This document summarizes an innovative energy efficiency project at Hindustan Coca-Cola Beverages Pvt. Ltd's Goblej plant to optimize the PET bottle blowing pressure and reduce power consumption of the 40 bar air compressor. The project team optimized the blowing pressure from 30kg/cm2 to 26kg/cm2 and installed a variable frequency drive for the compressor, resulting in annual energy savings of 1.8 million Indian rupees with a payback period of 8 weeks.
The document discusses the new version 5.1 of the FSSC 22000 certification scheme published in November 2020. The main reasons for the updated version are to comply with the latest GFSI benchmarking requirements and strengthen CB performance requirements. Key changes in version 5.1 include additional requirements for multi-site certification, product design and development, and food safety culture. Organizations certified to version 5 must comply with the new requirements by their next upgrading audit.
This webinar discusses the upcoming changes to the FSSC 22000 version 6 food safety standard. The presenters are Smita Murthy, an India representative of FSSC, and Soumik Mondal, head of technical services at SGS India. Version 6 aims to strengthen requirements around food safety culture, quality control, equipment management, food loss and waste reduction, and communication between organizations and certification bodies. It incorporates the new ISO 22003 standard and supports organizations' contributions to UN sustainability goals. Certified companies will have a 12-month transition period to upgrade and complete audits under the new version by March 2025.
This document describes the application of Hazard Analysis and Critical Control Points (HACCP) quality control method to the production of pastry products without yeast. It identifies potential hazards in the production process and establishes critical control points to monitor and control hazards. Key points include identifying raw materials and the production process, establishing physicochemical and microbiological standards for the finished product, and procedures for verifying and reviewing the HACCP plan on a regular basis to ensure food safety.
The document discusses purity drop that occurs at various stages of sugar production such as during cane harvesting, milling, clarification, evaporation, and crystallization. It provides typical ranges of purity drop between different process stages. For example, purity may drop 1.3-1.6 units from primary juice to mixed juice, and 10-13 units from primary juice to last mill juice. Factors that influence purity drop include bacterial growth, sucrose inversion, and non-sugar extraction. The document also discusses ways to minimize purity drop such as proper sanitation, pH control, and minimizing retention times.
3rd installment by author with regard to issues faced by entrepreneurs in setting up a microbrewery. this presentation deals with equipment. entrepreneurs serious about setting up similar project and who have idea of the local excise policies are requested to contact at neo.brewmaster@gmail.com. copies of the presentation are not available for download.generic figures not entertained apart from the ones stated. presentation is figurative and can not be compared to any other quote from elsewhere, based on current trend and collected data from reliable personal references. consultation charges applicable
check website www.indobrews.com for more information,
Email us at brewindo@gmail.com
Freshtz Products is a pineapple jam manufacturing plant located in Sri Lanka that was established in 2000. It currently employs 400 people and produces jam to serve the local market. The company wants to implement an HACCP plan to assure product safety and expand its market share. It receives raw materials from qualified suppliers and follows Good Manufacturing Practices and sanitation procedures. The document provides an overview of HACCP and outlines the 8 forms needed to develop an HACCP plan for pineapple jam, including forms for product description, ingredients, hazard analysis, determining critical control points, establishing critical limits, and verification. It also describes the preliminary steps of assembling an HACCP team and documenting product details.
spray drying is technology widely used in milk powder and coffee powder manufacturing industry because of its working principle and technology involved..
- FSMS Management system audit and certification
- Understanding of how the FSMS management system operates
- FSMS Personnel training
- and more in our new FSMS Manual Template fully aligned with the new ISO/DIS 22000:2018.
The document discusses the new version 5.1 of the FSSC 22000 certification scheme published in November 2020. The main reasons for the updated version are to comply with the latest GFSI benchmarking requirements and strengthen CB performance requirements. Key changes in version 5.1 include additional requirements for multi-site certification, product design and development, and food safety culture. Organizations certified to version 5 must comply with the new requirements by their next upgrading audit.
This webinar discusses the upcoming changes to the FSSC 22000 version 6 food safety standard. The presenters are Smita Murthy, an India representative of FSSC, and Soumik Mondal, head of technical services at SGS India. Version 6 aims to strengthen requirements around food safety culture, quality control, equipment management, food loss and waste reduction, and communication between organizations and certification bodies. It incorporates the new ISO 22003 standard and supports organizations' contributions to UN sustainability goals. Certified companies will have a 12-month transition period to upgrade and complete audits under the new version by March 2025.
This document describes the application of Hazard Analysis and Critical Control Points (HACCP) quality control method to the production of pastry products without yeast. It identifies potential hazards in the production process and establishes critical control points to monitor and control hazards. Key points include identifying raw materials and the production process, establishing physicochemical and microbiological standards for the finished product, and procedures for verifying and reviewing the HACCP plan on a regular basis to ensure food safety.
The document discusses purity drop that occurs at various stages of sugar production such as during cane harvesting, milling, clarification, evaporation, and crystallization. It provides typical ranges of purity drop between different process stages. For example, purity may drop 1.3-1.6 units from primary juice to mixed juice, and 10-13 units from primary juice to last mill juice. Factors that influence purity drop include bacterial growth, sucrose inversion, and non-sugar extraction. The document also discusses ways to minimize purity drop such as proper sanitation, pH control, and minimizing retention times.
3rd installment by author with regard to issues faced by entrepreneurs in setting up a microbrewery. this presentation deals with equipment. entrepreneurs serious about setting up similar project and who have idea of the local excise policies are requested to contact at neo.brewmaster@gmail.com. copies of the presentation are not available for download.generic figures not entertained apart from the ones stated. presentation is figurative and can not be compared to any other quote from elsewhere, based on current trend and collected data from reliable personal references. consultation charges applicable
check website www.indobrews.com for more information,
Email us at brewindo@gmail.com
Freshtz Products is a pineapple jam manufacturing plant located in Sri Lanka that was established in 2000. It currently employs 400 people and produces jam to serve the local market. The company wants to implement an HACCP plan to assure product safety and expand its market share. It receives raw materials from qualified suppliers and follows Good Manufacturing Practices and sanitation procedures. The document provides an overview of HACCP and outlines the 8 forms needed to develop an HACCP plan for pineapple jam, including forms for product description, ingredients, hazard analysis, determining critical control points, establishing critical limits, and verification. It also describes the preliminary steps of assembling an HACCP team and documenting product details.
spray drying is technology widely used in milk powder and coffee powder manufacturing industry because of its working principle and technology involved..
- FSMS Management system audit and certification
- Understanding of how the FSMS management system operates
- FSMS Personnel training
- and more in our new FSMS Manual Template fully aligned with the new ISO/DIS 22000:2018.
Steam distribution system, utilization and designAzmir Latif Beg
n any steam plant or any process plant effectiveness of steam distribution system is dependent upon the project specific conditions like location and layout of the process plant and its steam consuming equipment like heat exchangers, decorators etc. Steam distribution circuit is one of the major link between the steam production point and the point of end use i.e. process plant. Primary steam generating source are co-generation plant and Steam generators. However it not the source of steam generation but the effective and efficient steam distribution system that decides right quality (pressure and temperature) and quantity of steam to reach to the process through it. Thus designing of steam distribution is to be given due importance along with installation and subsequently maintenance during operation.
The document discusses how steam is used extensively in dairy processing for heating, sterilization, and maintaining hygienic conditions. Some key applications of steam mentioned include pasteurization, homogenization, UHT processing, heating water and air, evaporation, and cleaning and sterilization of equipment. The document also emphasizes the importance of high quality steam delivered at the proper pressure and temperature for efficient and precise process control.
This document discusses process symbols and diagrams used in industrial processes. It defines symbols as graphical representations used to create diagrams of plants and processes. It then discusses different types of common diagrams - block diagrams, flow diagrams, process flow diagrams, and piping and instrumentation diagrams. For each diagram type, it provides details on what they represent and what information they typically include. It also discusses standard symbol sets adopted by international organizations and provides examples of specific symbols for equipment, instruments, valves, and other process elements.
