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1
“Cellulosic from Start to Finish”
Manufacturing Innovations
Presentation by
Rohan Batra
Special Projects and Sustainability
Dated 15th Oct 2015
2
AB Group – Taking India to the World
• A US $ 43 billion MNC, 50 companies across 6 continents in 36 countries
• Over 130 manufacturing units, 53% revenues from international operations
• Anchored by 136,000 employees, 42 different nationalities
• Ranked No 4 in Global “Top Companies for Leaders” survey (Aon Hewett, Fortune Magazine)
• Businesses encompass leadership in metals, cement, telecom, financial services, branded apparel,
textiles, yarns, fibres, etc
Birla Cellulose manufactures Man Made Cellulose Fibres - Viscose, Modal, Excel, Spun-Dyed
• Pulp in Canada, Sweden and India
• Fibre in India(4), China, Thailand, Indonesia
• Fully integrated Supply Chain for Chemicals, Power, Engineering & Employees.
• R&D spanning sapling to fashion
3
External Forces
Legal
Standards
2015
International
Standards /
Expectations
2020
Best Practice
2030
Requirements for
Business by 2050
Vision Sustainability Roadmap for ABG
- Mr. Tony Henshaw
Group CSO - ABG
4
Aditya Birla Group – Sustainability Focus
Sustainability Vision
“By 2017, the Aditya Birla Group
endeavours to become the leading
Indian conglomerate for sustainable
business practices across its global
operations.”
1. Responsible
Stewardship
2.
Stakeholder
Engagement
3.
Future-Proofing
by Creating Value
Brand Vison
The circle signifies the cycle of “nature &
sustainability”
Birla Cellulose - Leaves fall & grow all over again,
they are a renewable resource of nature.
5
Birla Cellulose: 360 degree Sustainability Engagement
Birla Cellulose – 360
degree Approach
1. Raw Material
•Responsible Wood
Sourcing Policy
2. Manufacturing
Process:
Pulp & Fibre
•Life Cycle Assesment
•R&D Leadership
3. Product
•Okeo – Tex 100
•REACH Compliance
4. Social –
Labour/Education
•SA 8000
•Sedex
5. Community
Village development
CSR Programs
6. Traceability
•LIVA Accredited
Partner Forum
•Backward
Intergration
6
Forest Management Programs - Certifications ( FSC, PEFC, SFI) and Third
party NGO
Pulp Sustainable programs –
1. LCA for process
2. Certifications
3. Safety and community
Programs
Fibre Sustainable Programs:
1. In addition, Product
certifications – Okeo-Tex
100, REACH etc
LAPF Support Programs -
1. Business sustenance service support
2. Transparency, Traceability and Visibility through the Value
chain
Co- Marketing Programs -
1. Sustainability backend
ownership
2. Consumer space.
connect
Birla Cellulose – Supply Chain for Sustainability Engagement
7
Seedling stage
1. Raw Material - Responsible Wood Sourcing
 BC strictly adheres to environment laws & regional
regulations
 BC does not purchase wood harvested from High
Conservation Value Forest
 Working closely with Canopy on the vision – ‘Fashion
loved by Forest’
SFI certificate
PEFC certificate
FSC certificate
Source: SLU (The Swedish University of Agricultural Sciences)
The carbon absorbed and released by the
forest over the lifecycle
8
2 - Sustainablity Through Pulp Manufacturing process
Wood to Pulp Conversion
• LCA - AVN, AVC and Domsjo Units by Control Union
• The Domsjo Unit – Zero Discharge unit.
