Marico Limited, Jalgaon

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This is a presentation from Marico Limited, 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, Technology, Business
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Marico Limited, Jalgaon

  1. 1. EXCELLENCE IN WATER MANAGEMENT - 2008 W ELCOME MARICO LIMITED, JALGAON MARI CO – U NCO MMON S ENS E ABOUT MARICO q FMCG WITH 1900 CR. TURN OVER IN 2007-08. q TOT AL 1300 EMPLOYEES ,WOR LD WIDE PR ESENC E IN U SA,EGYPT ,SOUTH AFRIC A,U AE,BAN GLAD ESH q 5TH LARGEST DISTR IBUT ION NET WOR K IN INDIA WIT H 17 LAC R ET AILERS. q 21 BRAN DS – 200 SKU’ S : EDIBLE OIL, VALUE ADD ED C OCONUT OIL, SUCC ESSFU L N EW VENTUR ES IN SKIN C ARE – KAYA CLINIC S & SUND ARI q MARICO WON 7 AWARD S IN 07- 08 & 9 AWARD S 08- 09 TILL D AT E IN VARIOUS C ATEGORIES OF LEAD ER SHIP, PACKAGIN G IN NOVAT ION, BR ADN S & HR MARI CO – U NCO MMON S ENS E 1
  2. 2. ABOUT JALGAON PLANT J ALG AON UNIT IS H AVING MANUF AC TURING F ACILITY FOR EDIBLE OIL. V ARIEN TS AS S AFFOL A, S AFFOL A GOLD, S AFFOL A TAS TY, S AFFOL A AC TIVE AND SWE EK AR. ü OHS AS -180 01 CERTIFIED ü ISO 14001 CER TIFIED ü NABL CER TIFIED PRODUCT L AB ü PR ACTICING ISO 220 00 ü PR ACTICING TPM & UNDERGOING HEAL TH AUDIT FRO M JIP M ü APPLIED FOR RBNQ A CERTIFIC ATION ü SELECTED FOR ENERG Y C ONSERV ATION AW ARD B Y S TATE GOV T. MARI CO – U NCO MMON S ENS E P ROC ESS FLO W – JALGAO N P LANT FINAL PRODUCT FILLING & FOR DIS PA TCH PACK AGING MARI CO – U NCO MMON S ENS E 2
  3. 3. PROCESS: “THINK F RESH, B E GREEN” Green mov ement under thre e v erticals 3 CULTURE CH ANGE 2 ENERG Y INCREASE AWAREN ESS INVOLVEMENT- Self, Famil y, Neig hbors. ELECTR ICIT Y SUGGESSIONS 1 REDUCTION W ATER FUEL R EDUCTION G o-G reen Champion GREEN T EA M Gajanan Patil REDUCE ST RUCT URE REUSE Water Energy Culture RECYC LE Agents - Ag ents - Agents - Yogesh Al ok Ravi REDESIGN Knowledge Peter Rishi V inay Wani Tejas V ishakha Coordina tor Resource Sanjay Praka sh B MANAGEMENT Muku l MARI CO – U NCO MMON S ENS E DA ILY WA TER CO NSUMPTIO N MEA SUREM ENT SY STEM Separate Wate r meter for separate departments Ever yda y Water meter readings T aken by Secu rity on ho urly b asis T his sheet is being reported to Concerned depa rtment via mail. Everyda y analysis is being done for Any abno rmal consumption T his is being tracked in SAP and Reviewed by Heads. The Only One Measurement Point BEFORE AFTER MARI CO – U NCO MMON S ENS E 3
  4. 4. A CTIVITIES FOR A WA RENESS O F WA TER C O NSERVA TION • We are conducting prog rams to increase awaren ess among workmen & staff. • We hav e shown the Video of ‘Inconv enient Truth’ to Staff and Workmen. Also giv en copies to nearby industrialists and MPCB peop le • We hav e done Group Work on Env ironment Day to take ideas and suggestions f rom Staff and Workmen. • Inv ited nearby Industrialists and MPCB P eople to giv e suggestions. • We are driv ing it under the initiativ e of ‘Be-Green, Think Fresh’. • We hav e f ormed diff erent Teams such as, - Water Consumption Reduction Team - Energy Consumption Reduction Team - Culture Dev elopment Team ( To sustain and improv e the results) • Under Th ese three teams, we are doi ng brai nstorming an d identify ing