This document provides information about the sugar milling and boiling house processes. It discusses the key components and processes involved, including:
- Milling house which uses mills to extract juice from sugarcane with 95-97% efficiency. Modern mills use improved cane preparation, feeding, and three-roller designs.
- Boiling house which uses steam boilers to heat water into steam to transfer heat to processes like juice heating and pan boiling. Water tube boilers are most common and produce steam at higher pressures.
- Steam distribution which sends steam generated to various processes like juice heating (15-18%), evaporation (2-10%), and pan boiling (20-25%).
Fruit Processing Industry. Production of Mango & Pomegranate JuiceAjjay Kumar Gupta
Fruit Processing Industry. Production of Mango & Pomegranate Juice. Start a Profitable Fruit Juice Business
Fruit processing is a profitable business. Fruit processing enhances the shelf life of the fruits. In addition, value-added processed fruits fetch more profit than fresh fruits. The fruit processing industry caters a wide range of segments. It includes fresh, fresh-cut, canned, frozen, dried, and convenience products, as the method of processing is different for each of these segments. On the basis of operation type, you can adopt semi-automatic or fully automatic operation.
The fruit processing industry is growing rapidly worldwide. However, major reasons are consumer demand for healthy and fresh products that are easily available and require minimal preparation time. And Asia Pacific region has the best potential of this industry.
See more
https://goo.gl/tBGeKy
https://goo.gl/c8exQb
https://goo.gl/oRhv23
https://goo.gl/utodnv
Contact us:
Niir Project Consultancy Services
An ISO 9001:2015 Company
106-E, Kamla Nagar, Opp. Spark Mall,
New Delhi-110007, India.
Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886, 8800733955
Mobile: +91-9811043595
Website: www.entrepreneurindia.co , www.niir.org
Tags
#Fruit_Processing, #Fruit_Processing_Industry, #Processing_of_Fruits, #Fruit_and_Fruit_Juice_Processing, Fruit Processing Plant, Fruit Processing Unit, Fruits and Fruit Processing, Industrial Fruit Processing, Fruit Processing Factory, Small-Scale Fruit Processing, Fruit Processing Industry in India and Its Opportunities, Indian Fruit Processing Industry, How to Start Fruits Processing Industry, How to Start a Fresh Juice Business, How to Start a Fruit Juice Business in India, Starting a Fruit Juice Business, Fruit Juice Production, How to Start a Fruit Juice Processing Plant, Juice Business Opportunities, Juice Business Plan Pdf, Fruit Juice Processing Business Plan in India, Start Commercial Production of Fresh Juice, Project on Mango Juice Industry, How to Start a Mango Juice Business, Mango Juice, #Mango_Juice_Production_Process, Mango Processing Plant, Commercial Processing of Mangoes, Mango Juice Processing Pdf, Mango Juice Processing Plant, Mango Processing Flow Chart, Mango Pulp Processing Unit Cost, Mango Juice Processing Flow Chart, Mango Processing Plant Layout, Mango Juice Manufacturing Process, Mango Juice Making Business, Production of Mango Juice, Pomegranate Processing, Setting up a Pomegranate Juice Production Unit, Pomegranate Juice Processing, #Production_of_Pomegranate_Juice, Pomegranate Juice Processing Plant, Pomegranate Processing Project Report, Pomegranate Juice Manufacture, #Project_Report_on_Fruit_Processing_Plant_Industry, Detailed Project Report on Fruit Juice Production, Project Report on Mango Juice Processing Industry, Pre-Investment Feasibility Study on Fruit Juice Production,
In petroleum refining, the Crude Distillation Unit (CDU) (often referred to as the Atmospheric Distillation Unit) is usually the first processing equipment through which crude oil is fed. Once in the CDU, crude oil is distilled into various products, like naphtha, kerosene, and diesel, that then serve as feedstocks for all other processing units at the refinery.
Shell and Tube Heat Exchanger in heat TransferUsman Shah
Shell and tube heat exchangers consist of a bundle of tubes enclosed in a cylindrical shell. Fluids flow through either the tubes or shell to facilitate heat transfer between the two fluids. They are widely used in chemical processes due to their ability to achieve a large heat transfer surface area in a compact volume. Key components include tubesheets, baffles, support rods and segmented baffles which direct fluid flow across the tube bundle for efficient heat transfer. Design considerations include allocating the more corrosive or fouling fluid to the tubeside for easier cleaning and maintenance.
1. The document provides information about different types of chillers, including vapor compression and vapor absorption chillers. It describes the basic cycles and components of each type.
2. Details are given about a specific chiller unit, including its make, model, type, capacity, refrigerant used, and other specifications.
3. The main parts of the chiller are described, such as the compressor, evaporator, condenser, expansion valve, and other control components.
ISO 22000:2018 FSMS standards gives more comfort to implement the food safety system in your food business, its based the HLS and Risk based approaches.
This document is an assignment submission on tea manufacturing and packaging. It discusses various steps in black tea production, including leaf quality assessment, withering, fermentation, drying, sorting, and packaging. It describes how factors like leaf temperature, damage, and red leaf formation can impact tea quality. The effects of packing density and transportation conditions on leaf quality are also examined.
The document discusses cooling towers, including:
1. Types of cooling towers like natural draft, mechanical draft, forced draft, induced draft, cross flow and counter flow towers.
2. Parameters for assessing cooling tower performance including range, approach, effectiveness and cooling capacity.
3. Energy efficiency opportunities like selecting an appropriately sized tower, using efficient fill media to reduce pumping needs, and optimizing fans and motors.
CIP vs COP - Hygienic Pumps and Meeting Government Regulations - Carotek Proc...Carotek
This document discusses trends in clean-in-place (CIP) versus clean-out-of-place (COP) processes in the food and pharmaceutical industries and how these trends impact process equipment selection. It defines CIP and COP, outlines the four parts of a CIP/COP process (chemicals, action, temperature, time), reviews regulations and hygiene requirements in food and pharma, and discusses third-party validation standards like 3-A and EHEDG. Key considerations for hygienic equipment design include materials, surface finish, corners/crevices, drainability, and access for cleaning.
The document discusses different types of vapor absorption refrigeration systems, including a simple system using ammonia and water, a practical system with additional components, an Electrolux system using ammonia, water and hydrogen, and a lithium bromide system. It also covers the types of refrigerants used in these systems, including halocarbons, inorganic refrigerants, azeotropic refrigerants, zeotropic refrigerants and hydrocarbon refrigerants. Finally, it discusses the environmental effects of refrigerants such as ozone depletion and global warming.
Evaporators are components in refrigeration systems that absorb heat from the surrounding environment. They operate at the low pressure side where the refrigerant changes from a liquid to a vapor phase. The heat transfer capacity of an evaporator depends on factors like the heat transfer coefficient, surface area, temperature difference, and refrigerant velocity. There are several types of evaporators classified by their construction, refrigerant feed method, heat transfer mode, and operating conditions like frosting, non-frosting, and defrosting. Evaporators are widely used in industries like food processing, beverages, chemicals, and more to absorb heat for cooling applications.
The document discusses steam generation and the temperature-enthalpy (t-h) diagram. It explains that steam can exist in three states - wet steam, dry saturated steam, and superheated steam. The t-h diagram graphically represents the transformation of ice to superheated steam at constant pressure, showing the stages and corresponding temperatures and enthalpies. Methods for determining the dryness fraction of steam using different types of calorimeters are also summarized.
IRJET- Improvement of Coefficient of Performance of ICE PlantIRJET Journal
This document summarizes a student project that aims to improve the coefficient of performance (COP) of an ice plant test rig. The students analyze using R134a refrigerant and adding a copper header and accumulator to the vapor compression system. An accumulator prevents liquid refrigerant from entering the compressor, improving COP. A copper header stores excess refrigerant not in circulation. The students will repair the test rig, add these components, and evaluate the system before and after to determine if COP is improved and freezing cycle time reduced.
