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25-03-2013
1
RESPONSE TO CLIMATE CHANGERESPONSE TO CLIMATE CHANGERESPONSE TO CLIMATE CHANGERESPONSE TO CLIMATE CHANGE
TATA MOTORS LTD. PANTNAGAR
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• Established in 1945, Tata Motors' presence cuts across the length and breadth of India.
• Over 7.5 million Tata vehicles ply on Indian roads, since the first rolled out in 1954
• India's largest automobile company, with consolidated revenues USD 32.5 bn in 2011-12.
• Leader in commercial vehicles in each segment, and among the top in passenger
vehicles
• The world's fourth largest truck and bus manufacturer.
• Presence in Europe, Africa, the Middle East, SE Asia, South Asia, South America and Russia
• Over 55,000 employees are guided by the mission
• Working on four thrust areas - employability, education, health and environment
COMPANY PROFILE
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Uttarakhand
Pantnagar - 2007
� In Uttarakhand State
(Northern part of India)
� 250 kms North–East of Delhi
� 7419 Employees
Karnataka
Dharwad - 2011
Maharashtra
Pune - 1966
Gujarat
Sanand- 2009
Geographical Plant Location of TATA Motors
Uttar Pradesh
Lucknow - 1992
Jharkhand
Jamshedpur - 1945
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Present Models
ACE 0.75 Ton
ACE CNG
Magic
Magic CNGACE -Fuel Efficient
Super ACE
Magic IRIS Ace ZIP
Venture
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Concern for the
Environment
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• Bhumi Poojan - March 30, 2006
• Construction started - April 2006
•Construction completed - Feb 2007
•Trial production started - April 2007
•Export Started - May 16, 2008
• 1,00,000th Vehicle- Feb 2009
• 2,00,000th Vehicle - Oct 2009
• 5,00,000th Vehicle - Apr 2011
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2
3
4
5
7
6
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9• 8,00,000th Vehicle - Mar 2012
10• 10,00,000th Vehicle – 27th Oct 2012
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Environment Policy Climate Change Policy
Env Procurement Policy Energy Policy
EMS / ISO 14001 OHSAS : 18001
Water Policy
Audit done &
Recommended for
ISO 50001 - EnMS
by BVC
ISO 500017
Facilitating and
Maximizing Reduction
in Carbon Footprint
through Value Chain
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Actions :
� To reduce 30% Steel for building structure
� Modular concept
� To reduce heat load on ventilation by installing Double
insulated side and roof walls .
� To reduce illumination load by installing Sky light sheets
� To install energy efficient motors for blowers, conveyors
� To install Screw chillers for AC system
� VFD for Compressor and all High powered motors
� Servo controller for Compressed Air Supply .
� Fan less cooling towers for compressor
� Propane for process heating, instead of
conventional fuel e.g. HSD/LDO/FO
� Use of natural resource Artisan wells
� CFL Lamps, Solar Lamps, Wind Ventilators
� Lakes & Rain water harvesting
Infrastructure Manufacturing
Actions :
� Efficient Washing Machines
� Inter Shop Conveyor
� Friction roller conveyor
� “Wet on Wet” Painting process
� Process Optimization
� Power & Free Conveyor
� Electrified Monorail System
� CNC Machines
� Reuse, Recycle, Reduce process waste
Strategy - To Reduce Environmental Footprint
New Product Introduction
Actions :
� CNG Vehicle
� Fuel Efficient Vehicle – with Start-Stop arrangement
� Adherence to emission norms
Logistics
Actions :
� Vendor park near the mother plant to reduce inbound
transportation
� Out bound Transportation
� Transportation internal & employee transport 9
�
STRATEGY Reducing
Environmental
Foot printInfrastructure
�Integrated
Manufacturing
� Modular concept
� Innovative construction
� Less Cement & Steel
� Efficient Facilities
� Water conservation
Logistics� Vendor Park Near Mother
Plant
� Transportation
� Recyclable bins , pallets
Manufacturing
� System
� Process
� Ramp up plan
� Continuous Improvement
New Products
� CNG vehicles
� BS III & IV
…. towards green plant10
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TML Plant Area - 616 Acres Vendor Park area - 337 Acres
Roads length ~ 15 km
Effluent Treatment Plant (Largest ETP in SIDCUL Industrial Estate, Udham Singh Nagar, Uttarakhand).
