Second Prize

Food Processing

PERFETTI VAN MELLE INDIA PVT. LTD

Manesar Plant, Gurgaon (Haryana)

Unit Profile
"Perfetti Van Melle India Pvt. Ltd.", a fully owned subsidiary of the global conglomerate Perfetti Van Melle, headquartered in Lainate, Italy, started its Indian operations in 1994. The company today enjoys close to 30% market share, thus making them one of the leading players in the confectionery industry in India today. Perfetti Van Melle entered the Indian market in 1994 by offering its first brand Center Fresh, followed by Big Babol and Alpenliebe in 1995. The other brands like Chlor.mint, Mentos, Fruittella, Cofitos, Happydent and Marbles followed subsequently. PVMI enjoys a huge brand recall among its consumers which form a total estimated market size of Rs.3000 cr.

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Perfetti Van Melle India has more than 15 brands under its umbrella, all of which have been launched after considerable market research and insight so as to adapt to the likes and preferences of the consumers. The climatic conditions of the Indian geographical region have been kept under consideration for product composition and long shelf life. The PVMI manufacturing units in India are located in Gurgaon and Chennai with another plant commissioned at Rudrapur, Uttarankhand in 2007. The Indian subsidiary also takes care of the development of South Asian markets and exports to other Asian countries. The Manufacturing processes of Perfetti Van Melle India Private Limited are carried out in the three manufacturing locations (Manesar-Gurgaon Plant, Chennai Plant & Rudrapur Plant) with specific product ranges.

Energy Consumption

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Energy Conservation Action & Results (Projects Implemented During the Year 2011-12)

Examples of Energy Conservation Initiatives

1. Relocation Of 170 TR Chiller along with Pumps with modification of condenser & chilled water piping To Improve Chilled Water System Efficiency: Description Of The Energy Conservation Measure: In process air-conditioning system (Section - II), three chillers (227 TR + 250 TR + 150 TR) are installed and located at separate locations (Phase wise installation). Due to complicated chilled/condenser water piping network, all three chiller running at 50 % partial loading with full power consumption along with other accessories. These chillers were running on less efficiency and not getting properly loading (Short circuit of chilled water was going-on in main header of chilled water line). Detail study was carried out along with load management, modification in chilled water piping and positioning at same location (Relocation of chiller & optimum pipe line sizing and route modification) carried out.

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Now only two chillers (227 TR + 250 TR) are running on full/desire load and 01 No. chiller (170 TR) is now as standby and subsequent energy saving.

BEFORE :- Electrical Load = 522.3 Kw , Electricity Consumption = 3,008,448 KWh/Year After :- Electrical Load = 394.5 Kw , Electricity Consumption = 2,272,320 kWh/ Year Electricity Saving = 736,128 KWh / Year 2. Improvement in steam condensate recovery from 20 % to 40 %.

In process using lots of steam for process heating direct / indirect and condensate generate. Earlier 20 % condensate recovery was taking place i.e. in boiler 80 % fresh water used for feed water purpose. System for condensate recovery installed in cooker area and increased upto 40%. i.e. now in boiler plant is using 60 % raw/fresh water for feed water purpose. Resulting into higher feed water temperature helping to save furnace oil consumption in boiler. BEFORE Total Furnace Consumption =204,000Ltr/Year After Total Furnace Consumption = 153,000 Ltr/Year Furnace Oil Saving = 51,000Ltr / Year

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Energy Management Policy:

At PVMI, it is unit constant endeavor to reduce energy consumption / ton of production so as to be very cost effective in the highly price sensitive market and also help to control CO2 emission to prevent environment. This is made possible by: Internal and external energy audits are being conducted on regular basis. Creating the awareness of energy conservation among the employees and encouraging by rewarding the key initiatives taken by them. Critically monitoring various data on daily basis and taking instant corrective steps in case of any major deviation. By setting a standard of reduction in energy consumption by minimum 5% years over year. Initiating investment proposals to use renewable resource; Up-gradation of processes and equipments with latest technology.

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Certificate of Merit

Food Processing

JAIN IRRIGATION SYSTEMS LIMITED

Food Park, Jalgaon (Maharshtra)

Unit Profile
Jain irrigation systems limited (JISL) is transnational organization headquartered at Jalgaon (MS), India. It manufactures a range of products in diverse fields which nevertheless focused on its main stakeholder; the farmer. JISL's entire gamut of activities is centered on and around farmer, farm & farming. It's mapping of various categories of products & services demonstrate this effectively. 1. 2. 3. Hi-Tech Agri Products & Services Agri Processed Products Natural resources Conservation Products

The food division was established in year 1996. The division has two main businesses namely dehydrated Onion and vegetable and fruits processing. The dehydrated Onion business account for more than 50 % share of country's export of dehydrated onion & vegetables and company is number Three onion and vegetable dehydrator in the World. Also, company process fruits like Mango, Banana, Guava, Pomegranate, Tomato and Papaya. For fruit processing the organization account more than 35 % of the Mangoes processed in India and is number one Mango processor in the World.