Energy Saving and Water Cooling Facility in an Industry Using Prgrammable Log...IJERA Editor
This project gives the idea about how to reduce the power loss in an industry, which are being wasted by the
fans and pumps in operating condition as well as to get water as per the necessity by an industry with proper
quality. This can be done by proper switching and speed control of motors used in fans and pumps. As the
power consumed is directly proportional to the cube of speed so by reducing the speed energy can be saved. An
attempt is also made to connect the power factor improving capacitor for energy saving. By using this concept
the industry can save huge amount of energy and can be able to reduce the electricity bill.
Steam distribution system, utilization and designAzmir Latif Beg
n any steam plant or any process plant effectiveness of steam distribution system is dependent upon the project specific conditions like location and layout of the process plant and its steam consuming equipment like heat exchangers, decorators etc. Steam distribution circuit is one of the major link between the steam production point and the point of end use i.e. process plant. Primary steam generating source are co-generation plant and Steam generators. However it not the source of steam generation but the effective and efficient steam distribution system that decides right quality (pressure and temperature) and quantity of steam to reach to the process through it. Thus designing of steam distribution is to be given due importance along with installation and subsequently maintenance during operation.
The document discusses how steam is used extensively in dairy processing for heating, sterilization, and maintaining hygienic conditions. Some key applications of steam mentioned include pasteurization, homogenization, UHT processing, heating water and air, evaporation, and cleaning and sterilization of equipment. The document also emphasizes the importance of high quality steam delivered at the proper pressure and temperature for efficient and precise process control.
This document discusses process symbols and diagrams used in industrial processes. It defines symbols as graphical representations used to create diagrams of plants and processes. It then discusses different types of common diagrams - block diagrams, flow diagrams, process flow diagrams, and piping and instrumentation diagrams. For each diagram type, it provides details on what they represent and what information they typically include. It also discusses standard symbol sets adopted by international organizations and provides examples of specific symbols for equipment, instruments, valves, and other process elements.
This document provides information about the sugar milling and boiling house processes. It discusses the key components and processes involved, including:
- Milling house which uses mills to extract juice from sugarcane with 95-97% efficiency. Modern mills use improved cane preparation, feeding, and three-roller designs.
- Boiling house which uses steam boilers to heat water into steam to transfer heat to processes like juice heating and pan boiling. Water tube boilers are most common and produce steam at higher pressures.
- Steam distribution which sends steam generated to various processes like juice heating (15-18%), evaporation (2-10%), and pan boiling (20-25%).
Fruit Processing Industry. Production of Mango & Pomegranate JuiceAjjay Kumar Gupta
Fruit Processing Industry. Production of Mango & Pomegranate Juice. Start a Profitable Fruit Juice Business
Fruit processing is a profitable business. Fruit processing enhances the shelf life of the fruits. In addition, value-added processed fruits fetch more profit than fresh fruits. The fruit processing industry caters a wide range of segments. It includes fresh, fresh-cut, canned, frozen, dried, and convenience products, as the method of processing is different for each of these segments. On the basis of operation type, you can adopt semi-automatic or fully automatic operation.
The fruit processing industry is growing rapidly worldwide. However, major reasons are consumer demand for healthy and fresh products that are easily available and require minimal preparation time. And Asia Pacific region has the best potential of this industry.
See more
https://goo.gl/tBGeKy
https://goo.gl/c8exQb
https://goo.gl/oRhv23
https://goo.gl/utodnv
Contact us:
Niir Project Consultancy Services
An ISO 9001:2015 Company
106-E, Kamla Nagar, Opp. Spark Mall,
New Delhi-110007, India.
Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886, 8800733955
Mobile: +91-9811043595
Website: www.entrepreneurindia.co , www.niir.org
Tags
#Fruit_Processing, #Fruit_Processing_Industry, #Processing_of_Fruits, #Fruit_and_Fruit_Juice_Processing, Fruit Processing Plant, Fruit Processing Unit, Fruits and Fruit Processing, Industrial Fruit Processing, Fruit Processing Factory, Small-Scale Fruit Processing, Fruit Processing Industry in India and Its Opportunities, Indian Fruit Processing Industry, How to Start Fruits Processing Industry, How to Start a Fresh Juice Business, How to Start a Fruit Juice Business in India, Starting a Fruit Juice Business, Fruit Juice Production, How to Start a Fruit Juice Processing Plant, Juice Business Opportunities, Juice Business Plan Pdf, Fruit Juice Processing Business Plan in India, Start Commercial Production of Fresh Juice, Project on Mango Juice Industry, How to Start a Mango Juice Business, Mango Juice, #Mango_Juice_Production_Process, Mango Processing Plant, Commercial Processing of Mangoes, Mango Juice Processing Pdf, Mango Juice Processing Plant, Mango Processing Flow Chart, Mango Pulp Processing Unit Cost, Mango Juice Processing Flow Chart, Mango Processing Plant Layout, Mango Juice Manufacturing Process, Mango Juice Making Business, Production of Mango Juice, Pomegranate Processing, Setting up a Pomegranate Juice Production Unit, Pomegranate Juice Processing, #Production_of_Pomegranate_Juice, Pomegranate Juice Processing Plant, Pomegranate Processing Project Report, Pomegranate Juice Manufacture, #Project_Report_on_Fruit_Processing_Plant_Industry, Detailed Project Report on Fruit Juice Production, Project Report on Mango Juice Processing Industry, Pre-Investment Feasibility Study on Fruit Juice Production,
In petroleum refining, the Crude Distillation Unit (CDU) (often referred to as the Atmospheric Distillation Unit) is usually the first processing equipment through which crude oil is fed. Once in the CDU, crude oil is distilled into various products, like naphtha, kerosene, and diesel, that then serve as feedstocks for all other processing units at the refinery.
Shell and Tube Heat Exchanger in heat TransferUsman Shah
Shell and tube heat exchangers consist of a bundle of tubes enclosed in a cylindrical shell. Fluids flow through either the tubes or shell to facilitate heat transfer between the two fluids. They are widely used in chemical processes due to their ability to achieve a large heat transfer surface area in a compact volume. Key components include tubesheets, baffles, support rods and segmented baffles which direct fluid flow across the tube bundle for efficient heat transfer. Design considerations include allocating the more corrosive or fouling fluid to the tubeside for easier cleaning and maintenance.
1. The document provides information about different types of chillers, including vapor compression and vapor absorption chillers. It describes the basic cycles and components of each type.
2. Details are given about a specific chiller unit, including its make, model, type, capacity, refrigerant used, and other specifications.
3. The main parts of the chiller are described, such as the compressor, evaporator, condenser, expansion valve, and other control components.
ISO 22000:2018 FSMS standards gives more comfort to implement the food safety system in your food business, its based the HLS and Risk based approaches.
This document is an assignment submission on tea manufacturing and packaging. It discusses various steps in black tea production, including leaf quality assessment, withering, fermentation, drying, sorting, and packaging. It describes how factors like leaf temperature, damage, and red leaf formation can impact tea quality. The effects of packing density and transportation conditions on leaf quality are also examined.
The document discusses cooling towers, including:
1. Types of cooling towers like natural draft, mechanical draft, forced draft, induced draft, cross flow and counter flow towers.
2. Parameters for assessing cooling tower performance including range, approach, effectiveness and cooling capacity.
3. Energy efficiency opportunities like selecting an appropriately sized tower, using efficient fill media to reduce pumping needs, and optimizing fans and motors.
CIP vs COP - Hygienic Pumps and Meeting Government Regulations - Carotek Proc...Carotek
This document discusses trends in clean-in-place (CIP) versus clean-out-of-place (COP) processes in the food and pharmaceutical industries and how these trends impact process equipment selection. It defines CIP and COP, outlines the four parts of a CIP/COP process (chemicals, action, temperature, time), reviews regulations and hygiene requirements in food and pharma, and discusses third-party validation standards like 3-A and EHEDG. Key considerations for hygienic equipment design include materials, surface finish, corners/crevices, drainability, and access for cleaning.
The document discusses different types of vapor absorption refrigeration systems, including a simple system using ammonia and water, a practical system with additional components, an Electrolux system using ammonia, water and hydrogen, and a lithium bromide system. It also covers the types of refrigerants used in these systems, including halocarbons, inorganic refrigerants, azeotropic refrigerants, zeotropic refrigerants and hydrocarbon refrigerants. Finally, it discusses the environmental effects of refrigerants such as ozone depletion and global warming.