Total area - 953 Acres
TML
Background
Vendor Park
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UtilityAir, Water, Power, Fuel
ETP,STP
Ready Paint Shop
Utility
WIP
Plant layout Training
TC
F 1
C
TC
F 1
B
TC
F 1
A
BIW
1C
BIW
1B
BIW
1AEngine
&
Gear Box
Inter shop Conveyor
Weld shops to Paint toAssy Lines
1.5 Km long
Engine
&
Gear BoxTC
F 1
D
BIW
1D
TC
F 1
E
BIW
1E
We
ld S
ho
p 2
A
Ve
hic
le A
ssy
2A
,
2B
Service
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Employee Buses run up to
1. 40 Km from Plant
2. On 9 Routes
3. 70 Buses
Transportation Facilities
Inter shop Conveyor for Fast, Safe & Efficient Body
movement
Floor Conveyor - FRC
Floor Conveyor with Dolly
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Carbon Footprint - tCO2 / Eq Ace Veh
Indirect Emissions - UPCL Power
0.25
0.15
0.15
0.15
0.00 0.05 0.10 0.15 0.20 0.25 0.30
2008-09
2009-10
2010-11
2011-12
Year
T CO2 / Eq Ace Vehicle
UPCL Electrical
Direct Emissions - Fuel
0.07
0.08
0.08
0.06
0.00 0.02 0.04 0.06 0.08 0.10
2008-09
2009-10
2010-11
2011-12
Year
T CO2/ Eq Ace Vehicle
Fuel (HSD + Propane)
Specific emissions (Scope I + Scope II)
Scope I (Fuel) emissions Scope II (Electricity) emissions
0.32
0.24 0.23
0.21
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
tCO2 / Eq Ace Vehicle
2008-09 2009-10 2010-11 2011-12
Specific GHG Emisisons (Electricity + Fuel)
45
%
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Use of Environmentally
Sustainable Technologies
Minimize Waste
Generation and Enhance
Recycling and Recovery
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With help of Robots and Efficient
Painting guns, the wastage is reduced by
20-25%
Use of Eco – Friendly (Water Based)
Paints
Reducing Waste Generation
Incineration Recycling
Recycling of Paint sludge into Industrial Reusable Primer
Total Paint Sludge Recycled : 100 MT (i.e. 200 KL Fresh Paint Saved) 16
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Modular Concept
ETP : 1300 + 1300 KLD
STP : 600 + 600 KLD
Effluent & Sewage Treatment Plant
Total ETP Sludge Reused : 400 MT (i.e. 4 Lakhs Bricks Manufactured)
Re- Utilization of ETP Sludge as a raw material into Paver Blocks
ETP Sludge utilization for Pavement Tiles
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120
218
410
0
70
140
210
280
350
420
490
FY 08 -09 FY 09 -10 FY 10 -11 FY 11 -12
CUMSUM Utilization of ETP Sludge
MT
Approved by
CBRI
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Objective : Use of Zero Ozone depletion potential
refrigerant in HVAC system - R 410A
Eco - friendly activities
Objective : Use of Recycled materials such as AAC
bricks, made of Ash content.
Objectives :
• Low VOC Paints, Adhesives, Sealants
• No TOBACCO / NO SMOKING premises
• Reserved car parking for car pooling users
• Electric charging station for electric vehicles
Objective : Recycling of E – Waste
Total E – waste Recycled : 15 MT
Proactively initiated along with draft proposal in March 2011
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250 tCO2
Reduction
per Year
Offset Carbon Footprint
Total 40, 000 Trees Planted till date
Tree Transplantation
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Select, Purchase and Use
Appropriate Energy
Efficient Equipments,
Services and Eco-
Friendly Technologies
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Screw Compressor
With VFD Savings 250 MWH/Yr
Fan less cooling tower
Servo Control Valve
Efficient Facilities
22% Energy saved
Picture/ sketch/ drawing before modification
Picture/ sketch/ drawing after modification
Patent
CFLs
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Wind Ventilators
Renewable Energy
More than 1280 no’s installed and saved 2.9
Million Units.
