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Titan Company Limited Hosur Green Manufacturing 10-Sep-18 1 Green Manufacturing G

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Titan Company Limited

Hosur

Green Manufacturing

10-Sep-18 1 Green Manufacturing

G

• Joint venture Promoted by TATAs & TIDCO.

• Year of Establishment - 1987

• Products - Quartz Analog Wrist Watches, Precious

Jewellery , Precision Components & Fashion

accessories .

• Brand – Titan, Sonata,Fast Track & Xylus in Watches

& Accessories and Tanishq in Jewelry

• Watch market share - 60 %

• Exports -More than 39 countries

Company profile

Watches & Accessories Division Titan Company Limited

783 918 946

1052

1309 1530

1676 1791

1921 1974 2028 2126

0

500

1000

1500

2000

2500

06-07 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17 17-18

in R

s. C

rore

Year

2136 3041

3848 4703

6571

8970 10009

10916 11903

11179

12782

15742

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

06-07 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17 17-18

in R

s. C

rore

Year

10-Sep-18 2 Green Manufacturing

G

Manufacturing process

Case Manufacturing

Press Machining Plating Polishing

Movement Manufacturing

Turning Machining Treatment Press

Assembly

Movt.Assly Watch.Assly Strapping Testing

10-Sep-18 3 Green Manufacturing

G

Green Manufacturing - Approach

Pursue energy & water conservation initiatives • In-house experience • External expertise

Systems and procedures to sustain – QEMS , EnMS ISO 50001 & GreenCo

Maximize the renewable energy substitution • Wind energy • Solar energy

+

Conservation of natural resources Elimination of waste

Green Perspective in all our business

10-Sep-18 4 Green Manufacturing

G

Green Manufacturing - Focus areas

Renewable energy substitution

Energy & Fuel conservation

Water & Effluent management

Hazardous waste management

Cleaner manufacturing process

10-Sep-18 5 Green Manufacturing

G

Renewable Energy

10-Sep-18 6 Green Manufacturing

G

9

29.9 35.5

25.7

48.1 48.3 52.4

49 50.3

77.2 82.6

0

10

20

30

40

50

60

70

80

90

07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17 17-18

Year

Wind power contribution in %

Renewable Energy substitution – Wind energy

Installed capacity - 6.0 MW Located in Theni – Tamil Nadu

Annual generation capacity – 13 MkWH

Annual energy consumption

12 ~ 13 MkWH

Better

10-Sep-18 7 Green Manufacturing

G

Renewable Energy substitution – Rooftop solar System

Solar Power – Till 2017 -18

Capacity - 216 kW Installed during – May 2014 Investment – Rs 174 Lakh MNRE subsidy – Rs 55 Lakh

Plan 2018 -19 - To add 150 kW

As first phase , we have taken up the installation of rooftop solar system in

concrete roofing

Annual energy generation

System capacity - 3 LkWH/ annum

2.8 2.9

2.9

2.7

2.4

2.6

2.8

3.0

14-15 15-16 16-17 17-18

L.k

WH

r

Year

Better

10-Sep-18 8 Green Manufacturing

G

Application - Shop floor general lighting

Area covered - 50000 Sq ft

Investment – Rs 24 Lakh

Energy saving – 35000 kWH/ annum

Renewable Energy substitution – Solar light pipe

Solar light pipe

10-Sep-18 9 Green Manufacturing

G

2000

2300

1200 1035

200

0

500

1000

1500

2000

2500

13-14 14-15 15-16 16-17 17-18

Lite

rs

Year

• Installed during – May 2012 •No of dishes :15 •Solar system capacity : 75 kg/ Hour •Steam generation between 11.00 to 3.00 PM •Supplementing our Canteen steam requirement about 4 Hrs •Target diesel savings – 3000 Liters /Year •Investment - Rs 43 Lakh

Annual diesel saving

Renewable Energy substitution – Solar cooking system

Savings is less due to poor solar irradiation

10-Sep-18 10 Green Manufacturing

G

10-Sep-18 11 Green Manufacturing

G Resource conservation - Energy & Fuel conservation

Time Horizon (Years)

