Saving water cost

1. Balkrishna industries Ltd
Water Saving
Project

2. Project Selection
To Improve The Low Water
Consumption

3. Water Extracts from Natural Sources.
Reduce the Utility Cost.
Proper Controlling on Distribution of water.
Help in Zero Drain Drive.
Proper Recycling of Water.
Why This Project

4. Team Formation
1
Pankaj Kudesia
2
MM Kidwai
3
Manoj Gupta
4
Vipin Kausal
5
Lokesh pandey

5. Project Statement
To Reduce Water Consumption in Over all Plant
Performance Measure : Avg. Water consumption in
Kl/ton of production of last few
months.
: Maximum Consumption in
1100Kl per day in year 2007
Target : 6 Kl per ton of Production
Time Frame : Started - August 2008
Completed - feb. 2010

6. Water Distribution During -2007
* Total water Consumed per Day= 1100 Kl
* Avg. Water Consumption per TOP = 10.5 Kl
* Avg. Production per Day= 105 Tons

7. Current Situation
Avg. Water consumption /TOP
9.8
6
0
2
4
6
8
10
12
2008 Target
Year
Water
(Kl)

8. Water Consumption During -2008
Water Distribution During -2008
• Total water Consumed per Day= 931 Kl
• Avg. Water consumption per TOP = 9.8 Kl
• Avg. Production per Day= 95 Tons

9. Analysis
First of all our team identified the areas where there is
a scope of reduction in Raw Water Consumption.
1. Plant wise – All water waste points.
2. Hot water #1 - To Control the Make up Water by
recycling of water.
3. Hot water #2 - To Control the over flow & Make up
Water by recycling.
4. Gardening - To Control the raw water for
irrigation by RO Reject water.
5. Toilets - To Reduce the raw water Consumption.

10. Improvement Plan
After Identifying areas of high consumption of raw water,
We brain stormed the issue and following suggestions
came from our team, then we made Improvement
Action plan.
a. Observed many raw water waste points plugged.
b. Recovery water quantity improved in both hot water
stations by prepared collection tanks & also utilize in
process.
c. RO reject water utilized in toilets flush & civil work.
d. Raw water supply controlled in gardening.
e. ETP water used for make up in Hydrant tank filling.
f. Process water recovery from 4 roll areas (mills drain).

11. Result
Avg. Water consumption /TOP
9.8
8.2
6
0
2
4
6
8
10
12
2008 1st 3 Qtrs of 2009 Target
Years
Water(Kl)
Improvement
(16%)
Conclusion : Avg. Raw water consumption reduced 16 %
from last year, but again brain stormed by our team for
achieve the target .

12. Water Distribution During 1st 3 Qtrs-2009
• Total water Consumed per Day= 804 Kl
• Avg. Water consumption per TOP = 8.2 Kl
• Avg. Production per Day= 98 Tons

13. Following actions taken by team for further improvement
a. Proper utilization of RO reject water in Gardening & toilets.
b. Better utilization of recovery water in process like make up in
hydraulic water tank, cooling towers & process water etc.
c. DCC commissioned in both plant ,so controlled over flow & open
drain.
d. Flush Steam condensate collected from plant -2 curing and
utilized in Hot Water plant.
e. RO Water circulated in marangoni m/c for cooling so reduced
process water consumption.
f. Modified raw water distribution header & managed well manner.
g. Monitoring & controlling on Bore Well operation time.
Improvement Action Plan

14. Avg. Water consumption /TOP
9.8
8.2
6.8
6
0
2
4
6
8
10
12
2008 1st 3 Qtrs of 2009 4th qtr of 2009 Target
Duration
Water(Kl)
Result
Improvement
(17%)
Conclusion
Conclusion : Avg. Raw water consumption reduced 8.2
to 6.8 (17 %) from last result, but again brain stormed by
our team for achieve the target. .

15. Hot Water Pl-
2, 25, 4%
Hot Water Pl-
1, 88, 15%
Toilets, 10, 2%
Drinking, 45,
8%
Gardening, 30,
5%
RO Plant, 380,
66%
Water Distribution During 4th Qtr-2009
• Total water Consumed per Day= 578 Kl
• Avg. Water consumption per TOP = 6.8 Kl
• Avg. Production per Day= 85 Tons

16. Improvement Action Plan
Following actions taken by team for further
improvement to achieve the goal.
a. Effective utilization of RO reject water in Gardening, toilets
& cleaning of floor & trolley.
b. Better utilization of recovery water in plant process so
reduced soft water consumption in both hot Water station.
c. Cold water from cooling Tower re circulated in H/W supply
pump’s gland cooling instead of soft water.
d. Water locking arrangement provided in plant -1 mills.
e. After better utilization of recovery water reduced
regeneration of softener unit in both plant.
f. Keep close watch on OHT over flow.
g. Monitoring & controlling on Bore Well operation time.

17. Result
Avg. Water consumption /TOP
9.8
8.2
6.8
5.4 6
0
2
4
6
8
10
12
2008 1st 3 Qtrs of
2009
4th Qtr of
2009
1st Qtr of
2010
Target
Duration
Avg.
Water
(Kl)
Improvement
(20 %)
Conclusion : Avg. Raw water consumption reduced 6.8 to
5.4 (20 %) from last result, Now we have gone blow the
target. .

18. Water Distribution During 1st Qtr-2010
• Total water Consumed per Day= 572 Kl
• Avg. Water consumption per TOP = 5.4 Kl
• Avg. Production per Day= 106.3 Tons

19. Standardization
Controlling on Water Waste.
Proper Monitoring on Utilization of
Recovery Water.
Educate & Awareness to Employees time
to time.
Proper Monitoring on Water extraction.
Keep Close Watch on Each area.

20. Remaining Opportunity
Reduction in RO Water Consumption by recovery
of Steam Condensate in plant.
Maximum utilization of Recovery Water by
Recycling after commissioning of ETP & STP.

21. Lessons Learnt

22. Energy Conservation Cell
(Bhiwadi Plant)
T
THANKS