Solar Water Heating System
Main Features: Main Features: Main Features: Main Features:
� Used for Hot water requirement
� Total system capacity – 5000 Litre / Day
� Max water Temperature – 900 C
� 1, 25, 000 KWH saved per year
� 1.05 Lakh tCO2 per year
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Main FeaturesMain FeaturesMain FeaturesMain Features
� Energy efficient building
� Use of eco friendly and recycled building
materials such as AAC Blocks
� Zero VOC paint and materials
� Automatic control of lighting
� Zero ODP HFC refrigerant
LEED INDIA – GOLD RATING
Green Building 220 KV Switch Yard & Open Access
220 KV Switch Yard Hence Pow er Quality
Improvements
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5 430 0
0
5
10
15
20
P owe r Fa i lur e Ov er / Unde r Vol t a ge Fluc t ua t ion
2011 2012
500
0 tCO
2
50 % Reduction in Direct Emissions 23
-
Use of DALI (Digital addressable light interface) Ballast 75%
reduction in energy consumption
Maximize comfort and reducing strain / glare.
Objective : Energy Conservation in ventilation
Energy conservation activities
Objective : Energy saving in lighting load
Use of Low U Value (thermal transmittance) Glass.
Double jacket glass to reduce thermal loss.
Tinted Glass to save reduce energy consumption in Air
conditioning
Objective : Energy saving on air conditioningDay Light Sensor / LDR for Street Lights
Total Annual Saving = 1 Lakh KWH24
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Insulated the
Washing machine
Insulation of Washing Machine Timer Based Switch (On/Off)
Benefits:
Energy Saving of 0.135 Lakhs KWH PA
Benefits:
Energy Saving of 0.91Lakhs KWH PA
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BASE PRIMERTOP COAT
(RUBY RED)
BAKING OVEN
2C-1B SYSTEM
Reduction in baking time & Fuel Savings Waste Heat Recovery
BAKING OVEN BASE PRIMER
SANDING
TOP COAT
(RUBY RED)
BAKING OVEN
2C-2B SYSTEM
Benefits:
Saving of 1403 Million Kcal PA
The waste heat of exhaust
flue gases from ED oven RTO
is recovered to raise the water
temperature of Hot Water
Generator system used in
paint Shop.
• 168 MT fuel saved PA
• 1 Cr INR saved PA
• 505 tCO2 saved PA 26
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Green Drive at DealersGreen Drive at Suppliers
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32
%
Specific Energy Consumption
32
%
Power Consumption
KWH / Vehicle
Fuel Consumption
M KCal / Vehicle
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Select, Purchase and Use
of Appropriate Water
Efficient Processes,
Equipments, Services and
Technologies for
Treatment, Reduction and
Recycling
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Efficient Facilities
Water conservation
Efficient Facilities
Water conservation
Eco Friendly Lake – water harvesting
Daily 500 KL/Daytreated water is used for gardening purpose
It saves 150 KWH per day
One of artesian well
is Supplying Raw water
to WTP with out power
Reduce the energy consumption for water pumps for WTP
Total Rain Water Harvested
78, 000 KL
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Recycling of Treated Industrial Effluent by Reverse Osmosis (RO) Technique and Reusing in Paint Shop Process
Main Features: Main Features: Main Features: Main Features:
� Recovery Capacity - 95% and unique system in recovery point of view.
� All the equipments are placed above the tank, hence looks compact & less space required
� Good quality of inlet water for paint shop and huge reduction in Ground water extraction.
� Stand by options with existing process water supply system.
� Reduction in 40% Ground Water withdrawal.
R.O. Recovery
started.
One
Lakh
KL
Reduction in Ground
Water
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-
Objective : Water efficiency in Gardening
•Water reuse- 100% STP water for landscaping
•Use of Shrubs and trees which needs less water.
•Gardening design so that minimum water should
flow out of the spaces.
Water conservation activities
Objective :
Prevent loss of soil and storm water during
construction due to rain
Objective : Reduce consumption of water
•Use of water efficient fixtures
• Saves approx 30% water
Objective : To harvest and recharge
•Total we have 5 no. of water bodies
•Total Rain Water Harvested 78, 000 KL
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PLC
PH Meter
Power Supply
GSM Modem
RS 232 PLC Input
PH & DO VALUE MONITORING SYSTEM LAYOUT
SMS Format
pH: High (> 9) / Low (<5)
DO : High (>4) / Low (<2)
DO Data Logger
Annunciator Panel
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Specific Water Consumption
47
%
Water Consumption
KL / Vehicle
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Suggestion Scheme Launched on Climate change & Environment Theme
…. towards green plant…. towards green plant…. towards green plant…. towards green plant
Reducing environmental foot print….Reducing environmental foot print….Reducing environmental foot print….Reducing environmental foot print….
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To generate awareness
STICKERS are developedAwareness
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