitoring Absolute water consumption 20 06 20 07 2 00 8 20 08 ac tual s 20 09 20 10 Tra ff ic KPI UO M a ct ua ls ac tual s Ta rge t Target Targe t Light Month YTD 2008 S ite 2007 Target Q3 2008 P lan 2008 FC Month YTD List of Water Conservation Projects Investment Water Savings Annual Saving Project/JDI (m3/day) Rs. in ‘000 (Rs.) Floor cleaning ma chine Floor cleaning ma chine 660 20 9782 Tray cleaning mach ine 365 55 26900 Optimization of water pressure - 100 105668 Improving con densate reco very 75 30 14673 Use of Cooling Tower water for va cuum - 130 60262 pump sealing Auto flush for toilets at Admin blo ck 12 2 978 Use of nozzles for drum washing - 5 4891 Treated Water for flushing of toilet 3 3 1467 End of hose control Treated water for coal wetting 5 5 4891 Modification of flushing at Amen ity 5 20 9782 blocks Introduction of self closing taps 1 5 4891 12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.05
  6. 6. Initiatives : Floor Cleaning machine (2006) Before Wastage of w ater arising fr om conventional floor cleaning is eliminated thr ough use of Flo or Cleaning m achine Investment : 6.6 Lakhs Water savings per annum : 7300 m 3 After Mech an ize d C le an in g usi ng Fl oo r Cle an in g ma chi ne Initiatives : Mechanization of Tray cleaning (2007) After Befor e Manual clea ning of foo d tr ays w as r eplaced w ith mechanized cleaning Investment : Rs. 3.65 Lakhs Water savings per annum : 20000 m 3 12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.06
  7. 7. Initiatives : Optimization of Water pressure • Redu ction of Water pr essur e : 1.5 to 0.9 Kgs/Sq cm • Use of Var iable Fr equency Drive Investment : Nil 1.5 Kg / cm2 Water savings per annum : 36500 m 3 0.9 Kg / cm2 Initiatives : Improving Condensate Recovery Impr ovement of Conde nsate r ecover y : 61.7 to 75 % Resu lt : Red uction in DM w ater consumption by 28.7 Cu. M / Day Investment : Rs. 0.75 Lakhs Befor e implementation : 84.3 m3/day After implementation : 55 m3/day Water savings per annum : 10700 m3 12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.07
  8. 8. Initiatives : Cooling Water for seal cooling of Vacuum pumps Cooling Tow er wa ter was r eused for seal c ooling of Vac uum pum ps in plac e of F resh water Inv estment : Insig nif icant Befor e im plement at ion : 130m 3 /day After im plem entation : Nil (As C ooling Tow er wat er is r eused) Wat er sav ings per annum : 474 50 m 3 Fresh water l ine disco nnec ted and c on necte d with Co oli ng water Initiatives : Auto flush for toilet Every drop count s … Small change … Sustained improvement 12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.08
  9. 9. Initiatives : Sprinkler & Drip Irrigation Sprinkler i n use Drip irriga tio n o n-si te Performance delivered 38% reduction In 3 yrs sp an 25 21.1 17.3 20 15.5 KL per Ton 13 15 10 5 0 2004 2005 2006 2007 Speci fi c Water co nsum ption 12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.09
  10. 10. Performance delivered 45% reduction 277 In 3 yrs sp an 300 255 250 Lit. per Day 172 152 200 150 100 50 0 2004 2005 2006 2007 Per capit a Wat er consumption Waste Water Treatment - Process KITCHEN Bio-gas Do me Not in use (50 Cu.M) Process Canteen / Do m estic Aerati on Tank – II (1013 KL) Fat Trap Eq. Tank UASBR Aerati on Clarifier Tank - I (25 KL) (200 KL) (287 KL) (271 KL) (510 KL) Treat ed Wa ter to Green Bel t 12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.010
  11. 11. Waste Water Treatment - Facility Supply to Cant een Bio-gas Collection Equalisation Tank UASBR (Anero bic Dig estion) Bio-gas Collecti on Dom e Green Bel t Treat ed Wa ter S tora ge Pon d Clarifier Aerati on Tank (A ero bic Sys tem) Rain Water Harvesting Objective : GSKCH , Ra jahmundr y uses bor e w ell w ater for its oper ation. In or der to avoid adverse effect of the oper ations on the w ater table, implemented Rain w ater har vesting. Rai n Wate r Co ll ecti on Rai n Wate r Ha rvest in g 12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.011
  12. 12. Waste Water Generation 22% reduction 9.4 In 3 yrs sp an 10 8.1 9 7.7 7.5 KL per Ton 8 7 6 5 4 2004 2005 2006 2007 Laurels External National Energy Cons erv ation Direc tor of Fac tories Award’ 05 APPC B Award 2004 FAPCCI Award -2008 Award 2005 for “OHSA S 18001” Internal CEO’s Award 2005 – First Place CEO’s Award 2005 - Vanguard CEO’s Award 2007 – Special Award pres ented by JIM in Aug’ 06 commendation Awards honor for U SE Methane- Aug’ 06 12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.012
  13. 13. Way forward… Installation of s ub me ters at ide ntifie d areas Conducting Water balance regularl y Year on year stretche d tar gets Innov ativ e suggestions / ideas fr om em ployees 20 % 20 % Reductio n Reductio n by 2010 by 2010 12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.013

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