Imp

rove

me

nt

of

Ene

rgy

Effi

cie

ncy

System Optimization

System Redesign

System Innovation

Approach - Energy Efficiency Evolution

2000-2005 2005-2010 2015 ~

10-Sep-18 12 Green Manufacturing

G

Energy Conservation

Compressed Air system

Air conditioning system

Lighting system

Fuel Conservation

10-Sep-18 13 Green Manufacturing

G

No of project category

40

35

30

25

20

15

10

5

0

2000-2005

11 37 06

51

9 5

Energy

Fuel

Renewable

78%

ENCON Project summary

8%

14 %

11

2005-2010 2010-2015 2015~17

65 Categories

Individual projects > 400

Projects

10-Sep-18 14 Green Manufacturing

G

ENCON – Key Improvements so far ..

V Belt to Flat Belt conversion

Intermediate controllers

Screw air compressors

Refrigerant dryer

Transvector nozzle for clean air guns

SCADA system for battery of compressors

SYSTEM

10-Sep-18 15 Green Manufacturing

G

Lighting transformer

Induction lighting for high bay application

LED lighting for shop floors and street lights

ENCON – Key Improvements so far ..

Silver shield reflectors

Occupancy sensors for office area

Auto lighting control

10-Sep-18 16 Green Manufacturing

G

Recip chiller to Screw chiller – water cooled

Star delta Star convertors

Flat belt conversion for AHU’s

Energy efficient pumps

BMS for air conditioning

Aircon savers for smaller A/c units

VFD’s or AHU’s

Free cooling system

Thermal Energy storage system

ENCON – Key Improvements so far ..

IE 3 Motors for AHU’s

AHU’s with DC motors

Automatic Tube Cleaning System

2016-17

10-Sep-18 17 Green Manufacturing

G

Concept : Store the Cold energy during night hours and discharge during peak hours for Air conditioning

Capacity : 625 TR hours X 2 Nos Investment : Rs 125 Lakh Energy saving : 1 LkWH Fuel saving : 65000 Litres

Overall cost saving : Rs 42 Lakh

Chiller is operated at night hours and hence higher efficiency and less specific energy /

TR

Operation of brine chiller at night delivers high efficiency due to lower condenser temperature

Avoids the operation of

air cooled chiller

operation in day time

Discharging during peak hours avoids DG operation

Higher efficiency Energy saving Fuel saving

Reduction in carbon emission

CO2 Reduction

Demand reduction

Demand management

Thermal Energy Storage System (TES )

10-Sep-18 18 Green Manufacturing

G

TES – Schematic

THERMAL

ENERGY STORAGE TANK

BRINE

CHILLER

BRINE PRIMARY PUMP

BRINE LOAD PUMP

CHILLED

WATER LOAD PUMP

PLATE TYPE

HEAT EXCHANGER

Brine chiller

Leverage on dual tariff system from TNEB

(Lower tariff of TNEB power during night

hours)

Night hours

Storage tank

Peak hours

10-Sep-18 19 Green Manufacturing

G

LED Retrofitting Conversion of 36 W fluorescent tube fittings with 18 W LED lighting No of fittings converted - 3000 Energy saving / annum – 1.80 LkWH Investment – Rs 30 Lakh

Retrofitting of LED fixtures for street light fitting No of fittings converted – 60

Installation of Variable Frequency Drives for Air handling Units No of AHU’s retrofitted - 11 Energy saving / annum – 0.80 LkWH Investment – Rs 4.40 Lakh

VFD’s For AHU’s

10-Sep-18 20 Green Manufacturing

G

IE3 Motors Retrofitting

Installation of IE3 energy efficient motors for AHU ‘s No of AHU’s retrofitted - 10 Energy saving /annum – 0.50 LkWH Investment - Rs 3.50 Lakh

Brushless DC motor for AHU

Installation of Brushless DC motor for the AHU Induction motor - Pilot study Capacity of the AHU Motor - 11 kW Energy saving /annum – 7200 kWH Investment - Rs 5.00 Lakh

10-Sep-18 21 Green Manufacturing

G

• ATCS - Efficient and reliable automatic on line solution for keeping shell and tube heat exchangers in a good / clean condition . • It cleans condensers by pushing a soft balls through the tubes and so that it cleans the fine scale deposits inside the condenser tubes . • Automated process and controlled by a PLC .