diff erent projects and executing those. • We are doing Rev iews on this with Works Head, Man uf acturing Head and Gre en Champion of the organi zation. • We are conducting Qui z Competitions f or Workmen on this. • We hav e planted 10000 Trees outside the Factory Premises. • We hav e started giv ing Tree f or Plantation on Birthday s of Members. • We hav e done Roof Water Harv esting f or all Buildings in the Plant. MARI CO – U NCO MMON S ENS E A CTIVITIES FOR A WA RENESS O F WA TER C O NSERVA TION QUIZ COMPETITION ON SHOPF LOOR TREE PL ANTATION OUTSIDE P LANT MARI CO – U NCO MMON S ENS E 4
  5. 5. WA TER CO NSERVA TION P ROJECTS IMPL EM ENTED 2004-2008 Saving Year o f Sav in g in terms App rox. Inv estment Pa yback S.N. Pr oject Desc rip tio n (Rs. Imp . of Saving (m3) (Rs .L akh) (Yrs ) Lak h) Seperation of Effluen t and Effluent treatment 1 20 04-05 10000 5 .4 3 0.56 Sto rm wate r gutters cost Roof Water Ha rvesting for 2 20 04-05 W ater Cost 180 0 0.18 1.25 16.67 Packaging Hall Conn ecting flow meters for 3 20 04-05 W ater Cost 432 0 0.43 0.25 0.58 water a dditi on i n the process Evaporation of Boiler Effluent treatment 4 bl owdown wa ter by founta in 20 05-06 266 4 1.44 1 .5 1.04 cost arrange men t. Autocontroll er for Ho twater 5 20 05-06 W ater Cost 648 0 0.65 0.25 0.38 T ank Level controller for Bo iler 6 20 05-06 W ater Cost 180 0 0.18 0 .1 0.56 feedwater tank Softner wate r sent for ga rd en 7 20 06-07 W ater Cost 864 0.086 0 .1 1.16 pon d Chan ging trees which can 8 grow on treated water inste ad 20 06-07 W ater Cost 360 0 0.36 0 .1 0.28 of fresh water F loat valve for all domesti c 9 20 06-07 W ater Cost 180 0.02 0 .1 5.56 water tanks W ater cost & Utilizing condensate water fo r 10 20 07-08 Effluent treatment 540 0 2.92 0 .5 0.18 hot water application cost Using Raymond pond wa ter Effluent treatment 11 for ga rd ening inste ad of 20 07-08 720 0 3.89 0 .5 0.13 cost treatment MARI CO – U NCO MMON S ENS E WA TER CO NSERVA TION P ROJECTS IMPL EM ENTED 2004-2008 S avi ng Year of Savin g i n terms App rox. I nvestmen t Payback S .N. Pro ject Descripti on (Rs. I mp. of Savin g (m3) (Rs. Lakh ) (Y rs) Lakh) Bund & Trap near OLD T F Eff luent t reat ment 12 2007-08 120 0.080 0.15 1. 88 circul at ion pumps cost & Wat er cost Taps wit h bell t ype Eff luent t reat ment 13 arrangem ent t o be given f or 2007-08 900 0. 60 0.05 0. 08 cost & Wat er cost cleaning of floor VAM overfl ow t o be avoided 14 2007-08 Wat er Cost 1200 0. 15 0.5 3. 33 during power OF F Hot wat er tank overflow during Eff luent t reat ment 15 2007-08 360 0. 24 0.25 1. 04 reprocessing run cost & Wat er cost MIDC Water l ine provision for POND near A mm enit y for 16 2007-08 Wat er Cost 3600 4.5 0.1 0. 03 mixing ETP and MI DC wat er for gardening. Provision of Side covers to t he Eff luent t reat ment 17 2007-08 2400 1. 60 0.3 0. 19 barometric cooling tower cost & Wat er cost Boiler blowdown wat er to be 18 used f or bagasse warehouse 2007-08 Wat er Cost 1800 0. 23 0.1 0. 44 for doing wet . Seperat or water t o be reuse Eff luent t reat ment 19 2007-08 6000 3. 99 0.5 0. 13 for LMX cost & Wat er cost Provision of ETP water for preparat ion of lime solution 20 2007-08 Wat er Cost 3000 0. 38 0.2 0. 53 and pl ant cleaning at ET P & AOP Provision of Sprinklers for 21 2007-08 Wat er Cost 2400 0.3 0.15 0. 50 Gardening Separator Wash water reuse proj ect is b ein g ap plied for pate nt a nd he nce n ot s hared i n The bo ok o f prese nta tion. We will s hare it duri ng Prese nta tion. MARI CO – U NCO MMON S ENS E 5