Evaporators are components in refrigeration systems that absorb heat from the surrounding environment. They operate at the low pressure side where the refrigerant changes from a liquid to a vapor phase. The heat transfer capacity of an evaporator depends on factors like the heat transfer coefficient, surface area, temperature difference, and refrigerant velocity. There are several types of evaporators classified by their construction, refrigerant feed method, heat transfer mode, and operating conditions like frosting, non-frosting, and defrosting. Evaporators are widely used in industries like food processing, beverages, chemicals, and more to absorb heat for cooling applications.
The document discusses steam generation and the temperature-enthalpy (t-h) diagram. It explains that steam can exist in three states - wet steam, dry saturated steam, and superheated steam. The t-h diagram graphically represents the transformation of ice to superheated steam at constant pressure, showing the stages and corresponding temperatures and enthalpies. Methods for determining the dryness fraction of steam using different types of calorimeters are also summarized.
IRJET- Improvement of Coefficient of Performance of ICE PlantIRJET Journal
This document summarizes a student project that aims to improve the coefficient of performance (COP) of an ice plant test rig. The students analyze using R134a refrigerant and adding a copper header and accumulator to the vapor compression system. An accumulator prevents liquid refrigerant from entering the compressor, improving COP. A copper header stores excess refrigerant not in circulation. The students will repair the test rig, add these components, and evaluate the system before and after to determine if COP is improved and freezing cycle time reduced.
Energy Saving and Water Cooling Facility in an Industry Using Prgrammable Log...IJERA Editor
This project gives the idea about how to reduce the power loss in an industry, which are being wasted by the
fans and pumps in operating condition as well as to get water as per the necessity by an industry with proper
quality. This can be done by proper switching and speed control of motors used in fans and pumps. As the
power consumed is directly proportional to the cube of speed so by reducing the speed energy can be saved. An
attempt is also made to connect the power factor improving capacitor for energy saving. By using this concept
the industry can save huge amount of energy and can be able to reduce the electricity bill.
This document is a 4 week internship report submitted by Ammara Haider to her supervisors Syed Mahmood Mehdi and Zuhair Sadiq at Pak-Arab Refinery Limited (PARCO). It provides an overview of PARCO's facilities including its process units and their design capacities, products, and key utilities systems. The utilities systems discussed include chemical handling, plant and instrument air, flare, fuel gas and fuel oil, water, and effluent treatment. The report also includes sections on additional assignments completed by the intern, an environmental assessment of DHDS installation, and a P&ID diagram.
We, the fourth-year students of the Dept. of Mechanical Engineering, SUST, vi...Joy Raj Bhowmik
We, the fourth-year students of the Dept. of Mechanical Engineering, SUST, visited the Shahjalal Fertilizer Company Limited (SFCL) along with our two respected teachers Saad Been Mosharof and Tahmidul Haque Ruvo on October 17, 2023. SFCL is an institution of BCIC under the Ministry of Industries to meet the growing demand for urea fertilizer. The visit is a part of our course MEE 482, named Power Plant Engineering Sessional. The focus of that visit was to witness the two-steam generator of that industry capacity of 24MW, 12MW each turbine.
I was lucky enough to learn and watch the working of the Deaerator, Economizer, Boiler, Superheater, Steam turbine - Generator, and Condenser. Also witnessed the Natural Gas supply and Flue gas circulation.
This document proposes a ventilation system for an MSM factory to improve working conditions and reduce costs. It analyzes how increased heat lowers productivity and increases electricity bills. The proposed system includes installing 10 wind turbine ventilators and 10 larger exhaust fans to replace the factory air once per hour, reducing heat, pollution and machine maintenance issues while improving worker health, satisfaction and output. Technical specifications show the system will replace the air 3 times per hour and lower electricity costs by 5% while improving conditions by 30%. Funding of RM10,500 is requested for installation.
The demand of power is increasing exponentially results in installation of new stations whereas the sources of water are depreciating acutely. In future there may be a situation in which water sources may not cope up with this requirement.
Also the serious concerns of the regulatory authorities regarding usage of natural resources, definitely the norms will be further be tightened, which will curtail the freedom of usage of water in power plant.
In present scenario land acquisition is one of the toughest hurdles in plant installations which can be averted by locating stations in water scarce regions, by employing air cooled system which eliminates dependencies on water for CW.
Although dry cooling systems are costly technologies on techno-economic considerations, but foreseeing the future it is the need of hour to employ dry cooling system which offers possible solution for power plant installation eliminating the above mentioned challenges.
Electric motors and the systems they drive consume electrical energy more than twice as much as lighting, while lighting is typically considered a major low-lying fruit for energy reduction in a factory. It is estimated that motors account for between 43% and 46% of all global electricity consumption particularly from the manufacturing sector. The presentation will cover topics like the effort to ensure the motor efficiency in manufacturing sector; the application of variable speed drives and other factors which affect the motor efficiency such as power quality; and good maintenance regimes for energy reduction
This is first time ever developed four stroke engine technology, that can run on miture of water and fuel. Due to this fuel efficiency can be increased as well as consumption of fuel can be decreased, this is the engine technology developed by Arpit Jayaswal.
The document describes ReCon, a tool to help PepsiCo optimize water and energy usage. It aims to minimize environmental impact through standardized metrics, benchmarking, best practices sharing, and technical solutions. Key aspects include profiling energy use, diagnosing opportunities, setting priorities via a scorecard, training regional experts, and recognizing high-performing sites. The tool focuses on reducing usage in motors, compressed air, steam systems, and recovering waste heat.
Testing of Mixed Flow Vertical Turbine PumpIRJET Journal
This document summarizes the testing of a mixed flow vertical turbine pump. The pump was tested at Kirloskar Brothers Limited's Hydraulic Research Center to obtain performance data. A variety of instruments were used to measure discharge, head, power input, speed, vibration, and noise. Test results showed the pump operated at 87.5% efficiency at its duty point with acceptable vibration and noise levels. A performance curve was generated from test data that closely matched the required curve, demonstrating the pump would perform as intended.
This document summarizes a field study conducted in Minnesota to evaluate the energy savings and performance of an intelligent, networked water heater controller. Over 30 controllers were installed on electric and gas water heaters across the state. Detailed monitoring was conducted on 10 sites to analyze the impact on energy use profiles, hot water delivery, and savings. Preliminary results found energy savings of up to 15% from reduced standby losses, lower tank temperatures, and eliminating unnecessary reheats. Further monitoring through summer 2017 will assess annual savings with the goal of validating the technology for utility rebate programs.
IRJET- IC Engine Waste Heat Recovery SystemsIRJET Journal
The document summarizes various waste heat recovery systems for internal combustion engines. It discusses organic Rankine cycle systems and thermoelectric generator systems for recovering heat from engine exhaust gases. Organic Rankine cycle systems use a turbine to convert the thermal energy of exhaust gases into electricity via a Rankine cycle. Thermoelectric generators use the Seebeck effect to directly convert a temperature difference into electricity. The document analyzes the advantages and disadvantages of these waste heat recovery technologies and their potential to improve engine efficiency and reduce emissions.
This document summarizes a presentation on district cooling and sustainable design. It discusses the history of district cooling in the Middle East since the 1960s. It then covers key topics in the presentation such as the growth and future outlook of the district cooling market, why district cooling is important, the main drivers of district cooling adoption, and sustainable design considerations for district cooling plants including energy efficiency, reliability, and water optimization. The document provides examples of district cooling plant designs and operational strategies to reduce costs and environmental impacts.