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The food division constitutes 15 % of the company's revenue, with compounded annual growth of 25%. The present turnover of the food division is INR 520 Cr. Food division has six manufacturing plants and employs about 1200 associates across the World. The Food Park, Jalgaon unit has capacity to handle 350 MT onion & vegetables/ day and 850 fruits/day. The present turnover of unit is INR 350 Cr.

Energy Consumption
The Main sources of energy in plant are fuels and electricity from grid. Following are sources of electrical as well as thermal energy in plant. Electricity from Gird Captive 1.7 MW Biogas power plants Coal - input in boiler for steam generation LPG- onion frying Purpose Diesel- used in DG sets for electricity generation & forklift etc. The total consumption of energy of applying unit is 20763 MTOE. The electricity is supplied from MSCDCL. Fuels are major sources of energy in plant i.e. almost 85 % energy requirement met by fuels. Main fuels used in plant are coal, diesel, LPG out of which coal is dominant fuel. The following is the energy consumption & Specific energy consumption Scenario of applying unit.

Energy conservation measures implemented during FY 11-12

Project 1. Installation of 7 TPH Biomass fired Boiler This 7 TPH biomass fired boiler used other non digestible waste generated during processing such as mango stone etc. and purchased briquettes. Almost 15 % of input biomass is purchased remaining 85% is from mango stone i.e. waste generated in mango processing operation in plant. From this project almost 20 % reduction in coal consumption was achieved.

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Total Investment, INR 55 lakh. Total amount saved/year INR 211 lakh. Project 2. Conversion of Dehumidifier condenser from air cooling to water cooled Earlier dehumidifier in onion division is air cooled. The unit has converted air cooled condenser to water cooled. It has resulted into uniform cooling and also reduction in compressor pressure. Total Investment, INR 7 lakh. Total amount saved/year INR 14 lakh. Dehumidifier condenser Picture before modification

Picture after modification

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Project 3. Energy Efficient lighting project Unit has replaced HPMV lights of 290 watt by CFL light of 144 watt resulting into saving of 30660 kWh /annum. Total Investment, INR 1.65 lakh. Total amount saved/year INR 2.3 lakh.

Energy efficient lighting. Project 4. Installation of Turbo Ventilators on roof. Earlier total 5 exhaust fan of 5.5kW rating are used. Now 40 turbo ventilators of are used for ventilation. Total Investment, INR 6 lakh. Total amount saved/year INR 7.8 lakh Turbo Ventilators on roof

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Project 5. Waste Heat recovery from 1.68 MW biogas power project In 1.68 MW Biogas power project, unit has installed WHRB for steam generation and 350 TR vapor absorption chiller operating on steam & 150 TR vapor absorption chiller is on hot water. Amount of energy saved is 10.69 lakh kWh/annum. Total Investment, INR 100 lakh. Total amount saved/year INR 80 lakh. Project 6. Installed Flash steam Recovery system In dryer section of onion dehydration unit, organization has recovered the flash steam by installing the heat exchanger. Through this project implementation, unit is able to recovered 450 kg/hr flash steam. This recovered flash steam is used to heat the air through which unit is able to reduce its steam consumption. Also due to condensate recovery unit is able to save DM water which is used in boiler. Total Investment, INR 15 lakh. Total amount saved/year INR 51 lakh. Project 7. Installation light pipe for available day light utilization This project initiates to reduce 33% lighting load in DHO plant by utilizing naturally available daylight. The transparent silicon sheet with aluminum reflectors numbers is installed. Total Investment, INR 7.5 lakh. Total amount saved/year INR 1.98 lakh.

Picture before modification

Picture after modification

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Light pipe installation Project 8. Modification for increasing production capacity of drying line 3 In existing dryer of capacity 7 MT unit has done some design modification and increased the dryer capacity to 10 MT. This improves dryer productivity and resulted into energy saving. Total Investment, INR 175 lakh. Total amount saved/year INR 35 lakh.

Ongoing ENCON projects Improving performance of various refrigeration compressors Improving performance of vapour absorption machine Improving performance various cooling & chilled water/brine pumps Improving performance various refrigeration systems for the cold storage Optimize heat recovery from flash steam of onion dryer Optimizing performance of onion dryer by partial recirculation of exhaust air Installation of 2 MW solar PV power project on roof top of manufacturing plant. Capacity enhancement biogas project 8.5 MW solar power project

Energy Management Policy

Jain Irrigation systems Ltd, the associates and management are committed to utilize the Energy as a vital resource rationally and efficiently. Company will do every attempt in its daily endeavor to enhance innovative and creative ideas for driving & aiming at energy conservation. Company plan to achieve the above dogma within the framework of sustainable business and environment by : Promoting awareness on the significance of energy conservation among all associates of the Jain Group & its stakeholders at large. Optimizing energy utilization through adoption of best available technology, effective operation, understanding for timely maintenance and periodic review of company practices. Supporting scientific research & technological development to deliver ecofriendly and cost effective sources of renewable energy.

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Integrating energy management vis-a-vis business management by establishing performance driven goals. Carrying out regular audits and periodic refresher training of employees to promote sustainable drive for energy conservation as a work culture across the entire business functions. Continuously benchmarking with superior norms of company energy efficiency and energy productivity. ... ...... . Company believe in "Energy Saved is Energy Generated"

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