  6. 6. PROJECT : ROOF WA TER HA RVESTI NG FOR A LL BUILDI NGS I N THE PLA NT. ROOF WATER STORAGE TANK THIS WATER IS STOR ED IN UTILISED FOR THE PROCES S REQUIRE MEN TS MARI CO – U NCO MMON S ENS E PROJECT : PROVISIO N OF TREA TED WA TER FO R A SH PIT & LIM E SOL UTION PREPA RA TION I NSTEA D OF F RRESH WA TER Old Circuit (F resh Water) Ash Pit Lim e Solut ion New Circuit (ET P Water) Tan k App rox. 18-20 m 3/d ay W ater Sav ed. To Pla nt Cleaning Secon da ry Cla rifie r of ETP Keepi ng this v alv e OFF. Valv es MIDC T an k MARI CO – U NCO MMON S ENS E 6
  7. 7. PROJECT : EL IMI NA TING VA M CHILL ED WA TER OVERFLO W A FTER EVERY PO WER O N/O FF Proble m Sta teme nt: Cou nter meas ure: After Every Powe r On/Off, all the chilled water We have put an Actuato r in the retu rn line of from the jacke ts of Dewa xing Vessels getting Chilled Water Jacket of vessel which automatically ove rflow and goes into the gut ter. N eed top up gets closed after power failure & helps to eliminate with Fresh water aft er po wer resumes. overflow of Chilled Water. Return Line Sav ing of around Of Chilled Water 2 -3 m3 Water at ev ery Power Failure MARI CO – U NCO MMON S ENS E PROJ ECT: DI VE RTIN G BOIL ER BLO WD O WN WAT ER T O THE FOU NT AI N FR OM EFFLUEN T G UTTER AND U SING IT FOR G ARD ENI NG AFT ER FILTR ATI ON Proble m Sta teme nt: Cou nter meas ure: Boiler Blow down wate r was going to th e effluent. Water from boiler blow dow n, dive rted fro m effluent T he quantity was around 7 – 8 m 3/day. gutter to the separate Fountain pond. It is circulated T he effluent load was increased by that much qty. through the fountain and afte r settling of suspended solids, it is used for gardening purp ose. This is r unnin g smooth ly with a red uction In Effluent lo ad b y around 8 m 3/d ay. Example of – ‘UNCOMMON SENS E’ MARI CO – U NCO MMON S ENS E 7
  8. 8. PROJECT : PROVISIO N OF SIDE COVERS TO BA ROM ETRIC COOLI NG TOWER TO A VOID WA TER WA STA GE DUE TO SPILLA GE Proble m Sta teme nt: Baromet ric Cooling T ower is a Nozzle type cooling tower. It sprays w ater f rom the no zzles to reduce the te mp. of wate r. But the wate r spreads out f rom the lowe rs and mixes with the Effluent. Also the level of cooling tower reduces and n eeds top up with f resh wate r. Cou nter meas ure: Provided I nclined Sheets at the bottom of lowe rs to collect water which spreads out fro m lowers. T his ensures minimum top up of Fresh Wate r the Cooling T ower Pond. Benefi ts: 1. Water Sav ing o f approx. 6 -7 m3/da y. 2. Redu ces Efflue nt l oad b y a bov e qty. MARI CO – U NCO MMON S ENS E PROJECT : MOD IFYI NG WA TER TA PS WITH BELL TYPE A RRA NGEMENT TO A VOID WA TER WA STA GE Proble m Sta teme nt: At different locations in the plant, water taps p rovided f or to use water at t hat location. People were using that water fo r cleaning of floor. T hey were using hose pipe fo r floor cleaning. Due to this huge wate r getting used fo r floor cleaning and mixes with the effluent. Cou nter meas ure: T hese taps modified with the Bell type shape to avoid fixing of hose pipe. People are instructed to use water in small container and mopp er to clean the floor. T hey can’t connect hose to that. Benefi ts: 1. Water Sav ing o f approx. 1 -2 m3/da y. 2. Redu ces Efflue nt l oad b y a bov e qty. MARI CO – U NCO MMON S ENS E 8
