Team Leader : Pradip Sahu Utility Lead Team Members : KV ...
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Team Leader : Pradip Sahu Utility Lead Team Members : KV Satyanarayana: Plant PM Lead
Transcript of Team Leader : Pradip Sahu Utility Lead Team Members : KV ...
Team Leader : Pradip Sahu Utility LeadTeam Members : KV Satyanarayana: Plant PM Lead
Our Purpose & Mission
Purpose
Mission
Empower people to snack right
Lead the future of snacking around the world by offering
the right snack for the right moment made the right way
Our Power Brands
Multi Category Mega Site Expandable To ~300,000 Tons p.a.
PHASE 1
2016
Chocolates
57000MTA
30000MTA Crumb
PHASE 2
20XX
Chocolates
54000MTA
PHASE 3
20XX
Biscuits
45000MTA
PHASE 4
20XX
TBD
PHASE 5
20XX
TBD
3
ENVISAGED MULTI CATEGORY MEGA SITE - MONDELEZ SRICITY
CDM Plain 16 KT
CDM Inclusion 24 KT
Tang – 24 KT
Crumb Atom – 22 KTCrumb TR – 9 KT
PEOPLE SNAPSHOT
Leadership Capability
o Personal resourcefulness
o 80 % coverage for SG 5+ on B@MB and
Powerful Conversations
o Team Effectiveness
o 100 % IL6S Council Team
o PLT workshop to strengthen common
purpose & relationships
Diversity
o Sustained 50 % diversity
o Key infrastructure enablers – Vacuum lifters,
Community Living, Feminine hygiene, Creche
o Well being & engagement programs
o Regular & periodic assessment for impact
through OPM.
SCBPPS* with Phase progression
o Structured accelerated program for
TM’s to transition to leadership roles in
an accelerated manner.
o Benchmarked with sites & SME’s
across Mdlz globally to design best fit
framework for Sricity
*Skill and contribution based progression and pay system
One Vision-CompellingBusiness Need (CBN)
High Performance Work Culture (HPWS)
Manufacturing system Driving Continuos Improvement Mindset ( IL6S)
SITE STRATEGY-LOSS ELIMINATION
START OF THE JOURNEY
2018
2019
2020
Year of Innovation
Year of Validation
Year of Innovation
2017
Year of Optimization
2021
Gold Certified
Site Selection & Planning
Innovation in Design
Material Conservation
Indoor Environmental
Health & Occupational
Hazards
Energy & Water Conservation
Journey Towards Best In Class
ENERGY JOURNEY
Year of BIC
ENERGY CONSUMPTION VS PRODUCTION 2017-2020
31
53
15
00
33
47
87
70
39
44
96
26
22
96
11
30
19
13
40
00
28
45
20
00 49
19
10
00
30
73
10
00
2017 2018 2019 2020
Energy (Kwh) Final Product (kg)
9
Power (kwh) Thermal Energy (kcal)
Energy Management System
100% Engagement
OrganizationalStructure
Daily Data Analysis by focused groups
Monthly Progress Monitoring by Dedicated Site Team
Metering
64 Power Monitors15 Water Meters10 Steam Meters
Personalized Access Control
ENERGY MAPPING
78%
3%
7%
6%6%
C&C
Paddle drier
Tang
De-areator
T-Loss
DAILY LOAD : 48000 KCAL/DAY
5%
8%
3%
2%
22%49%
11%
16K Power (KWH)
LOF Power (KWH)
TANG Power (KWH)
UL power (KWH)
C&M (KWh)
Utility (KWH)Chiller,CDA
Miscillenaeous (KWH)
DAILY LOAD -117522 KWH/Day
SPECIFIC ENERGY CONSUMPTION 2017-2020
0
500000
1000000
1500000
2000000
2500000
3000000
3500000
4000000
JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER
ELECTRICITY CONSUMPTION (KWH) 2017-2020
2017 2018 2019 2020
Reasons for varying in consumption :
1. Production number has got increased YOY. Which is 61 % over last three year.2. Line adding equipment for increasing capacity of Line.3. 14% Increased on Power VS Production increased 61 % over three year.
14%
SPECIFIC THERMAL ENERGY CONSUMPTION 2017-2020
0
500000
1000000
1500000
2000000
2500000
JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER
THERMAL ENERGY (KCAL)2017-2020
2017 2018 2019 2020
Reasons for varying in consumption :
1. Production number has got increased YOY. Which is 61 % over last three year.2. Consumption is varying based on production 3. Flu Gas we are not able to use, due to less load , Which is impacting less recovery.4. Steam distribution loss as pipe size is higher than what we are using currently.