• Byproduct 1- Sawmill chips, Saw dust and Bark go into fibre
• Byproduct 2 - Bark and Sieving dust go into power plant
FY 13 FY 15
Power Consumption
(KWh / T Pulp)
FY 13 FY 15
Steam Consumption
(T/T Pulp)
• Improvement in Steam & Power
Consumption
Percentage change – 4.5% Percentage change – 7.1%
9
1. LCA for 7 Fibre Units and 5 distinct fibres - partnered by Global Consultants, Control Union, SGS, SimaPro
2. MMCF exhibit better LCA backed by environmental performance - Water, land and energy consumption is lower
3 - Sustainability through Fibre Manufacturing process
FY 13 FY 15
Steam
Consumption
(T/T Fibre)
FY 13 FY 15
Water
Consumption
(M3/T Fibre)
Material
Sustainable Closed Loop Programs in the
Plants to Ensure ZERO discharge
Wood Pulp - RM • Conversion into Fibre
CS2 - RM
• Maximum through Condensation
• Remaining gases passes through controlled
technology. i.e. WSA Scrubbers & Genosorb.
Caustic /
Sulphuric Acid -
RM
•Recovery in terms of conversion to Sodium
Sulphate
Zinc – RM
• Converted into inorganic sludge.
• ETP having primary and secondary
treatment.
Sodium Sulphate
- By Product
• Paper, Glass, Detergents, Textile dyeing,
Tanning, Pharmaceuticals, Freezing reagent
& Ceramic Industries
% change – 4.9% % change – 4.6%
Improvement in Steam &
Water Consumption
10
4 - Sustainability through Product Innovation
Water Saving
up to 70
lts/kg
Reduced
Effluent
Load 70%
Power Saving up
to 3.5-4.0 KW
Time Saving
6-8 hrs/ Batch
Spundyed VSF Reduces Processing Cost as it
ensures Better 1st Grade Processed Fabric
Production – Better Profits
- Natural base
- Biodegradable
- Oeko-Tex100 for all fibres
- Safe for baby articles
Birla Cellulose Fibres Spun-Dyed Fibres
Gas
Saving/Batch
100-115 Kg
Steam
Saving/Batch
450-500 kg
11
5b. Supplier Integration Linkage – Backward Integration
Birla Cellulose –
Manufacturing
Sites
Energy
Power
Chemicals
Man -
Power
LAPF -
Partners
Supplier Integration Buyer Integration
12
5b. Supplier Integration Linkage – Backward Integration
Birla Cellulose –
Manufacturing
Sites
Energy
Power
Chemicals
Man -
Power
LAPF -
Partners
Supplier Integration Buyer Integration
Birla Cellulose – Fully Integrated Supply Chain
Increased Efficiency in terms of Cost, Time, Distance, Man
Power & Production. Reduction in Production foot-print
13
Environmental Sustainability Support
Spinners Fabricators Processors
Business Sustenance through service support
5a. LAPF : A Robust Ecosystem for 360 Degree Sustainability
Traceability & Visibility Through Chain
Parameters
Industrial Stand
ards
Challenges & Work Process to set LAPF Standards
pH Values 5.5 – 9
• Use of high caustic is seen in industry like other fibres. Shared
best levels product-wise.
• Choosing of chemicals, technology and good ETP shared
• Project cost and ROI supported
COD, (Mg/L) < 250
BOD (5 days at 20 degree
C) Mg/L
< 30
TDS (Mg/Litre) <2100
14
Safety
WASH
CSR
Employees, Staff
Govt.
Authorities &
Policy makers
NGOs, Local
Communities
Customers, Value
Chain Partners
Shareholders,
Investors
Suppliers,
Service
Providers
6a - Sustainability through Stakeholder Engagement
1. Apex level Safety Council Team
2. Safety observation program - Biannual
3. The WBCSD (World Business Council for
Sustainable Development) - Water and
Sanitation, Hygiene (WASH)
4. Score improved to1.7/2.0 now
15
6b. Engagement with Communities & Society
Women Empowerment:
• Vocational training
• Handicraft
• Handlooms
• Home based businesses
• Loans
Education & Infrastructure:
• Focus in Rural India
• Hospitals
• Schools
• Girl-child Education
• Adult education programs
16
There are many shades of green.