IRJET - IC Engine Waste Heat Recovery SystemsIRJET Journal
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3. Manufacturing Map of Coca-Cola In
India
33 Manufacturing
Plants
Current Manufacturing Locations
CBOs + FBOs + Co pack
Production lines (CBO & Copack)
• Sparkling RGB 32
• Juice RGB 10 (2 cold fill)
• Sparkling PET 24
• Juice Hotfill 6
• Juice Tetra Pack 3
• Retail water 11
• Bulk Water 4
• Cans 1
Co-Pack
9 Plants 24 Plants
CBO
4. Goblej Plant - Overview
2nd Largest Plant In India,
Largest By 1st Jan 2013
Plant Commissioned : Year 1998
Total Plant Area : 53 Acre
Built Up Area : 23 Acre
Green Belt Area : 30 Acre
Capacity :
600 X 2 BPM RGB line
300 X 1 BPM Maaza Line
120 X 1 JPH Kinley Jar
600 X 2 BPM PET line
120X1 BPM PET line
Zero Discharge Plant
Water Neutral Plant
5. Process – Over View
RGB Empty
Bottle Handling
& Conveying
Bottle
Washing
Filling / Crowning /
Capping
Water Treatment
Soft Water Treated Water
Syrup
Processing
Beverage
Processing
Conveying & Fulls
Handling
CO2
PET Bottle
Blowing &
Conveying
OR
6. Energy Contribution
Two Areas
Contributes 87%
Of The Total
Power & Fuel
Cost
40%
2%
5%
53%
Contribution ( MJ )
Power Sourced
HSD
Furnace Oil
Briqueete
42%
58%
Contribution ( MJ )
Electrical
Thermal
67%
20%
7%
4% 2% Power-Variable
Fuel-Briq
Power-Fix
Fuel - FO
HSD - DG Set
Focus
Area
Contribution ( Cost )
7. Plant Power Distribution
13%
13%
13%
10%
7%
7%
5%
5%
5%
4%
4%
3%
3%
3% 2%
1% 1% 1% 1% 600 BPM Pet CSD Line
HP Air Compressor
ETP & MVRE
Refrigeration
600 BPM Pet Juice Line
LP Air Compressor
Process
Lighting
AHU's & Air Conditioing
120 BPM Pet Line
Line-1
Maaza RGB Line
WTP/Borwell
Others
Boiler
FL Charging
Cold Storage
RGB Line-2
Admin Power
Top 9 of 25 Area Contribute To 78% of The Power Consumption
80-20
Technique
8. En-Con Projects In Last 3 Year
Sr.
No.
Year
Nos. of En-con
Projects
Implemented
Investment
(Rs. INR MM)
Saving
(Rs. INR MM)
Pay Back
(Months)
Average
1 2011-2012 19 20.7 42.6 6
2 2010-2011 13 2.7 29.3 1
3 2009-2010 13 5.4 14.1 5
Total 45 28.8 88.7 3
9. En-Con Projects In 2009-2010
Sr. No. Project Description
Investment
(Rs.MM)
Saving (Rs.
MM / Annum)
Pay Back
(Months)
1 Installation of 4 Ton Agro Waste Solid Fuel Boiler 3.0 10 4
2 Installation of PHE type condenser In place of Shell & Tube 1.1 1 10
3
Installation of New Pasteurizer for Precise Temperature Control
of Maaza Beverage
Nil 0.6 0
4 Installation of VFD for 40 Bar Compressor of 120 Pet CSD Line 0.6 0.5 15
5 Optimum capacity Rinse pumps of Line-1 & 2 bottle washer 0.13 0.4 4
6 Flow Meter For Monitoring of Air Consumption In Various Area 0.25 0.3 10
7
Common Cooling Tower for Raw Syrup System, Low Pressure
Air Compressor & Maaza Cooling Tunnel
0.08 0.3 4
8 Automation of Maaza Line Conveyors 0.04 0.2 2
9 Sizing of Maaza Filling Hall Ahu with Optimization of Pulley 0.02 0.2 1
10
Installation of Exhaust Blower to remove the hot air of the oven
& reduce the air conditioning load of 120 pet blowing room
0.04 0.2 2
11 Energy Efficient CFL Light Fixtures for 120 Pet Line Halls 0.1 0.2 11
12 Installation of VFD for Soft Water Pump of WTP 0.02 0.1 4
13 Interlocking of Pet 600 Mixer Chilled Water Pump 0.01 0.04 3
Total 5.4 14.1 4.6
10. En-Con Projects In 2010-2011
Sr. No. Project Description
Investment
(Rs. MM)
Saving (Rs.
MM / Annum)
Pay Back
(Months)
1 Ambient Temp.(18⁰C) Filling for Pet Csd Instead of 4⁰C Nil 24 0
2 Optimization of Blowing Pressure For Pet Bottles Nil 3.9 0
3
Installation of Separate Condensate Recovery Pump for
Pasteurizer of Maaza RGB & Pet Line
0.5 1.1 5
4 Installation of VFD For AF Make 40 Bar Compressors 1.4 1.0 16
5
Conversion of Air Cooled Chilled Water to Water Cooled
Chilled Water System For Pet 600 CSD Line
0.4 1 6
6
Installation of Variable Frequency Drive for Chilled Water
Pumps for Pet 600 CSD Line & Process
0.15 0.3 7
7 VFD installation for ID & FD Fan of 4 ton briquette fired boiler 0.15 0.2 8
8
120 pet Mixer, Chilled water tanks & pumps removal &
avoided the double pumping & loss of cooling
0.02 0.1 2
9 Installation of VFD for Soft Water Pumps 0.04 0.1 6
10 Installation of Suitable Design & Capacity Pump for Irrigation 0.04 0.1 8
11
Conversion of Delta to Star Connection for Agitator of Maaza
RGB Syrup Tanks
Nil 0.1 0
12 Interlocking of Air Washer's & AHU's With Filler Machine 0.02 0.1 5
13 On/Off System for 40 Bar Cooling Tower Fan Based on Temp. 0.01 0.03 4
Total 2.73 32.03 1
11. En-Con Projects In 2011-2012
Sr. No. Project Description
Investment
(Rs. MM)
Saving (Rs.
MM / Annum)
Pay Back
(Months)
1 Installation of Agro Waste Solid Fuel FBC Boiler 10 27 4
2 Energy Efficient Pumps Installation In Utility 2.1 3.4 7
3 Transfer of 173 TR Cooling Load From -2 ⁰C To + 6 ⁰C 0.1 2.7 0.5
4 Installation of Energy Efficient Screw Comp. 4 2.0 24
5 Supply of Cooling Water Instead of Chilled Water (6⁰C) 0.2 1.2 2
6
Installation of Energy Efficient T5 Fixture ( 216 watt ) In
Place of HPMV Lamps ( 400 Watt )
1.2 0.9 16
7
Installation of Energy Efficient T5 Fixture (4x14 watt)
Instead of Tube lights (2x36 Watt )
1.2 0.9 16
8
Installation of Effimax for Online O2 Monitoring & Improved
Combustion Efficiency
0.7 1 11
9
Blower Installation for Date coding air instead o
compressed air of 7 kg/cm2 (5 Lines)
f
0.4 1.0 5
10 Improvement Of Condensate Recovery Nil 0.6 0
12. En-Con Projects In 2011-2012
Sr. No. Project Description
Investment
(Rs. MM)
Saving (Rs.
