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

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

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

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

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

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

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

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

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

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

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

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

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