27%
JOURNEY SO FAR AND INTERNAL BENCHMARK
3.5 KL/Ton2018 5.7 GJ/Ton
2019 4.08 GJ/Ton
2020 (YTD) 4.05 GJ/Ton 2 KL/Ton
2.4 KL/Ton
Y-O-Y Reduction
Overall Reduction 44 % 88.1%
16.8 KL/Ton2017 7.2 GJ/Ton
ENERGY BIC : 3 GJ/T
ROAD MAP TO BEST IN CLASS IN MONDELĒZ GLOBALRoad Map
2018 2019 2020 2021 2022
GJ/T 5.7 4.08 4.05 3.3
BIC 3 3
GE (%) 80 85 85 88
Key ProjectsCooling optimization
Heat pump Magnetic Resonators Scale Bio Remover for CT
Desuperheater utilisation
Solar PV Cogged Belts AI pumps for chilling Plant
Lighting Solar Concentrator VFD for Chiller Process Pumps Heat Pump (2)
Paddle Drier SOPT - 4 nos EC fans 2 MW Solar PV
3DTracer Heat Less Vapouriser Flash Steam Recovery System
Compressor PHE Heat Recovery from Compressor
Smart Air Unit 80 % Utilization of Desuperheater
VFD for Coling Fan at Chiller
Elimination of Heater bank from Dehumidifiers
Energy Manager for Compressor
LNG replacement of LPG fuel
20.8% Reduction
14% Reduction
Energy Thermal Energy
2018: YEAR OF INNOVATION
210
130
40
147
110 2
6
2017 YTD Volumes OptimisedCooling
De -Superheater
SolarConcentrator
Solar PV Water ProcessOptimisation
2018 YTDTarget
DVE - $/ton
ENERGY
2018
• ANNUAL COST SAVING (INR): 11,16,000• CAPEX (INR): 30,000• OPEX (INR): NA• PAYBACK (years): 2 Months
Internal Lighting (kWh)
-32%
External lighting (kWh)
-61%
2019: YEAR OF INNOVATION
33% Reduction
15% reduction
Energy
Thermal Energy
YTD 2019 YTD 2019
2.5
10.3
0.75
2.8
12.1
0.8 1.6 0.8 0.2 0.2 1.3 2.4 1.2 0.04 4 0.402468
101214
PROJECTS PLAN 2019 (INR MM)
Actual Target
ENERGY
2019
33% Reduction
Thermal Energy
Energy
33% Reduction
15% reduction
YTD 2020 YTD 2020
2020: YEAR OF INNOVATION
2.19
0.20
1.40
0.16 0.46
0.98
0.55 0.31
0.67
0
0.5
1
1.5
2
2.5
Magneticresonators
Cogged belts EC fans Desuperheater Flash steamrecovery
Energymanager forcompressors
Seal Cooling Rain waterharvesting
VFD for chillingplant process
pumps
Project planned In 2020
Series1 Series2
ENERGY
2020
0
5
10
15
20
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
S/F Ratio & o2 – 2019 Average
Steam to fuel Ratio ( Avg) Flu Gas (o2) %
15 S/F Ratio o2- 8 %
16
.5 17
16
.5
6 6.2
6
M A R A P R I L M A Y
Total Cost for supply & installation
of MR. 200000 INR
Qty of fuel saved per day 132 Kgs
Total fuel saved per year 47520 Kgs
Cost of Fuel Saved per year 2005344 INR
Savings from March 2020 to May
2020 512477 INR
Payback 0.10 Year
Expected fuel savings achieved
through magnetic ressonators 3 %
V BELT DETAILS
FAN MOTORPully Ratio 1 1.6
RPM 8751467 At 50Hz
RPM Ratio 0.59 1
DIA335mm 200mm
COGGED BELT
FAN MOTOR
Pully Ratio 1 1.04
RPM 7901050At35Hz
RPM RATIO 0.74 1
DIA 320 305
Cogged Belts Saving
Parameter Number Units
Avg power consumed per day with existing V Belt & pulley (6
Units)1296 KWH
KWH consumed when replaced with Cogged belt (6 units)
972 KWH
KWH Saved per Day 324 KWH
KWH saved Per Year 106920 KWH
cost saved per year 646866 INR
cost spent for cogged belt supply & Installation 200000 INR
2020: HVAC PROJECT
HVAC PROJECT
Parameter Number UnitsPower Consumption of 16K
AHU per year124320
KWH
KWH cost per year 752136 INRPower consumption with EC+
fan 78120 KWH
Net Power Saving Per year 46200 KWH
Cost saved per year 279510 INRCost Spent for EC+ fans Supply