MM / Annum)
Pay Back
(Months)
11 Improvement of Power Factor 0.1 0.6 2
12 Conversion of V Belts to Cogged Belts 0.2 0.5 5
13
Installation of Suitable Capacity Pump for Pet Juice Line
Pasteurizer
0.1 0.3 5
14
Lighting Energy Saver Installation for Pet 600 CSd Line
Lighting
0.15 0.2 9
15 Installation of VFD for Cooling Tower Pump 0.08 0.1 8
16
Chilled Water System for 120 Pet Line Blow Molding
Room In Place of Dx Cooling System
0.05 0.1 6
17
Timer Provision For All The Lighting Circuit Across the
Plant For Automatic On & Off
0.05 0.1 6
18
Interlocking of Ahu's & Air Washers With Running of
Machine
0.03 0.1 5
19 Level Control System for UFRO Syntax Water Tank 0.02 0.1 5
Total 20.7 42.6 5.8
13. Specific Energy Consumption
12.1
12.4
12.6
13.2
11.9
12.5
13.1
2008 2009 2010 2011
Electricity Usage Ratio ( Bev of Liter / Unit )
• Continuous Improvement In
Electricity & Furnace Oil
Usage Ratio
• Significant Reduction In
Utilization of Overall Energy
Year After Year
86.5 93.7
113.6
164.4
60
80
100
120
140
160
180
2008 2009 2010 2011
Fuel Usage Ratio ( Bev of Liter /
Unit )
0.90
0.86
0.83
0.76
0.72
0.66
0.62
0.72
0.82
0.92
2007 2008 2009 2010 2011 2012
Energy ( MJ / Ltr )
14. Bench Marking
Q-Spec Report ( Coca-Cola India )
25.3
24.0
23.3
22.7 22.7
22.5
21.9 21.8
21.0
23.5
26.0
Consistently
Achieving 1st
Rank In HCCBL
– India, Since
Last 1 Year
Electricity Usage Ratio ( Beverage of Litre / Unit )
15. Road Map To Be Best In Class
0.66
0.40
0.11
0.10
0.05
0.00
0.20
0.40
0.60
0.80
Energy Usage Ratio ( MJ / Liter )
Ref. Screw Compressor
18 Degree Filler
Energy Efficient Pumps
Pet 600 Csd Block Line to
Eliminate Rinser & Conv.
Screw Type Air Compressors
In Place of Recip. Comp.
Energy Efficient Lighting
Captive Power Generation
Recovery From HP Air
Flash Steam Heat Recovery
De-Humidifier In Place of Air
Conditioning System
De-Super Heater for Ref.
System
Heat Recovery From Raw
Syrup
RGB & Pet Line Conveyors
Automation
Interlocking of Ahu’s & Pumps
Date Coding Blowers
Interlocking With Lines
Scada System for Tracking
Utility Parameters
VFD Installations
16. Innovative Project 1 : Optimization of Blowing Pressure Of
Pet Bottles From 30 to 26 Kg/cm2
Project Name: Project #: Project Start/End Dates:
PET blowing pressure & 40 bar air compressor power optimization. NA-PH-xxx From 13.01.10 To 15.5.10
Project Lead: Piyush Shah Executive Sponsor: Rajeev Chawla
Team Members: Project Costs: (include required capital, expenses)
[1]Mahesh Kore
[2]Parthiv
[3] Dilipkumar
[4] Rizwan
[5] Bhavik
[6] Hemendra
[7] Ajay
[8]Manoj Pal
[9] Viral
- Capital: - Expenses:
INR 1.8 Mn
Mission/Project Overview:
Optimization of PET blowing pressure & Unload power of 40 bar air
compressor to achieve energy efficiency.
- KPI's:
Optimization of PET blowing pressure from 30 kg/cm2 to 26 kg/cm2 & VFD
Installation for 40 bar air compressor
- Visual Mgmt Tools being implemented:
PET blown bottle quality reports, Blow moulding machine recipe, Log
sheet of 40 bar compressor
Objectives: (include beginning & ending KPI's) Net Benefits:
To optimize the PET blowing pressure and optimization of 40 bar air
compressor unload power.
Annual savings of INR 1.8 Mn
In Scope: OE Tools to be used: Out of Scope:
PET Blow Moulding Machine & 40 Bar Air Compressor.
DMAIC Method, Yield Graph,
Process Capability Chart
Assumptions: Risks & Constraints:
Based on feedback of Dasna plant successful trials. Higher reduction of blowing pressure may affect quality of pet bottle.
Project Milestones: Dependencies:
1.PET bottle blowing at lower pressure ( 26 kg/cm2 ) & study the
parameters of same - 15/1/2010
2.Validation of QA results for reduced blowing pressure - 1/2/2010
3.Training of PET blow moulding operators, chemist, 40 bar operator.
4. VFD Installation for 40 bar air compressor
Production & QA Department
Project Lead Time: (Total time required to implement) Other Key Stakeholders & Areas Affected:
8 week [1] Finance Dept [2] Plant Operation
Approvals:
Project Lead: PIYUSH SHAH Date:
Area Lead: MR. RAJEEV CHAWLA Date:
Finance: MR. SAMEER AGRAWAL Date:
Executive Sponsor/
Steering Committee:
MR. RAJEEV CHAWLA Date:
17. The critical quality impacted by blowing pressure parameters
were identified as height, brimful volume, wall thickness and
stress cracking
Compressor Receiver Dryer Filter
Blow Molds
3 – Way Valve
BottlesBlowingPreforms
Process Flow
. . . Gaining Process Understanding
D M A I C
Innovative Project 1 : Optimization of Blowing Pressure of
Pet Bottles From 30 to 26 Kg/cm2
30 kg/cm2
19. Process Controls
. . . Sustaining The Gains
Recipe changes saved on blowing machine, old recipe removed
Check process capability for critical quality parameters at regular interval.
Process parameters specification chart display on the machine.
Process parameters locked – Access to change limited to authorized
person.
Error Proofing Done To Ensure That Process Runs In Control
Innovative Project 1 : Optimization of Blowing Pressure of
Pet Bottles From 30 to 26 Kg/cm2
D M A I C
20. 2010 2011 2012 Saving
Prod - Cs Units Ratio Prod - Cs Units Ratio Prod - Cs Units Ratio
2011 vs
2010
2012 vs
2011
45,34,453 13,33,663 3.4 89,89,147 20,43,100 4.4 44,59,774 8,45,354 5.3 -29% -20%
Saving :
2011 Vs. 2010 : Rs. 3.9 Million
2012 Vs. 2011 : Rs. 1.2 Million
Comparison Of Power Consumption : 2010 - 2011 - 2012
Innovative Project 1 : Optimization of Blowing Pressure of
Pet Bottles From 30 to 26 Kg/cm2
21. Objective : Optimization of PET blowing pressure
Target : 600 ml PET bottle blowing @ 26 kg/cm2
Achieved: Optimization of blowing pressure @ 26 kg/cm2
Target Savings : INR 1.8 MM Per annum
Saving Achieved: INR 3.9 MM Per annum
Project Summary
Innovative Project 1 : Optimization of Blowing Pressure of
Pet Bottles From 30 to 26 Kg/cm2
22. Innovative Project 2 : Transfer of 173 TR Cooling Load
From -2 Degree To + 6 Degree Chilling System
Glycol
supply to
process at
-2⁰C
Glycol
return from
process at
+1⁰C
Chilled water
to process at
+6⁰C
Chilled water return
from process at +10⁰C
Ready Syrup
at 25⁰C
Raw Syrup
(Flow Rate
5KLPH)
Temp.(45⁰C)
Before After
23. Innovative Project 2 : Transfer of 173 TR Cooling Load
From -2 Degree To + 6 Degree Chilling System
Annual Saving of INR 2.65 MM Per Annum
Parameters
Raw Syrup
5 KL System
Raw Syrup
10 KL
System
120 Pet
Line
Chiller
Total
Raw Syrup/Chilled Water Flow Rate (LPH) 5000 10000 25000 40000
Raw Syrup/Chilled Water Inlet Temp. (⁰C) 45 50 15
Raw Syrup/Chilled Water Outlet Temp. (⁰C) 25 25 8
Cooling Used ( TR Per Hour ) 33 83 58 174
Power Consumption Per Hour(-2⁰C System) 38 95 67 200
Power Consumption Per Hour(+6⁰C
System)
28 70 49 148
Annual Power Saving ( Kwh ) 74405 161210 130208 365823
Annual Saving ( Rs. ) 5,39,435 11,68,775 9,44,010 26,52,220
Investment ( Rs. ) 30,000 40,000 30,000 1,00,000
Pay Back Period ( Months ) 1 0.4 0.4 0.5
24. Chilled water to PHE at 07⁰C
