This is a proprietary document of Kirloskar Brothers Limited 1

KIRLOSKAR BROTHERS LIMITEDA Kirloskar Group Company

Kirloskar Brothers Limited Sanand.

Presentation on Material Conservation and Recycling

Presentation by : MCR Team

This is a proprietary document of Kirloskar Brothers Limited 2

Leader in fluid handling and one of thelargest manufacturers and exporters of centrifugal

pumps

Yamuna Global Headquarter Kirloskar Brothers Limited, India, LEED Certified Platinum Rated Green Building

Centrifugal pumps, Valves, Hydro Turbines, Pumping Projects

Core business

Established 1888

Incorporated 1920

Corporate Profile

This is a proprietary document of Kirloskar Brothers Limited 3

Kirloskar Brothers Limited Sanand Plant

ISO 9001:2008 certified

BS OHSAS 18001:2007 certified

ISO 14001:2004 certified

SA 8000 certified

Nation Award for Excellence in Energy Management 2014 Certified as Energy efficient

unit.

CII - Exim Bank award for Business Excellence: Significant achievement award

This is a proprietary document of Kirloskar Brothers Limited 4

Green Co Journey

ISO

9001,1993

ISO

14001,199

8

OHSAS

18001,200

8

This is a proprietary document of Kirloskar Brothers Limited 5

RM Store Machine shop CED Coating Assembly line

On line TestingPackingFG Store Performance testing

Operation Sequence

This is a proprietary document of Kirloskar Brothers Limited 6

Reducing consumption of virgin material :

1. Reducing raw material consumption

2. Reducing Packing material consumption

3. Re use packing material

Material Conservation Project

This is a proprietary document of Kirloskar Brothers Limited 7

Raw material consumption reduction

We have planned to reduce the consumption of raw materials through design change with out affecting the performance of the product.

In this project, we have reduced the material consumption by Avg. 10 % to 90 % through material

reduction and by changing of material of construction.

Our internal work, planning and review diary is made from recycled paper and it inspires us to achieve company goals for environment protection and natural resource saving.

This is a proprietary document of Kirloskar Brothers Limited 8

Material Conservation ProjectMaterial of Construction change from Cast iron to Noryl plastic

Before Moc: Cast iron After Moc: Noryl Plastic

Noryl plastic is 100% recyclable

Weight of the component also reduce to 89.76 %

Material Code Description

Previous Wt./ Kg.

Present Wt./Kg.

Reduction In Wt./Kg.

Reduction %

Qty Procured

Total Wt.Saved

in Kg.

01543130 Noryl Dol ABCD 0.654 0.067 0.587 89.76% 9457 5551

Breakage issue.

Machining and coating required

This is a proprietary document of Kirloskar Brothers Limited 9

Before Moc: Sheet metal After Moc: Noryl Plastic

Noryl plastic is 100% recyclable

Weight of the component also reduce to 48.05 %

Material Code Description

Previous Wt./ Kg.

Present Wt./Kg.

Reduction In Wt./Kg.

Reduction %

Qty Procured

Total Wt.Saved

in Kg.

01530150 NORYL BOWL KP4N -07 SERIES 0.077 0.040 0.037 48.05 % 57258 2118.55

Material Conservation ProjectMaterial of Construction change from Sheet Metal to Noryl plastic

This is a proprietary document of Kirloskar Brothers Limited 10

Before Moc: Cast iron After Moc: SS investment casting

Weight of the component reduce by 65.12 % with increased life of Bearing

Material Code Description

Previous Wt./ Kg.

Present Wt./Kg.

Reduction In Wt./Kg.

Reduction %

Qty Procured

Total Wt.Saved in

Kg.

03660160 Fixed Thrust Bearing 1.075 0.375 0.700 65.12% 18278 12794.6

Material Conservation ProjectValue addition in Thrust bearing by MOC & Design Change

This is a proprietary document of Kirloskar Brothers Limited 11

Before Moc: Cast iron After Moc: SS investment casting

Weight of the component reduce by 62.35 % with increased life of Bearing

Material Code Description

Previous Wt./ Kg.

Present Wt./Kg.

Reduction In Wt./Kg.

Reduction %

Qty Procured

Total Wt.Saved in

Kg.

03660170 Tilting pad Thrust Bearing 0.850 0.320 0.530 62.35 % 2726 1445

Material Conservation ProjectValue addition in Thrust bearing by MOC & Design Change

This is a proprietary document of Kirloskar Brothers Limited 12

Material Code Description

Previous Wt./ Kg.

Present Wt./Kg.

Reduction In Wt./Kg.

