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Sundram Fasteners Limited

Established in 1966

Sales: US$ 555 million

Global manufacturing presence: India, China, UK and Germany

Comprising of 12 manufacturing plants

First Indian company to get ISO 9000

Winner of TPM special/ TPM excellence/ TPM consistency award

Global customer base

Unique IR record: not a single working day lost since inception

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Establishment 16th March 1981

Location Aviyur Village , Virudhunagar District.

Products ManufacturedHigh Tensile Fasteners - Bolts, Nuts, Studs, Screws

Powder Metallurgy Parts

No. of Employees 408

Annual Sales - (2014-15) USD 52.66 million

Export Sales - (2014-15) USD 6.48 million

Total Land Area 85 Acres ( 360,000 Sq.M )

Total Built-up Area 23,178 Sq.M (6.5%)

Green Cover & Open areas 93.50%

Varieties & Range 2000 parts nos

High tensile fasteners - Bolts, Nuts, Screws,sockets

Powder Metal Parts

SFL ,Krishnapuram Plant

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1990

ISO 90021981

Start of

Production

1998

TPM

Excellence

Award

2006

SHE Award

2001

ISO 14001

2008

TPM

Special

Award

2012

TN Govt.

GREEN

Award

Milestones of KPM

2013

Greenco

Gold

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Journey to become a Greenco

Registration with CII and Training – Nov’12

Formation of CFT’s - Dec’13

Awareness and Training programmes - Jan’13 to

Mar’13

Handholding visits by CII -Feb’13

Celebrating Greenco Month - Jun’13

Document Submission – Oct’13

Final assessment – Nov’13

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Schematic Process Flow Chart - Fastener

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Best Practices in Waste Water Management

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Factory Location

Krishnapuram

40-60 cm. annual

rainfall

• Located in dry area

• Has scanty rainfall

• Ground water at high depths

• Even that water not suitable for

industrial use

Background of the project

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Stream segregation

STP

Sources of effluent

Metal

finishing

Coil

phosphating

Domestic

(canteen, toilet)

Zinc

plating

Zinc

phospahting

Acid/

alkali

wash

Zinc wash Chrome

wash

ETP

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B/O

Water

Early Days

Process

Domestic

usage

IETP

Sewage

Treatment Dischar

ge to

ground

220 KL /day

30 KL / day

190 KL / Day

30 KL

day

220 KL /

day

190 KL / Day

• Bought out water 100 %

• Recycle 0 %

• Water consumption 220 KL / day

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B/O

Water

Recycle Stage 1– RO I

Process

Domestic

usage

IETP

STP

Discharge

to ground

125 KL /

day50 KL / day

250 KL / day

250 KL / day

40 KL / day

RO

Reject

High

Dissolved

solids

Reuse

175KL

RO I stage

75 KL / day

Solar

pond

Sl No Item KL/Day %

1 Consumption 300

2 Bought out 125 42

3 Bore water 0 0

4 Recovery 175 58

5 Recycled 300 100

6 Discharge 50 17

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B/O

Water

Process

Domestic

usage

IETP

STP

Discharge

to ground

100 KL /

day50 KL / day

400 KL / day

400 KL / day

50 KL / day

RO

RejectHigh

Dissolved

solids

Reuse

360

KLUltra

Filteration RO – 2 stages

40 KL / day

Solar

pond

Recycle Stage 2– UF& RO II 2

SlNo

Item KL/Day %

1 Consumption 450

2 Bought out 125 28

3 Bore water 0 0

4 Recovery 360 80

5 Recycled 400 89

6 Discharge 50 11

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Recycle – III & IV stage

Two stage recycle in evaporation

• I stage by Mechanical Vapour Recompression (MVR)

• II stage by Triple effect evaporation (Crystallizer)

Advantages of 2 stage evaporation

• In MVR, running cost is one-tenth of Crystalliser, 90% of

effluent volume can be evaporated, even treated sewage can be

added

• The 10% reject from MVR alone need to evaporated

thro’ Crystalliser

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Details of III stage recycle

Details of Mechanical Vapour Recompression (MVR) and

Crystalliser for evaporation

• Reduction in boiling point at vacuum used

• At 180 mbar vacuum, boiling point reduces to 58 deg C

• Vapour is also recompressed and recycled

• Evaporation is done till crystallization occurs

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58 0C

Vacuum pump

MVR fan

Condensate tankTo crystalliser

section

Heat exchanger

Recirculation pump

Concentrate pump

Condensate pump

Concentrate is pumped to crystalliser

Condensate Out

Feed

Schematic of MVR for evaporation

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Evaporation stage 1 -MVR

RO reject

Treated

sewage

Permeate

MVR

Reject

40 KL / day

100 KL /day

10 KL / day

70 KL / day

Solar

Pond

MVR

UNITBought out 10 KL/ day

From RO 360 KL

/ day

RO plant

To O/H tank 460

KL /day

Sl

No Item KL/ day %

1 Consumption 470

2 Bought out 10 2

3 Bore water 0 0

4 Recovery 460 98

5 Recycle 470 100

6 Discharge 0 0

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Concentrate

Condensate

Vapour

SteamVapour

Waste Heat

Feed

Cooling

WaterCONDENSER

Vapour Vapour

Vapour

Primary Condensate

Triple effect evaporation for crystallizer

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Evaporation stage 2 Crystallizer

Permeate

MVR

Reject

100 KL / day

10 KL / day

Permeate

6 KL / day

Slurry

2000

Kg

MVR

UNIT

Crystallizer

ROTo O/H tank 466 KL /day From RO 360 KL / day

Solar Pond

Sl No Item KL/ day %

1 Consumption 470

2 Bought out 10 2

3 Bore water 0 0

4 Recovery 466 99

5 Recycle 470 100

6 Discharge 0 0

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Water ManagementJourney Towards 100% Recycling

Effluent Treatment

Plant

Ultra Filtration Reverse Osmosis

Crystallizer Mechanical Vapour

Recompressor

Zero discharge plant since with 100%

recycle of both Industrial effluent and

Sewage effluent

Before RO

RO IUF/

RO IIMVR

MVR/Crys

Series1 0 57 80 98 99

020406080

100

% R

eo

cve

ry

Recovery

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Water Conservation

12 % reduction in water consumed in last 3 years

through various projects – Industrial use

20 % reduction in water consumed in last 3 years in

domestic use

Rain water harvesting improved water table and

quality

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Challenges

• ETP: For effective metal precipitation, stream segregation

is a must

• One of the first RO plants for recycling metal finishing

effluent and recovery was limited to 75% (I stage RO)

• Oil carry over issue solved by effective oil removal

• To filter organics and colloids, Ultra Filteration was added

• RO II was added to recover 90% of effluent

• Effective cleaning of membranes at designed frequency

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Challenges (contd..)

• Concentrate chemicals to be treated separately

• Premature failure of heat exchanger bags in MVR – design

changes were done

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Details of III stage recycle