Automatic Tube Cleaning System (ATCS)

Investment - Rs 7 Lakh Annual Energy savings – 1.20 LkWH Cost saving – Rs 10.80 Lakh

Installed one number during April’16 and two more systems have been installed during April’17 as horizontal deployment .

12 % Energy reduction

10-Sep-18 22 Green Manufacturing

G

Energy Valve for AHU’s

Why Energy valve ? •To maintain the temperature with required delta “T” across the AHU coil with flow control - •This valve operates based on the set temperature and controls the flow with the set delta “ T” of the AHU .

Vendor - M/s Belimo Our Experience - We have installed in two of our AHU’s ( 50 TR capacity ) as trial and under observation

It ‘s a two way valve with –

• Multiple operation Modes / Control Algorithms – ∆T manager – Flexibility in Controls

• Accurate measurement of Flow, Temp with in-built Flow meter and temperature sensor

10-Sep-18 23 Green Manufacturing

G

Flow Sensor & housing

Smart Actuator

Characterized Control Valve

Temperature Sensor

Energy Valve for AHU’s

Position control – Works as two way valve Flow control - Control the flow for the required temp setting Delta T manager – Maintains AHU coil Delta T with flow

10-Sep-18 24 Green Manufacturing

G

Energy loss reduction

Power factor correction – Improved power factor maintenance ( 0.99 ) with APFC panels

Harmonic study - To understand the harmonic presence and to take appropriate measures in Electrical distribution system

Thermo graphic study - to find out the electrical hot spots and addressing the route causes

10-Sep-18 25 Green Manufacturing

G

Energy monitoring

SLD Daily reporting ON line trend

History

ON line monitoring system connected across load centres - 72 Multi function energy meters Real time monitoring Demand management Energy consumption reports – Customized Data analysis / history

Energy monitoring for top energy consuming equipment – Chillers / Air

compressors / presses and PVD Equipment

10-Sep-18 26 Green Manufacturing

G

ENCON - Reviews

Initiative review Monthly - With the SMT

Review of the projects with metrics

Monthly reports Reports covering all aspects of energy consumption / conservation

Weekly production meeting New projects progress

Monthly - Unit head and to Plant head

Monthly - Sharing to plant head / unit heads

Daily review Project progress / Energy consumption

Department meeting

Sharing of information to operating team

Mid course correction based on

the review outcome

Awareness and Training

Awareness training Creating awareness on ENCON for the employees - In house training & through external agencies

Awareness posters and displays on ENCON

Participating external seminars / programmes

Nominating people for the external seminars/ programmes on ENCON

Energy conservation Day celebration Awareness messages to employees from SMT /

Display of energy efficient gadgets through vendors

Employee suggestion scheme Idea + , Inviting suggestions / SGA ‘s and Emails from individuals

4.88 4.69

4.22

3.71

3.27 3.07

2.88 2.57

2.72

2.10 1.88

2.01 2.21

2.35 2.07 2.00

2.21 2.51

2.28 2.39

2.72

2.28

0

1

2

3

4

5

6

Energy Conservation - Specific energy consumption

53 % Reduction

Better

10-Sep-18 29 Green Manufacturing

G

Fuel Reduction Initiatives

10-Sep-18 30 Green Manufacturing

G

Dedicated power feeder - Optimizing DG set utilization

Key challenges

Grid availability Power & demand restrictions

Higher DG set operation

Un utilized wind power

Reduce the fuel consumption Increase the grid availability

Initiated during 2013-14

Commissioned during - Feb’15

Investment - Rs 60 L

10-Sep-18 31 Green Manufacturing

G

18.15

11.05

6.36

2.73 1.51 1.30

2.05

0

2

4

6

8

10

12

14

16

18

20

12-13 13-14 14-15 15-16 16-17 17-18 Plan 18-19

Die

sel C

on

sum

pti

on

In L

akh

.Lit

ers

Key outcome- diesel consumption

Key results – DFS

92 % Reduction

Power availability

0.0

20.0

40.0

60.0

80.0

100.0

13-14 14-15 15-16 16-17 17-18

55.1

69.1

98.3 97.9 98.3

10-Sep-18 32 Green Manufacturing

G

33

MVR – Mechanical Vapor Recompressor

• MVR is the evolving technology to evaporate effluent in an optimal way .