Before After
Chilled Water
Supply @
40m /hr
Cooling Water
Supply @ 55m /
hr
Process water
flowrate 55m /hr
Chilled water from
PHE @ 12⁰C
Cooling Water
From PHE At 36⁰C
Cooling water to
PHE at 32⁰C
Innovative Project 3 : Supply of Cooling Water In Place
of Chilled Water ( 6 Degree )
25. Annual Saving of INR 1.15 MM Per Annum
Parameters
Before
Chilled Water
After
Cooling Water
Process Water Flow Rate 25000 25000
Process Water Temp. - Inlet to PHE (⁰C) 42 42
Process Water Temp. - Outlet from PHE (⁰C) 36 36
Cooling Used (TR Per Hour) 49.6 49.6
Specific Power Consumption for Chilled Water System &
Cooling Tower Water System
0.9 0.2
Power Consumption Per Hour (Kwh) 44 12
Per Hour Power Saving (Kwh) 31.7
Annual Running Hours 5000
Annual Power Saving (Kwh) 158651
Annual Saving ( Rs. ) 11,50,218
Investment ( Rs. ) 2,00,000
Pay Back Period ( Months ) 2.1
Innovative Project 3 : Supply of Cooling Water In Place
of Chilled Water ( 6 Degree )
26. Innovative Project 4 : Elimination of Compressed Air
With Air Blower
Air Blow Is Required Before Date Coding On Glass Bottles
Before After
Compressed Air
@ 3 Bar
Air Blower @ 0.8
Bar
27. Annual Saving of INR 1.00 MM Per Annum
Innovative Project 4 : Elimination of Compressed Air
With Air Blower
Air Requirement for Air Knife of Date Coding Machine ( CFM ) 25
Running Load of 7 Bar Air Compressor With Cooling Tower ( KW ) 6.5
Connected Load of Air Blower Motor ( KW ) 2.2
Running load of Air Blower 1.9
Power Saving Per Hour ( KW ) 4.6
Running Hour of All Lines ( 5 Lines ) 30000
Annual Power Saving ( Kwh ) 138000
Annual Power Saving ( Rs. ) 10,00,500
Investment ( Rs. ) 4,00,000
Pay Back Period ( Months ) 4.8
28. Carbon Emission Reduction
Parameter Value
Briquette Used ( Kg ) 30,93,500
Briquette Cost ( Rs ) 1,70,14,250
Equivalent Furnace Oil (Ltrs.) 10,31,167
Equivalent Furnace Cost (Rs) 4,43,40,167
Saving ( Rs. ) 2,73,25,917
Reduction In Co2 Emission Equivalent To 1031 KL Of
Furnace Oil
Project Name : Installation of 8 Ton Capacity Agro Waste FBC
Boiler
29. Carbon Emission Reduction
Reduction In Co2 Emission Equivalent To 24.7 KL Of
Furnace Oil
Parameter Value
Briquette Used ( Kg ) 30,93,500
Reduction of Briquette Cons.(Kg) 74,244
Equivalent Furnace Oil (Ltrs.) 24,748
Equivalent Furnace Cost( Rs) 10,64,164
Saving (Rs.) 10,64,164
Project Name : Installation of On line O2 Analyzer
4% Reduction In Excess Air In Flue Gas Leads to 2.4%
Improvement In Boiler Efficiency
30. Carbon Emission Reduction
Reduction In Co2 Emission Equivalent To 17 KL Of
Furnace Oil
Project Name : Installation of Precise Temperature Control System In
Pasteurizer To Control Temp. Overshoot For
Reduction of Steam Consumption
32. Involvement of Employees, Team Work In Encon, Monitoring
& Reporting Formats & Implementation Methodologies
Team
Member
Responsibility
Piyush Shah Coaching The Team For Energy Management.
Abhishek
Sikligar
Power Monitoring & Improvement of Electrical
Energy In Utility.
Nimish Nikam
Monitoring & Control of Efficient Air Generation
& Distribution System.
Hemendra
Rawat
Monitoring & Improvement of HP Air Usage
Ratio
Vaibhav
Deshpande
Monitoring & Improvement of Refrigeration
System Operation
Rahul Saxena
Automation & Electrical Energy Improvement on
RGB Lines
Saurabh
Trivedi
Automation & Electrical Energy Improvement on
Pet Lines
Hemul Joshi
Monitoring & Improvement of Condensate
Recovery & Fuel Yield
Manish Singh
Provide Support for Automation Activity on Pet
Lines
Sachin
Parashar
Provide Support for Automation Activity on RGB
Lines
Rajneesh
Sharma
Monitoring & Control ETP & WTP Operation As
Well As Support for Process Optimization.
Cross Function Team Continuously Working on Energy Conservation
Through Operational Excellence For Sustainance
33. Involvement of Employees, Team Work In Encon, Monitoring
& Reporting Formats & Implementation Methodologies
Employees Involvement System
Training : ON Energy Conservation & Environmental Awareness
Audit : Internal & External Energy Audit
Improvement Project : Promoting More & More Energy Conservation
Projects and Rewarding The Project Team
Workshop : Participation In Energy Conservation Workshop
Review : Daily, Weekly, Fortnightly & Monthly Review of Action Plan /
Projects, Further Planning
Display : Temperature & Pressure Set Points, Loading / Unloading Set points
Periodic Circulation of Do’s and Don’ts For The Effective Use of Energy
Most of The Energy Projects Are Executed By Inter
Departmental Team
34. Team work
Sr.
No.
Proposal
Source Of En-
Con Idea
Year
Extent of
Manpower
Involved
Implementation
Progress
Investment
( Rs. MM)
Saving
Potential
( Rs. MM
Per
Annum )
Achi
Sav
( Rs.
eved
ing
MM )
1
Interlock of air blower with labeller
machine start & stop
Supervisor 2011 2 Implemented Nil 0.02
2
Provision separate lighting circuit
for LT room lights
Workmen 2011 2 Implemented Nil 0.02
3
Installation of VFD for chilled water
pump of pet 600 csd line
Middle
Management
2011 4 Implemented 0.1 0.15
4
VFD installation for AF make 40
bar air compressors
Top
Management
2011 5 Implemented Nil 1
5
Installation of centrifugal pump In
place of submersible pump for
Irrigation water pump
Supervisor 2011 5 Implemented 0.04 0.06
6
Level control system for UF RO
tank
Workmen 2011 3 Implemented 0.01 0.03
7
Conversion of V belts to Coggeed
belts
Top
Management
2011 4 Implemented 0.2 0.25
8
Installation of air regulator for
Maaza rgb line crowner air
Supervisor 2011 2 Implemented 0.005 0.04
9
SS pipeline in place of pu pipe in
pet 600 cip room due to
atmosphere condition
Workmen 2012 4 Implemented 0.08 0.1
35. Sr.
No.
Proposal
Source Of En-
Con Idea
Year
Extent of
Manpower
Involved
Implementation
Progress
Investment
( Rs. MM)
Saving
Potential ( Rs.
MM Per Annum
)
Achieved
Saving
( Rs. MM )
10
Installation of limit switch &
interlocking with door air curtain
Supervisor 2012 3 Implemented 0.1 0.12
11
Timer installation for switching of the
ware house lights in day time
Workmen 2012 4 Implemented 0.1 0.12
12
VFD & Pressure Transmitter
installation for cooling tower pump
Middle
Management
2012 3 Implemented 0.1 0.12
13
Rain maker day tank piping
modification to avoid double pumping
Supervisor 2012 4 Implemented 0.04 0.08
14
Ventury trap installation in place of
conventional trap
Top
Management
2012 4 Implemented 0.2 0.2
15
Installation of motion & occupancy
sensors for plant less movement area
Supervisor 2012
Under
Consideration
0.5 0.7
16
Installation of On line O2 Monitoring
system ( Effimax 2000 )
Middle
Management
2012 5 Implemented 0.7 0.8
17
Optimum capacity pump for pet juice
line pasteurizer
Middle
Management
2012 6 Implemented 0.1 0.25
18 Solar Lighting
Top
Management
2013
Under
Consideration
15 7.5
Team work
36. Monitoring & Reporting System
Parameter
Monitoring & Reporting
Frequency
Critical KPI Tracking ( Receiver Air Pressure, Product Temp.