Reduction %

Qty Procured

Total Wt.Saved

in Kg.61008411 SS Imp For KS6D Pump Clock-wise 1.125 0.924 0.201 17.87% 9576 1924.776

61008833 61009152 IMP For KS6EA Pump Anti Clock-wise 1.416 1.120 0.296 20.90% 4968 1470.5286100883161009151 SS Imp For KS6F Pump Anti Clock-wise 1.248 1.107 0.141 11.30% 9792 1380.672

Benefits : Increased Pump efficiency. Motor power consumption reduced Supplier machining time and power consumption reduced Reduce product weight and transport cost and Co2 emission

Material Conservation ProjectReduction in Raw material weight of impellers

This is a proprietary document of Kirloskar Brothers Limited 13

Material Code Description

Previous Wt./ Kg.

Present Wt./Kg.

Reduction In Wt./Kg.

Reduction %

Qty Procured

Total Wt.Saved

in Kg.

61008841 SS Imp For KS6G Pump Clock-wise 1.352 1.25 0.102 7.54 % 4920 501.84

61008851 SS Imp KS8P Dia. 140mm 2.400 2.193 0.207 8.62 % 315 65.21

Material Conservation ProjectReduction in Raw material weight of impellers

Benefits : Increased Pump efficiency. Motor power consumption reduced Supplier machining time and power consumption reduced Reduce product weight and transport cost and Co2 emission

This is a proprietary document of Kirloskar Brothers Limited 14

Material Code Description Previous Wt./ Kg.Present Wt./Kg.

Reduction In Wt./Kg.

Reduction %

Qty Procured

Total Wt.Saved in

Kg.

61009121 Impeller SS 100 HHN Series 0.834 0.365 0.469 56.24% 1273 597

Benefits : Weight of the component reduced by 56.24 % Increase Pump efficiency. Power Consumption reduce Reduce product weight and transport cost and Co2 emission

Before Moc: Steel cast After Moc: SS Fabricated

Material Conservation ProjectMaterial of Construction change from Steel Cast to Sheet metal

This is a proprietary document of Kirloskar Brothers Limited 15

Significant Improvement: Packaging waste reduction (KS4 Pump set)

For packing KS4 Pump set twin packing corrugated Kraft tube was used.

Transit damage issues were there in this type of packing. Tube is bulky and heavy.

Light weight easy to handle Corrugated box developed.

Code Description Previous Wt. (Kg)Present

Wt. (Kg)

Reduction In Wt. (Kg)

Reduction %

Purchase Qty.

Total Wt. Saved in

(Kg)06080990 Corrugated Box Sq. For KS4 640

mm2.53 1.752 0.778 30.75% 1483 1153.77

06081600 Corrugated Box Sq. For KS4 760 mm

2.97 2.008 0.962 32.39% 2299 2211.63

06081780 Corrugated Box Sq. For KS4 855 mm

3.47 2.272 1.198 34.52% 2827 3386.74

06081800 Corrugated Box Sq. For KS4 940 mm

3.81 2.492 1.318 34.59% 2245 2958.91

- KS4 Single Craft Tube 4.25 2.405 1.845 43.41% 1462 2697.39

- KS4 Single Craft Tube 4.91 2.925 1.985 40.43% 271 537.94

Total Average reduction in % 36.02% 10587 12946

Particulars Details Of Saving

Material Code -

Description Sq. box with 2 tube

Wt. Saved / Kg. 8.086

Purchased Qty 10587Purchase in Kgs. 12946

Conv. Factor per Kg to 1 Tree. 54

Number of Trees Saved 240

Before After

Material Conservation Project

This is a proprietary document of Kirloskar Brothers Limited 16

Significant Improvement: Weight reduction in plastic cap in packing (KS4 pump set)

For packing KS4 Pump set in twin packing corrugated Kraft tube twin caps were also used.

Since new corrugated box was developed with 2 separate thin inner tubes hence there are four small low weight caps are used instead of two twin caps.

Before After

Code Description Previous Wt./ Kg.(2Pc)Present

Wt./Kg. (4 Pc)

Reduction In Wt./Kg. Reduction % Purchase qty

Total Wt. Saved in Kg.

06080990 Corrugated Box Sq. For KS4 640 mm 0.18 0.072 0.108 60.00% 1483 160.16406081600 Corrugated Box Sq. For KS4 760 mm 0.18 0.072 0.108 60.00% 2299 248.29206081780 Corrugated Box Sq. For KS4 855 mm 0.18 0.072 0.108 60.00% 2827 305.31606081800 Corrugated Box Sq. For KS4 940 mm 0.18 0.072 0.108 60.00% 2245 242.46

- KS4 Single Craft Tube 0.18 0.072 0.108 60.00% 1462 157.896- KS4 Single Craft Tube 0.18 0.072 0.108 60.00% 271 29.268

Total Average weight reduction 60.00% 10587 1143.40

Material Conservation Project

This is a proprietary document of Kirloskar Brothers Limited 17

Significant Improvement: Packaging waste reduction (BIGflow Pump set) For packing BIGflow Pump set twin packing corrugated Kraft tube was

used.

Transit damage issues were there in this type of packing. Tube is bulky and heavy.

Suppliers box which was scraped earlier is used as internal packing and a light weight easy to handle Corrugated box developed for external packing.