• Evaporation process in a vacuumised chamber (200 mm/hg ). • Effluent evaporates at 63 Deg C .

• Polymer heat exchanger

Four Stage RO system

MES – Mechanical evaporator

Salt

60 to 70 KLD @ 2000 PPM

Reject 10 % @ 20000 PPM

Permeate - back to process @ 90 % recovery rate

6 to7 KLD

Effluent

KL/day

Op.

Cost/KL,

Rs

Op.

Cost/day,

Rs

Total Op.

Cost/annum

With MES 6.0 3500 21000 Rs 63.00

Lakh

ETP Existing Process with – Mechanical Evaporator System (MES)

System Capacity – 25 KL First of its kind in an Engineering Industry

10-Sep-18 Green Manufacturing

G

Four Stage RO system

MES – Mechanical evaporator

Salt

Reject 10 % @ 20000 PPM

ETP Process – with MES & MVR

60 to 70 KLD @ 2000 PPM

Permeate - back to process @ 90 % recovery rate

MVR Reject 1.2 KLD

MVR ( Mechanical Vapor Recopmressor )

25 KLD

Condensate @ 80 % recovery rate

6 to7 KLD

Overall water recovery > 95%

10-Sep-18 34 Green Manufacturing

G

Mechanical Vapor Recompressor

Pellet reactor

MVR vessel 10-Sep-18 35 Green Manufacturing

G

Operation principle

36

COMPRESSED VAPORSHAFT SEALINGIMPELLER VACUUM VESSEL

LOW SPEED VAPOR COMPRESSION FAN

LIQUID

DISTRIBUTION

CONDENSATION INNER SURFACE

FALLING FILM EVAPORATION

OUTER SURFACE

VACUUM

PUMPCONDENSATE

COLLECTION

CONDENSATE TANK

CIRCULATION WATER

CLEAN WATER

FEED SOLUTION

CONCENTRATE

VAPOR INLET

10-Sep-18 Green Manufacturing

G

2,690 2,460

1,896 2,036 1,907

1.36

0.94

0.7 0.63

0.44

0.6

0.00

0.50

1.00

1.50

2.00

0

500

1000

1500

2000

2500

3000

2013-14 2014-15 2015-16 2016 - 17 2017 - 18

Effluent processed in KL Diesel Consumption in KL

Effl

ue

nt

Pro

cess

ed

in K

L

YEAR

50.73 38.12 37

31 25

0

10

20

30

40

50

60

Die

sel C

on

sum

pti

on

/ K

L

Year

Mechanical Vapor Recompressor - Key results

Specific fuel consumption /KL

Diesel consumption Vs Effluent processed

Die

sel

con

sum

pti

on

in

Lakh

Lit

ers

10-Sep-18 37 Green Manufacturing

G

Beyond the fence - Energy audit for vendor sites

Educate the vendor community on ENCON

Share our best practices &Expertise

Optimize their energy cost

Support them for ( technical & financial ) the implementation

No of vendors covered 23

Saving potential identified Rs 60 Lakh

With out investment Rs 17 Lakh

With investment Rs 43 Lakh

10-Sep-18 38 Green Manufacturing

G

ENCON - Energy /Fuel Management System

10-Sep-18 39 Green Manufacturing

G

Water & Effluent /Waste management

10-Sep-18 40 Green Manufacturing

G

Water management

Conservation initiatives

• Installation of auto valve in plating line rinsing tanks with timer controls.

• Foam spray type filter for the water taps to reduce the water consumption .

• Accumulation of components to increase the Batch Sizes to reduce water consumption.

• Diffused Aeration system to improve the STP performance

• Recycling of domestic effluent for cooling tower, wash room flushing & other general

cleaning.