& installation 575000.0 INR
Payback 2.06 Years
AHU – Blower EC Fans
AHU ECBlue Centrifuge Fan
MakeZECO
Make
ZIEHL -ABEGG
AIR QTY (CFM) 22000 AIR QTY (CFM) 22000
Coil Brine Type EC Fan
FilterEU-4/7
Model
GR50C-ZID.GL.CR
Static Pressure 100 TOTAL QTY 4 NOS
FAN RPM 1445 MOTOR KW 4.02
MOTOR KW 14.8 TOTAL KW 9.3
Amps 33.2 Amps 15.5
VFD CHILLING PLANT PUMPS
Problem Statement :1. Chilled Water Process Pumps : 90KWH each2. Running in Star delta with full 50Hz3. 3888 KWH unit consumption per day
Analysis :1. Power consumption analyzed 2. Flow requirement also verified3. Project Duration : Nov 2019 ( 30 Days)
Savings :1. Currently VFD Connected 2. Process pumps are running in 45Hz with
81KWH3. Power consumption : 3456 KWH/Day4. Savings per Annum : 7.1 Lakhs
FLASH STEAM RECOVERY PROJECT
Flash Steam 3000kgHWS Design 50 M3/HrHWS Actual 16 M3/Hr Steam Requirements 3 TonsFuel Saved /Day 187.5Cost Saved /Day 7875
PROJECT SUMMERY
Year No of Proposals Investments(INR MM) Savings (INR MM)
2017-18 16 10 18.86
2018-19 14 115.9 16.39
2019-2020 15 22.1 11.44
2020-2021 9 55.1 32.59
Sl No Project Details Investments Savings Payback (Year)
1
3DTracer, Cooling
optimization, Deuperheater
Utilization, Lighting reduction 1018.86 2
2Solar PV, Solar Concentrator,
SOPT, Heat Less Vaporiser, 115.916.39 7.2
3Compresser PHE, Smart
Air Unit, VFD at Cooling
Fan, Flash Jet Pump22.1
11.44 2.9
4EC Fans, Magnetic
Resonator, Cogged Belt,
VFD for Chiller pumps.55.1
32.59 2.1
RENEWABLE ENERGY
UTILIZATION OF RENEWABLE ENERGY SOURCES
9000 kwh Renewable energy generation, utilization and 8.1% of Overall Energy
TechnologyType of Energy
Onsite /OffsiteInstalled Capacity (MW)
Generation (Million KWH)
% Of overall Electrical Energy
Solar PV Electrical Onsite 2 MW 0.009 8.1
TechnologyType of Energy
Installed Capacity (Million Kcal)
Usage (Million Kcal)
% Of Overall thermal energy
Solar Concentrator
Thermal 0.175 0.125 71.43
#DoItrightRecycling carton waste to make
sustainable stationery!
Turned into notebooks
That Grow into exotic plantS!
Carton Waste
WASTE UTILIZATION AND MANAGEMENT
WASTE UTILIZATION AND MANAGEMENT
Flash Steam UtilizationEarlier flash steam use to vent out, Which
we have thought to utilize for our hot water skid. which helped us to reduce 3T
STEAM everyday.
Heat extract from return Chilled WaterWe have heat pump, Which takes water from chiller return water line and give lesser temperature water , Where it
reduces load from Chiller.
2017 2018 2019
31.5kT 31.5kT 34.9kT
Mondelez Global Publishes the impact Report (attached) that talks about the GHG
emissions Scope 1, Scope 2 and Scope 3 Disclosures.
•Include Scopes included : Key Raw material , Packaging, manufacturing and others ( Scope
1 , Scope 2 and Scope 3) (Refer attached report)
•Absolute Emissions and Emissions intensity of last three years to be included
Mondelez India did an assessment of the Scope 1, Scope 2 and Limited Scope 3 emission in
2019.
The site uses Natural Gas and Grid Sourced Electricity are the highest contributors to the
emissions. The Grid emission is calculated at 227. kg/GJ CO2 emission
Sricity plant was commissioned in 2016 and ramped up to its capacity over a period of three
years. Hence an increase in emission may be noted.