Collaborative Association Today, to perform for a Better Tomorrow
Rohan Batra
Special Projects - Sustainability
Birla Cellulose
E : rohan.batra@adityabirla.com
+91 8108032464

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SAC - Birla Cellulose 12-Oct-15

  • 1. 1 “Cellulosic from Start to Finish” Manufacturing Innovations Presentation by Rohan Batra Special Projects and Sustainability Dated 15th Oct 2015
  • 2. 2 AB Group – Taking India to the World • A US $ 43 billion MNC, 50 companies across 6 continents in 36 countries • Over 130 manufacturing units, 53% revenues from international operations • Anchored by 136,000 employees, 42 different nationalities • Ranked No 4 in Global “Top Companies for Leaders” survey (Aon Hewett, Fortune Magazine) • Businesses encompass leadership in metals, cement, telecom, financial services, branded apparel, textiles, yarns, fibres, etc Birla Cellulose manufactures Man Made Cellulose Fibres - Viscose, Modal, Excel, Spun-Dyed • Pulp in Canada, Sweden and India • Fibre in India(4), China, Thailand, Indonesia • Fully integrated Supply Chain for Chemicals, Power, Engineering & Employees. • R&D spanning sapling to fashion
  • 3. 3 External Forces Legal Standards 2015 International Standards / Expectations 2020 Best Practice 2030 Requirements for Business by 2050 Vision Sustainability Roadmap for ABG - Mr. Tony Henshaw Group CSO - ABG
  • 4. 4 Aditya Birla Group – Sustainability Focus Sustainability Vision “By 2017, the Aditya Birla Group endeavours to become the leading Indian conglomerate for sustainable business practices across its global operations.” 1. Responsible Stewardship 2. Stakeholder Engagement 3. Future-Proofing by Creating Value Brand Vison The circle signifies the cycle of “nature & sustainability” Birla Cellulose - Leaves fall & grow all over again, they are a renewable resource of nature.
  • 5. 5 Birla Cellulose: 360 degree Sustainability Engagement Birla Cellulose – 360 degree Approach 1. Raw Material •Responsible Wood Sourcing Policy 2. Manufacturing Process: Pulp & Fibre •Life Cycle Assesment •R&D Leadership 3. Product •Okeo – Tex 100 •REACH Compliance 4. Social – Labour/Education •SA 8000 •Sedex 5. Community Village development CSR Programs 6. Traceability •LIVA Accredited Partner Forum •Backward Intergration
  • 6. 6 Forest Management Programs - Certifications ( FSC, PEFC, SFI) and Third party NGO Pulp Sustainable programs – 1. LCA for process 2. Certifications 3. Safety and community Programs Fibre Sustainable Programs: 1. In addition, Product certifications – Okeo-Tex 100, REACH etc LAPF Support Programs - 1. Business sustenance service support 2. Transparency, Traceability and Visibility through the Value chain Co- Marketing Programs - 1. Sustainability backend ownership 2. Consumer space. connect Birla Cellulose – Supply Chain for Sustainability Engagement
  • 7. 7 Seedling stage 1. Raw Material - Responsible Wood Sourcing  BC strictly adheres to environment laws & regional regulations  BC does not purchase wood harvested from High Conservation Value Forest  Working closely with Canopy on the vision – ‘Fashion loved by Forest’ SFI certificate PEFC certificate FSC certificate Source: SLU (The Swedish University of Agricultural Sciences) The carbon absorbed and released by the forest over the lifecycle
  • 8. 8 2 - Sustainablity Through Pulp Manufacturing process Wood to Pulp Conversion • LCA - AVN, AVC and Domsjo Units by Control Union • The Domsjo Unit – Zero Discharge unit. • Byproduct 1- Sawmill chips, Saw dust and Bark go into fibre • Byproduct 2 - Bark and Sieving dust go into power plant FY 13 FY 15 Power Consumption (KWh / T Pulp) FY 13 FY 15 Steam Consumption (T/T Pulp) • Improvement in Steam & Power Consumption Percentage change – 4.5% Percentage change – 7.1%