• Rain Water Harvesting

Electronic faucets for hand wash at shop floors

Dish washer for cleaning of Canteen utensils

Wash down and Clean up solutions for the Vessels & floor cleaning at

Canteen

Zero Discharge Compliance Plant – Since 2006

10-Sep-18 41 Green Manufacturing

G

Water management

15.76 16.48 16.45 14.20

15.80 13.20

2

5

8

11

14

17

12-13 13-14 14-15 15-16 16-17 17-18

Specific Water Consumption

252 223 227 217 210 204

0

50

100

150

200

250

300

12-13 13-14 14-15 15-16 16-17 17-18Year

Daily water consumption in KLD

in K

LD

Better

10-Sep-18 42 Green Manufacturing

G

Rain water harvesting & Recharging of ground water

• Recharge well created near

Assembly

• Open wall behind Ebauche

department

• Open Pond behind Service building

Storage capacity of 1 Lac Liter

during heavy down pour

10-Sep-18 43 Green Manufacturing

G

10-Sep-18

Recycling 100% of domestic effluent for Landscaping, A/C cooling tower, Wash room flushing's

Water management

44 Green Manufacturing

G

Waste Management - Overview

Waste

Liquid waste

Solid waste

Hazardous

Non Hazardous

Trade effluent

Domestic effluent

Recycled and sent back to process

Recycled – Used for Gardening / Cooling towers / Wash room flushing

Land fill

Incineration

Recycling

Scrap yard

Bio Medical waste Segregated and sent to

authorized agency

“E” Waste Sent to authorized

recycler

Waste Management System- Structure

Waste management Team Engineering services

Civil Engineering Stores

Concerned departments

Waste management manual

Operational controls/ Work instructions

Operating team

Input Effluent

TDS – 1500 ~ 1800 PPM

Pre-treatment

- Clarifier

- Pressure

Sand Filter

- Activated

Carbon Filter

-Softener

Micro Filtration RO – Stage 1

Good water – TDS < 100

PPM

RO – Stage 2

Rejection – 5000 PPM

Combined

Permeate

Storage Tank

Rejection – 9900 PPM

Good water –

TDS < 100 PPM

RO – Stage 4

Input – 14000 PPM

Input - Reject

20000 PPM

RO – Stage 3

Permeate from RO

IV

TDS < 500 PPM

Effluent treatment - flow diagram

MVR

Evaporation

System

Mechanical

Evaporation

System Input

Reject

Condensate

from MVR &

MES

Process

High conc

sludge

140 Kgs / day

To Storage

78 % recovery

Input – HCT

30000 PPM

Pellet

Reactor

Waste Management – Trade effluent

We are zero discharge compliance since 2006

Recycling of trade effluent

2010 - 2011

Year

Improvements

2006 -2007

3 Stage RO system with MES

4 Stage RO system with MES

4 Stage RO system with

MVR & MES 2014-15

Initiatives – Trade effluent treatment process

82 % water recovery

90 % water recovery

96 % water recovery

3 Stage RO4 Stage ROwith MES

4 Stage ROwith MVR &

MES

% Of Recovery 82 90 96

50

70

90

10-Sep-18 48 Green Manufacturing

G

Effluent from domestic wastes /wash rooms

Waste water from Canteen

Bar screen chamber

Anaerobic tank

Collection tank

UASBR

Aeration tank Primary

clarifier Secondary

clarifier Collection

sump

Filtration system – ACF

/PSF

Domestic treatment flow

Grit chamber

We are Zero discharge compliance

unit since 2006

pH – 6.97

TDS – 1500 ppm

BOD – 440 ppm COD – 1400ppm

pH – 7.2

TDS – 1490 ppm BOD – 5 ppm

COD – 35 ppm

Waste management - Domestic effluent treatment

10-Sep-18 49 Green Manufacturing

G

2005 - 2006

2015 -16

Year

Improvements

1998 - 2000

STP with surface aeration

Up gradation of STP with diffused aeration system

Full fledged UASBR -Anaerobic digestion system

(Up flow Anaerobic sludge blanket reactor)