  9. 9. P ROJECT : P ROV ISIO N O F SP RINKLERS FO R GARDENING P URPO SE FO R UNIFORM WAT ER DIST RIBUT IO N WITH MINIM UM QT Y Ben efits: 1. Unif orm d istri buti on of wat er wit ho ut man ua l i nterv enti on. 2. Com pl ete us ag e of ETP w ater. H en ce re du ce d MID C water con sum pti on. MARI CO – U NCO MMON S ENS E WA TER CO NSUMPTIO N TREND FRO M 2004 TO TILL DATE 3.00 2.47 2.46 2.50 2.36 m3/MT 2.03 2.00 1.79 1.50 2004 – 2005 – 2006 – 2007 – 2008 – 05 06 07 08 09 (till Oct.) MARI CO – U NCO MMON S ENS E 9
  10. 10. AWARDS & RECOGNISIONS S. N Aw ard / Corpora te Listing By Ye ar The Ba ngla de sh brand fo rum - a n Pa ra chut e ranke d 6t h 1 af fi liat e of t he Glo ba l Brand F orum, 2 0 08 Mo st Trust ed Bra nd in B ngla de sh a Singa pore Indi a Star A ard – w 2 India n Institute of Pa cka gi ng 2 0 08 Pa ra chute Adv anse d Hot Cha mpi Sa ff ola w on thre e Emvie Aw ard s - 1 . "Crit ics C ice Aw ard" ho 3 2 . "G old Emv ie - Radio Ca te go ry" Emvie F est iva l - Mumbai 2 0 08 3. "G ra nd Emv ie" F or Sa ff ol a 'World H ea rt D ay ' radio ca mpaign. Eco no mic time s in asso c. 4 Sma rt W orkpla ce Awa rd 2 0 08 w ith Ace r a nd I el nt 5 G oa Fe st 'Media' GO LD for 'Best Use of Ra dio' – AAAI – Go a Fe st 2 00 8 2 0 08 6 Ra te d One o f Ind ia’s Mos t Bus ine ss T day - o 2 0 08 Ma ric o Uncommo n Sense ca se st udy show ca sed i n 7 Annua l W orld Eff ie Cof fe e t able bo o k. Annual World Ef fi e Fe stiv al 2 0 08 Asia -Pac ific Eff ie Awa rds - 8 Sa ff ola W orld He art Da y campa ign - Bro nze. 2 0 08 Singa pore 9 Adva nc ed IT ba sed Sa les Inf orma tio n Syst em. SPJIMR Ma rk et ing Impa ct Awa rd 2 0 08 "Para chut e" the Out sta nding Marke ti ng Achie ve ment 10 Aw ard - Silv er . Gulf Marke ting Re vie w 2 0 08 Asso cia tio n o f Busines s Inte rna l N ew slet t er-MO R w on in tw o ca te go ries - N ew 11 Public at ion and Ne wsle t te r design . Communica tors 2 0 07 of India (ABCI) Aw ard f or The Parac hut e Adva nsed c ampaign "Go rge ous 12 H ame sha " . The Ya ho o Big Chair a w ard 2 0 07 F ea tured amongst e ight India n co mpanies in list of 13 Sta nd a rd & P oo r 2 0 07 G lobal Challe nge rs 2 00 7 . L ist ed a mongst 13 Indian firms by a s Asia 's 100 fa st est - 14 grow ing Companie s. Bus ine ss Wee k 2 0 07 Aw ard f or the "Best Business Le ader fo r F MCG in t he 15 NDTV 2 0 07 Pe rso nal Hygie ne ca t egory". 3 to p Awa rds at t he I ndia's Empl oye r o f Cho ice Aw ards CNBC-TV18, 2 0 07 Inst itut ed b y : U21 Glo ba l and Wa tso n W yat t Indi a's Emplo ye r of Cho ice 16 Wo rldw ide. 2 0 07 H R Exce lle nce Aw ard Aw ard f or the Best Employ er i n the Consumer Pro duct s a nd Hea lthca re Se ctor AND MAN Y MORE … MARI CO – U NCO MMON S ENS E THANK YOU MARI CO – U NCO MMON S ENS E 10

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