GHG INVENTORISATION
Target (short term/ long term) for CO2 emission reduction and action plan :
Type of waste 2017 2018 2019 Disposal Method
Production Waste 242 228 433 Animal Feed
Carbon waste 354 507 447 Upcycling/Recycling
Other waste incinerated with Energy recovery 91 93 45
Incinerated with energy recovery
Metal /Plastic waste 47 141 207 Sold to Recycler/Dismantler
•The plan is to target the highest Carbon emission source that is grid electricity and move to Renewable
Energy Sources through Power purchase.
•Natural Gas which is the second highest contributor cannot be switched to Biomass due to regulatory
constraints. Hence energy efficiency initiatives to reduce Natural gas consumption are in place.
•The target is to reduce E2E carbon emissions by 10% 2025.The site has a goal to maximize the
Renewable energy.
•Waste utilization in last three years
The waste disposal hierarchy is followed before discarding any waste ( Reduce, reuse, Upcycle,
Incinerate with energy recovery, Incinerate)
Hazardous waste is disposed as per the regulatory norms.
GREEN PURCHASE POLICY:• There is no Green Purchase policy as it in embedded in the
sustainability goals and referred as Sustainable ingredients ( refer attached report)
• a. Information on Projects implemented : Cocoa Life program in India to sustainably source Cocoa ( without deforestation), 100% RSPO certified palm oil sourcing.
• b. Information on Evaluation done : To help us keep learning and improving, we engage two independent third-parties, Ipsos and FLOCERT, to measure and verify that we are accomplishing what we set out to do.
• c. Information on Investment Benefits achieved: Currently 60% of cocoa is sourced through cocoa life .Cocoa is sold by the farmers in the open market and Mondelez purchases it from them.
ENERGY EFFICIENCY / AWARENESS TRAINING
SMALL GROUP ACTIVITIES (SGA)
SUSTAINABILITY COUNCIL MORALE
• Formation of a Sustainability council which undertakes weekly meeting with-
• Members from all departments
• Reviewing projects
• Identifying and discussing new opportunities
• With the agenda of
• Brainstorming on variousalternatives
• Getting alignement from all stakeholders
• Solve chronic issues which needattention
• Morale is kept high by-
• Holding regular competitions
• Rewarding hard work and right behaviors.
• Strong R&R Program
TEAM WORK & EMPLOYEE INVOLVEMENT & MONITORING
Project Tracking MOMDMS Report1
5
2.5 3.9
2018 2019 2020
CAPEX ( CRS)
1% of total turnover
DIGITAL DISPLAY AT SHOP FLOOR
SKILL MATRIX
LATEST TECHNOLOGY :
ROBOTIC AUTO STORAGE AND RETRIVAL SYSTEM
ROBOTIC PACKING MACHINE IINTEGRATED DIGITAL FACTORY
BUMS SYSTEM EMS SYSTEM CONTROL TOWER
RESULT ACHIEVED
157%
2017 2018 2019
PRODUCTION 19134 28452 49191
1913428452
49191
0
20000
40000
60000PRODUCTION
3112167032008413
35971266
28000000
30000000
32000000
34000000
36000000
38000000
2017 2018 2019
ELECTRICITY
1796077
15235251359366
0
600000
1200000
1800000
2400000
2017 2018 2019
LPG
32%
61%
13%
LONG TERM VISION ON EE
• Fuel reduction plan: LNG as a natural gas , required support on how it is safe to use..
• Required more ideas on reusages of energy ( Thermal )
• Waste recovery : Biogas project for small quantity food waste.
EXTERNAL RECOGNITIONS
Yield achieved for 2018 was 99.02% against target of 9Gold 8.7%
0 TIR on line in 2018
Manufacturing Excellence “Gold Award”
Sustainability 4.0 Award
“CII EHS Excellence ” award & 5 Star rating for demonstrating best HSE Practices across site
“CII Best Energy Saving ideas awards”
Clinched 3rd Position in Southern India
“CII Kaizen awards”
Excellence energy management unit , CII at 2019 Hydrabad,
2018 SUCCESS
Mondelēz India Foods Ltd (Formerly Cadbury India Ltd.)Site : Sricity
KV Satyanarayana – 9160003596 ( [email protected] )Pradip Sahu – 9908706871 ([email protected])