Anaerobic digestion system

pilot 2013-14

Initiatives – Domestic effluent treatment process

Overall water recovery - 90 %

2014 - 2015 2015 - 2016 2016- 2017

Dom Effluent(In KL)Generated

40560 53370 56390

Domestic Effluent(InKL) Recycled

36910 45487 50485

0

20000

40000

60000

Qty

in K

L

10-Sep-18 50 Green Manufacturing

G

Waste Management – Organic waste

Vegetable peels / dry leaves collected from Canteen / Gardens

Dumped in to Composting yard

7 Stage process

Converted as vermi

manure after 30 days

Vermi Composting

18.0 18.5 18.0 18.0 18.0 18.0

10

11

12

13

14

15

16

17

18

19

20

11-12 12-13 13-14 14-15 15-16 16-17

Year

Vermicomposting in Tons

in T

on

s

•Used for gardening •Distributed to our employees during WED

10-Sep-18 51 Green Manufacturing

G

Organic Waste Compost Compost used for Plants

Waste management - Organic waste

Handling capacity 500 Kgs /day

Food waste

10-Sep-18 52 Green Manufacturing

G

Waste Management - Hazardous waste

Waste collection Waste segregation Waste disposal

Heavy metal sludges from DM plant

Filter press / sludge drying bed

Collected in closed container – HDPE barrels

Hazadous waste storage yard

Chemical sludge from ETP /MES

Disposed to common land fill facility -TNWML

Spent resin from DM plant

Oil soaked cotton waste

Collected separately from shop floors

Storage yard

In line with M/s TNPCB Compliance

10-Sep-18 53 Green Manufacturing

G

Waste collection Waste segregation Waste disposal

Used solvent

MS /HDPE containers - Collected from shop floors

Storage yard

Disposed to authorized recyclers

Used oil

In line with M/s TNPCB Compliance

Waste Management - Hazardous waste

10-Sep-18 54 Green Manufacturing

G

Waste management -E waste

Disposed to authorized recyclers

Collected across shop floors / office area

10-Sep-18 55 Green Manufacturing

G

Waste Management

Reuse of packing material

Wooden packing materials Used to fabricate component packing boxes

Re use of Movement /ECB packing trays

Paper waste

Used papers are being sent to Gandhi gramodyog bhavan for recycling 10 Trucks / Year

5Tons /Year

Used to fabricate machine platforms

Cleaner manufacturing

10-Sep-18 57 Green Manufacturing

G

Dry Plating process ( PVD ) – Cleaner mfg Processes

• Ion Plating Process in place of conventional electro plating - PVD technique for gold plating

• Elimination of TCE – Substitution with ISOPAR –H solvent and ON line recycling system -

Reduction in Solvent consumption

• Process Optimization & Automation

• Resource Conservation –Raw material Optimization & Recycling of Brass Scrap

• Pro Active Pollution Control Measures – WPC & APC measures

• Hazardous Waste Management Processes

Advantages of PVD process

• Precious metal conservation • There is no water consumption in the process • No effluent generation • There is no emission/ fumes

• Adopting Physical Vapor Deposition (PVD) technique for gold plating instead of conventional Electroplating (Wet Plating ).

• We are the first people to establish PVD Process for Brass cases and bracelets.

Year 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 Gold Consumption in "g" 65,309 86,424 83,571 70,519 64,964 69,862 Gold Recovered in "g" 34,219 44,552 46,663 35,033 30,633 30,050 % Recovery 52% 52% 56% 50% 47% 43%

PVD Equipment

10-Sep-18 58 Green Manufacturing

G

Solvent reduction

On line solvent recycling using Durr cleaning equipment and which reduces the fresh solvent consumption Annual consumption has been brought down to 35 Tons

Isopar –H is the solvent used for component cleaning

Annual consumption was around 120 Tons

ON line recycling of solvent •We have invested around Rs 3 Cr for the recycling equipment – Durr cleaning equipment •This equipment will recycle the solvent ON line and the fresh ISOPAR consumption has been reduced drastically