Set Point, Blowing Pressure Set Point )
Every Shift
Condensate Recovery Every Shift / Daily / Monthly
Specific Power Consumption Tracking for Higher Power
Consuming Area’s
Daily / Monthly / Yearly
Identification of Gap In Electrical Consumption of Different
Area ( Standard Vs. Actual )
Daily
Boiler Efficiency Daily
Electricity Usage Ratio, Fuel Usage Ratio Daily / Monthly / Yearly
DG Efficiency Daily / Monthly / Yearly
Identification of Air & Steam Leak & Corrections Weekly
Monitoring of Steam Traps Working Fortnightly
Review of Energy Improvement Action Plan Monthly
Review of Power & Fuel Usage Ratio & Cost With Zonal
Supply Chain Head
Monthly
Free Air Delivery Check for Air Compressors Quarterly
37. Energy Monitoring & Reporting Formats
Specific Power Consumption Norms For High Impact Area
…….. Daily Tracking, Gap Identification & Corrections
HP Air LP Air
Target
5.5 ( Crate Pet
Unit )
5.5 ( Crate Pet
Unit )
Date Daily MTD Daily MTD
1-Feb 2.4 5.0 10.0 18.9
2-Feb 5.2 5.1 18.6 18.8
38. Energy Monitoring & Reporting Formats
Gap Identification Betn Std. Vs. Actual Power Consumption
…….. Daily Tracking & Corrections
Date
RGB1
(KWH)
RGB1 %
Opp.
RGB2
(KWH)
RGB2 %
Opp
HS PET 1
CSD
(KWH)
HS PET 1 CSD
% Opp.
1-Apr-12 331 21% 0 0% 640 12%
2-Apr-12 231 13% 0 0% 0 0%
39. Sequence Purpose
Bench Mark Gap Identification
Audit ( Internal / External ) Identify Potential Saving To Close Gap
Analysis Evolution or Project
Execution Improvement
Monitoring System Substance
Online Suggestion Value Creation
Energy Monitoring & Implementation
Methodology
Benchmarking
Audit
AnalysisExecution
Monitoring
Innovation
Step-1:
Categorization
Step-2 : Data
Collection
Step-3 : 80:20
Technique
Step-4 :
DMAIC
Approach
SIX SIGMA APPROACH FOR PROJECT
40. En-Con : Future Projects
Sr.
No.
Project Description
Investment
( Rs. MM )
S
( Rs.MM
aving
Per Annum )
Pay Back
( Months )
1 Solar Lighting 25 25 12
2 Captive Power Generation 4.5 4.5 12
3
Installation of Energy Efficient Lighting In Raw
Syrup, Ready Syrup, RGB Line-2 & Other Areas
1.5 3 7
4 Installation of Energy Efficient Pumps 1.2 1.8 8
5
Installation of PHE For Heat Recovery for Hot Syrup
To Product Water
0.5 1.5 4
6
Air Recovery System To Recover Blowing Machine
Exhaust Air To Low Pressure Air
0.03 1.0 0
7
Recovery Of Flash Steam For Pet Juice Line
Pasteurizer
1 0.9 13
8
Desuperheater @ KC9 - Use For Boiler Feed Water
Tank Water Heating
0.8 0.9 11
9
Automation of Lighting With Occupancy &
Movement Sensors
0.6 1 9
10
Ring Main System For Low Pressure ( 7 Bar ) Air To
Optimize The Receiver Pressure
0.15 0.5 4
11 Insulation of Bottle Washers Soak Compartment 0.3 0.5 7
12 Flash Steam Recovery - Maaza RGB Pasteurizer 0.5 0.5 13
41. En-Con : Future Projects
Sr.
No.
Project Description
Investment
( Rs. MM ) ( Rs. M
Saving
M Per Annum)
Pay Back
( Months )
13
Insulation Effectiveness using thermal Imager &
correction across the plant
0.2 0.4 6
14
Ring Main System For High Pressure ( 40 Bar ) Air To
Optimize The Receiver Pressure
0.1 0.3 4
15
Mech Seal Type Efficient Vacuum Pump In Place Of
Gland Type Vacuum Pumps For RGB Line-1 & 2
0.2 0.3 8
16
Installation of DI Pipe Line For Gravity Flow Of Raw
Water To Avoid The Double Pumping
0.15 0.2 10
17
Installation of Variable Frequency Drive For Maaza
Filling Hall Air Washer Blower
0.1 0.2 8
18
Heat Recovery From Bottle Washer Hydro Water For
Warmer Water Heating
0.1 0.2 8
19 Nitrile Rubber Insulation For Cold Lines 0.1 0.2 8
20
Installation of Variable Frequency Drives For Raw
Syrup Air Washer Blower
0.08 0.1 7
21
Automation of RGB & Pet Lines Conveyors & Pumps To
Stop During Non Production Time
0.01 0.1 1
22
Interlocking of Pet Juice Line Pumps For Auto Stop &
Start
0.01 0.1 1
Total 37.13 42.32 10
44. Continuous Reduction In Water Usage Ratio, 100%
Improvement In 4 Years
Water Usage Ratio ( Liter of Beverage Per Liter )
3.38
2.97
2.39
1.90
1.6
1.40
1.80
2.20
2.60
3.00
3.40
3.80
2008 2009 2010 2011 2012
Our Commitment to Conserve Water
45. Year Environmental Aspect Action
Environmental
Impact/Improvement
2010-
2011
Water-consumption per liter of
beverage production
( WUR/Water Usage Ratio)
1.Switch over from
ground water source to
surface water.
2.Installation of
Decaustizer.
Water consumption
reduced from 2.97 per
liter of beverage to 2.39
liter
Our Commitment to Conserve Water
46. UFRO SYSTEM
Year Environmental Aspect Action
Environmental
Impact/Improvement
2011-
2012
Water-consumption per liter of
beverage
production(WUR/Water Usage
Ratio)
Installation of UFRO
Scheme in Effluent
treatment plant to meet
requirement of utilities
Water consumption
reduced from 2.97 per
liter of beverage to 1.9
liter
Our Commitment to Conserve Water
47. Year Environmental Aspect Action
Environmental
Impact/Improvement
2011-
2012
Water -Consumption per liter of
beverage
production(WUR/Water Usage
Ratio)
Installation of recovery
scheme - Rainmaker
plant
Water consumption
reduced from 1.9 per liter
of beverage to 1.55 liter
Our Commitment to Conserve Water
48. RUN OFF WATER
RECHARGE WELL
RAINWATER HARVESTING AT GOBLEJ UNIT
Our Commitment to Conserve Water
Water Neutral
Plant
50. Waste Utilization
Process Waste Water From Bottle Washing & CIP Is Being Treated
Through The State of Art Plant Consisting Pretreatment
( Aeration, Membrane Bio-Reactor), Post Treatment ( Reverse
Osmosis), MVRE, Crystallizer and Centrifuge
The Treated Water Quality Meets IS 14543 & IS 10500 Standards
51. Replication of Best Practices
Sr.
No.
Best Practice / Replication Associates
1 V Belts to Cogged Belts Conversion
Hindustan Coca-Cola -
Bangalore
2
Filling of Sparkling Beverage at Temperature of 18 Degree In
Place of 4 Degree
KHS - Germany
3
Blowing & Filling - Block Machine For Pet Bottles In Place of
Separate Machine
Sidel - France
4 Energy Efficient ( T5 ) Lights Installation Philips - India
5 Use of Energy Efficient Bearings For Motors SKF - India
6 Wind Driven Exhaust Fans For Plant Sheds Ratna Construction
7
No Air Conditioning System For Blowing Machine Room With The
Installation of De-Humidifier
KHS - Germany
8 Energy Audit of Pumps & Installation of Energy Efficient Pumps Grundfos - India
9 Installation of High efficiency Vacuum Pumps For Filling Machine PPI - India
10 Power Standardization Template
Energy Manager Group -
HCCBPL
11 Energy Audit Devki Engg.
12
Ventury Trap Installation Instead of Conventional Bucket / Float
Traps
Zenith Marketing / GEM
Trap
53. Awards
Reduction of Water Foot Print By Rain Maker / Waste Water
Treatment Plant – Global Category
Innovation Award From International Water Association