Before After

Supplier box

Code DescriptionPrevious

Wt. (Kg)

Present Wt. (Kg)

Reduction In Wt. (Kg)

Reduction %

Purchase qty

Total Wt. Saved in

(Kg)

06089490 CORR BOX.BIGFLOW 2.53 0.581 1.949 77.04% 9621 18751

Particulars Details Of Saving

Material Code 06089490

Description Corr. Box Sq. BIGflow 3Ply X 570 X 225 X130 mm

Wt. Saved / Kg. 1.949

Purchased Qty 9621

Purchase in Kgs. 18751Conv. Factor per Kg to A

Tree. 54

Number of Trees Saved 347

Material Conservation Project

This is a proprietary document of Kirloskar Brothers Limited 18

Significant Improvement: Elimination of use of plastic cap in packing (BIGflow pump set)

For packing BIGflow Pump set in twin packing corrugated Kraft tube twin cap was also used.

Since new corrugated box was developed hence there is no twin cap required in that packing.

Before After

No Twin caprequired

Code Description Weight of cap (Kg)Reduction

% Purchase qtyTotal saving

(Kg)

06089490 CORR BOX SQ. BIGFLOW 3PLYx570x225x130mm 0.18 100.00% 9621 1732

Material Conservation Project

This is a proprietary document of Kirloskar Brothers Limited 19

Significant Improvement: Horizontal deployment of twin tubes reduction initiative

For packing KS3 Pump set twin packing corrugated Kraft tube was used.

Transit damage issues were there in this type of packing. Tube is bulky and heavy.

Initiative taken to replace BIGFlow pump set twin packing Kraft tubes with corrugated box was deployed in this also.

Before After

Supplier box

Code Description Previous Wt. (Kg)Present

Wt. (Kg)

Reduction In Wt. (Kg)

Reduction %

Purchase qty

Total Wt. Saved in

Kg.

06085330 CORRUGATED BOX SQ. FOR KS3 735x180x102MM 1.53 0.59 0.94 61.45% 10422 9796.68

06085320 CORRUGATED BOX SQ. FOR KS3 660x180x102MM 1.53 0.55 0.98 64.06% 422 413.78

06085340 CORRUGATED BOX SQ. FOR KS3 810x180x102MM 1.53 0.62 0.91 59.49% 2065 1879.15

Total Average reduction in % 65.51% 12909 12089

Particulars Details Of SavingMaterial Code

Description Sq. box with 2 tube

Wt. Saved / Kg. 2.83

Purchased Qty 12909

Purchase in Kgs. 12089Conv. Factor per Kg

to A Tree. 54

Number of Trees Saved 224

Material Conservation Project

This is a proprietary document of Kirloskar Brothers Limited 20

Significant Improvement: Packaging waste elimination (KS4 Stator & Rotor) Stator and Rotor received from Duke Plasto Technique were

supplied in Kraft tubes.

This tube was scraped.

We have developed new MS trolleys/pallets for receiving material from supplier.

These trolleys resend to supplier for reuse. Kraft tube usage is 100% eliminated in this supply.

Before After

Supplier trolley

Code Description Previous Wt. (Kg)Present Wt. (Kg)

Reduction In Wt. (Kg)

Reduction %

Purchase qty

Total Wt. Saved in

Kg.

-

Stator Rotor Craft Tube 0.86 0 0.86 100.00% 26922 23153

Particulars Details Of SavingMaterial Code -

Description St_Rt Tube

Wt. Saved / Kg. 0.86

Purchased Qty 26922

Purchase in Kgs. 23153Conv. Factor per Kg to A

Tree. 54

Number of Trees Saved 429

This initiative also results into saving plastic caps of Kraft tubes which were also scraped.

Cap weight: 0.013 Kg/Pc Saving in plastic waste = 834 Kg

Material Conservation Project

This is a proprietary document of Kirloskar Brothers Limited 21

Craft tube and Plastic caps of Stator and Rotor are Reused Previously these tubes and plastic cap sold as Scrap

Now, Stator and Rotor Packing tube with Cap re send to supplier for reuse

Year Total packed

Stator and Rotor receipt

Total Scrap tube back to vendor as reuse

% Recycled Material

2012-13 20673 10489 50.74%

2013-14 22231 10270 46.20%

2014-15 22755 11650 51.20%

Total 65659 32409 49.38%

Material Conservation Project

In addition to above saving we have also reused 64819 plastic caps worth 6.42 Mt weight.

This is a proprietary document of Kirloskar Brothers Limited 22

Material Conservation ProjectResult: Packing Material

Total Tree Saved: 1411 Nos.

This is a proprietary document of Kirloskar Brothers Limited 23

Material Conservation ProjectResult: Plastic Material

This is a proprietary document of Kirloskar Brothers Limited 24

Material Conservation ProjectResult: SS and CI Material

This is a proprietary document of Kirloskar Brothers Limited 25

THANK YOU