10-Sep-18 59 Green Manufacturing

G

Brass recycling

Horological brass is used as raw material for making watch cases

600 Tons of raw material is used / annum

420 Tons of brass material is from conversion route

180 Tons of virgin brass is purchased through fresh route

05-06 06-07 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17 17 - 18

Series1 222 316 336 376 372 449 424 397 377 500 507 540 619

Series3 210 301 303 336 362 418 422 394 377 496 494 532 565

Series2 94 96 90 90 97 93 100 99 100 99 97 99 91

94 96 90 90

97 93

100 99 100 99 97 99

91

30

40

50

60

70

80

90

100

0

100

200

300

400

500

600

700

% R

ecyc

ling

Ton

s /

Yr

Year

Brass Recycling

10-Sep-18 60 Green Manufacturing

G

Cyanide reduction / elimination

Cyanide is used for

• Rust removal / cleaning process • Gold stripping process

Leading to operational risk in storage , handling and treatment

Target to eliminate cyanide from our manufacturing process

Hand holded with M/s CSIR –NML Jamshedpur to develop alternate process

Identify the potential opportunity to eliminate cyanide from the following activities:

• Surface treatment

• Rust removal form steel module components

• Stripping of rejected gold plated brass main plates & wheels

• MED

• Stripping of market return components

• Ion Plating

• Stripping of SS straps

• Stripping of bicolor brass cases

10-Sep-18 61 Green Manufacturing

G

GHG Emission

Operation of DG sets Operation of Steam boilers

Purchased electricity Business Travel

Company level- Overall mapping

Presently we are not mapping

Sapling Distribution To promote green belt, tree saplings are distributed to employees on World Environment Day and general public through out year.

Tree Plantations

2540 2500 3350

4500 5425

9000 9400

7000

10500 11500

6500

2500

6890 6550

0

2000

4000

6000

8000

10000

12000

14000

03-04 04-05 05-06 06-07 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17

Number of trees planted

10-Sep-18 63 Green Manufacturing

G

Carbon Emission – Scenario

10-11 11-12 12-13 13-14 14-15 15-16 16-17 17 - 18

CO2 Emission- Kgs/ watch

1.20 1.00 1.41 1.47 1.22 1.16 0.87 0.52

CO2 Emission in 1000Tons

6.53 5.51 6.61 6.04 5.86 5.47 3.29 2.25

1.20

1.00

1.41 1.47

1.22 1.16

0.87

0.52

6.53

5.51

6.61 6.04

5.86 5.47

3.29

2.25

-1

1

3

5

7

9

11

13

15

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

10

00

To

ns

/an

nu

m

Kgs

/ w

atch

Better

10-Sep-18 64 Green Manufacturing

G

“SRISHTI “ good green governance award for the

year 2006 for practicing better EMS .

“Golden Peacock Eco Innovation Award” for the year

2007 for innovating alternate solvent for TCE .

“Golden Peacock Environment Management Award”

for the years 2003, 2006 & 2008 for practicing better

Environmental Management System.

“Greentech Environment Excellence award 2008”

for the outstanding achievement in the

Environmental Management.

“Golden Peacock Eco Innovation Award 2008 “for

design and Process Innovating – KLOTZ micro

precision plastic component development.

Awards & Accolades

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Awards & Accolades

CII - National Award for excellence in energy management for the year 2013 .

CII – National energy management award under excellent energy efficient category for

year 2015

Greentech Environment award under Gold category for the year 2015 , 2016 & 2018

Green Co certification by M/s CII - during 2017 – Silver category

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GreenCo ..Our Journey

Application submitted during April’17 Awareness training by M/s CII Team - May ’17 Submission of PPT’s - July & August ’17 Site assessment - Nov’17

Certified 350 – 449 Points - Level 1

Bronze 450 – 549 Points – Level 2

Silver 550 – 649 Points – Level 3

Gold 650 – 749 Points – Level 4

Platinum ≥ 750 Points – Level 5

Our Score band

GreenCo ..Our Journey

Plaque and Certificate was distributed on 23.11.2017 by -

Mr.Ullash Parlikar - Head ,Green building council - M/s.ACC Limited Dr. Sendas Gupta – Former Member secretary – CPCB Mr.Narayan – VP & Head Sustainability M/s .Wipro Ltd

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