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