  • 9. 9 1. LCA for 7 Fibre Units and 5 distinct fibres - partnered by Global Consultants, Control Union, SGS, SimaPro 2. MMCF exhibit better LCA backed by environmental performance - Water, land and energy consumption is lower 3 - Sustainability through Fibre Manufacturing process FY 13 FY 15 Steam Consumption (T/T Fibre) FY 13 FY 15 Water Consumption (M3/T Fibre) Material Sustainable Closed Loop Programs in the Plants to Ensure ZERO discharge Wood Pulp - RM • Conversion into Fibre CS2 - RM • Maximum through Condensation • Remaining gases passes through controlled technology. i.e. WSA Scrubbers & Genosorb. Caustic / Sulphuric Acid - RM •Recovery in terms of conversion to Sodium Sulphate Zinc – RM • Converted into inorganic sludge. • ETP having primary and secondary treatment. Sodium Sulphate - By Product • Paper, Glass, Detergents, Textile dyeing, Tanning, Pharmaceuticals, Freezing reagent & Ceramic Industries % change – 4.9% % change – 4.6% Improvement in Steam & Water Consumption
  • 10. 10 4 - Sustainability through Product Innovation Water Saving up to 70 lts/kg Reduced Effluent Load 70% Power Saving up to 3.5-4.0 KW Time Saving 6-8 hrs/ Batch Spundyed VSF Reduces Processing Cost as it ensures Better 1st Grade Processed Fabric Production – Better Profits - Natural base - Biodegradable - Oeko-Tex100 for all fibres - Safe for baby articles Birla Cellulose Fibres Spun-Dyed Fibres Gas Saving/Batch 100-115 Kg Steam Saving/Batch 450-500 kg
  • 11. 11 5b. Supplier Integration Linkage – Backward Integration Birla Cellulose – Manufacturing Sites Energy Power Chemicals Man - Power LAPF - Partners Supplier Integration Buyer Integration
  • 12. 12 5b. Supplier Integration Linkage – Backward Integration Birla Cellulose – Manufacturing Sites Energy Power Chemicals Man - Power LAPF - Partners Supplier Integration Buyer Integration Birla Cellulose – Fully Integrated Supply Chain Increased Efficiency in terms of Cost, Time, Distance, Man Power & Production. Reduction in Production foot-print
  • 13. 13 Environmental Sustainability Support Spinners Fabricators Processors Business Sustenance through service support 5a. LAPF : A Robust Ecosystem for 360 Degree Sustainability Traceability & Visibility Through Chain Parameters Industrial Stand ards Challenges & Work Process to set LAPF Standards pH Values 5.5 – 9 • Use of high caustic is seen in industry like other fibres. Shared best levels product-wise. • Choosing of chemicals, technology and good ETP shared • Project cost and ROI supported COD, (Mg/L) < 250 BOD (5 days at 20 degree C) Mg/L < 30 TDS (Mg/Litre) <2100
  • 14. 14 Safety WASH CSR Employees, Staff Govt. Authorities & Policy makers NGOs, Local Communities Customers, Value Chain Partners Shareholders, Investors Suppliers, Service Providers 6a - Sustainability through Stakeholder Engagement 1. Apex level Safety Council Team 2. Safety observation program - Biannual 3. The WBCSD (World Business Council for Sustainable Development) - Water and Sanitation, Hygiene (WASH) 4. Score improved to1.7/2.0 now
  • 15. 15 6b. Engagement with Communities & Society Women Empowerment: • Vocational training • Handicraft • Handlooms • Home based businesses • Loans Education & Infrastructure: • Focus in Rural India • Hospitals • Schools • Girl-child Education • Adult education programs
  • 16. 16 There are many shades of green. Collaborative Association Today, to perform for a Better Tomorrow Rohan Batra Special Projects - Sustainability Birla Cellulose E : rohan.batra@adityabirla.com +91 8108032464