Jubilant Life Sciences Ltd

Nanjangud, Mysore

Excellence in Water Management

TQM FORUM FOR ORGANISATIONAL EXCELLENCE – 2012

Company Profile

Jubilant Group

An India Based Multinational group…

Global position # 1

1. Pyridine and its derivatives

Anti depression & Anti epileptic

2. Carbamazapine (Nanjangud)

3. Oxcarbazepine (Nanjangud)

4. Lamotrigine (Nanjangud) – Central Nervous system

Global Position # 2

5. Citalopram(Nanjangud)–Anti Depressant

6. Respiridone (Nanjangud) – Anti Psychotic

Global Position # 3 – Specialty Chemicals

7. Niacin & Niacinamide

8. Allergenic Extracts

9. Acetaldehyde

10. Vinyl Pyridine Latex

11. Food Polymers

Discovery Preclinical CMC Clinical

Bulk products Manufacturing & their use

Bulk products Manufacturing & their use

Regulatory Approval from Globe

Company Profile- Global Footprint

India Noida, Uttar Pradesh, India Corporate Office & R&D Centres

Gajraula, Uttar Pradesh, India Largest integrated Pyridine & its derivatives facility in the world

Roorkee, Uttarakhand, India US FDA, UK MHRA approved facility for Solid Generic Dosage Forms

Samlaya, Gujarat, India Animal Nutrition Products

Bharuch, Gujarat, India SEZ for Vitamins, Crop Science Chemicals and Pyridine derivatives

Ambernath, Maharashtra, India Exclusive Synthesis of Pyridine derivatives

Nira, Maharashtra, India Life Sciences Chemicals

Bengaluru, Karnataka, India State-of-art Discovery Centre

Nanjangud, Karnataka, India US-FDA, AFSSAPS-France, PMDA-Japan, COFIPRES-Mexico, KFDA-Korea and ANVISA-Brazil approved API manufacturing facility

Kolkata, West Bengal, India Healthcare Services

North America Spokane, Washington, USA Contract Manufacturing Facility of Sterile Injectables & Non-sterile Products and Allergenic Extracts - Approved by USFDA, UK MHRA, PMDA, ANVISA Brazil

Salisbury, Maryland, USA US FDA approved facility for Generic Dosage Forms

Bedminster, New Jersey, USA Clinical Research Centre Marketing Office

Raleigh, North Carolina, USA Clinical Research Centre Marketing Office

Montreal, Quebec, Canada US FDA approved facility for Contract Manufacturing of Sterile Injectables & Non-sterile Products and Radiopharmaceuticals

Europe Merelbeke, Belgium Regulatory & Generic Marketing

Dusseldorf, Germany Jubilant Clinsys Europe Office

China Shanghai, China Marketing Office

Aerial View – Jubilant Nanjangud

ETP

Chairman’s Msg. - Sustainable Development

• Sustainability approach was initiated in 2003. We are continuously working on

the “Triple bottom line” - Environmental, Economic, Safety and Social

development.

• In continuation with our philosophy of Sustainable Development the focus of

new Company remains in the areas of the “Triple bottom line”.

• The Company makes sure to improve the socio-economic environment.

• The Company communicated to employees to use water, paper, steam and

electricity judiciously. Employee awareness on energy conservation was

enhanced through sharing of knowledge and good practices.

• The Company continued various initiatives of energy conservation to mitigate

climate change. The activities for utilization of day light, replacement of

incandescent bulbs with CFL, creation of Environmental awareness to observe

Earth Hour, World Environment Day etc.

Jubilant Policies

Jubilant Policies

Reduction in specific water consumption for last 3 years

   Year Annual Water consumption

Production in tons or any other

unit of production

Specific Water

Consumption

(April - March)

Quantity (m3)Source of

Water

m3/MT

 Industrial

Drinking/Domestic

useIndustrial

2007 – 08 98443 5968 KIADB 308 59.6

2008 – 09 99204 6882 KIADB 347 49.4

2009 – 10 99767 6898 KIADB 328 44.1

2010 – 11 102869 6936 KIADB 421 52.6*

* Excess water due to New Plant equipment clean-up as per GMP practices, performance & calibration trail

Water cost increased from Rs 12 /KL to Rs 24 KL last year

Comparison with Global norms/benchmark data

National

Benchmark ***

International Benchmark ***

CPCB Benchmark ***

Jubilant Benchmark ***

Specific Water Consumption (m3/Ton)

Not Available Not Available 100 - 120 m3/Ton 44-60 m3/ton

Source of information:Guideline for optimum water consumption in Bulk Drugs Manufacturing Industry By CPCB,MOEF –August-2007 Programme Objective Series Probes/117/2007

Jubilant Average water consumption for the Process is in the range of 44 – 60 m3/Ton

2007 – 08 2008 – 09 2009 – 10 2010 – 11 2011-120

50100150200250300350400450500

308347 328

421

500

59.6 49.4 44.1 52.6 44

Production in TonsSpecific water consumption, m3/ton of production

Plant Specific water consumption, m3/ton

Road map or guideline for optimum water consumption in bulk drugs manufacturing industry

Reduction in Industrial Waste water discharge in last 3 years

Year (April-March)

Quantity generated (m3)

Quantity recycled (m3) Quantity discharged (m3)

(m3) % (m3) %

2007 – 08 18206 18206 100Zero Liquid discharge

facility2008 – 09 17053 17053 1002009 – 10 15261 15261 1002010 – 11 20769 20769 100

2007 – 08 2008 – 09 2009 – 10 2010 – 110

5000

10000

15000

20000

25000

0 0 0 0

Qty. Generated in m3 Qty. Recycled in m3 Qty. Discharged

Reduction in Domestic Waste water discharge in last 3 years

Year(April-March)

Quantity generated

(m3)

Quantity recycled (m3) Quantity discharged

(m3)

Waste Water Discharge/Ton

of Product

(m3) % (m3) %2007 – 08 5968 5968 100

Zero Liquid Discharge facility NIL

2008 – 09 6882 6882 1002009 – 10 6898 6898 1002010 – 2011 6936 6936 100

2007 – 08 2008 – 09 2009 – 10 2010 – 110

1000

2000

3000

4000

5000

6000

70005968

6882 6898 6936

0 0 0 0

Qty. Generated in m3 Qty. Recycled in m3 Qty. Discharged in m3

Year Industrial Colony water consumption

Consumption m3

Average employees per day

Percapita consumptio

n per person/day

Consumption m3

No of persons

Per capita consumption/

day2007-08 5968 500 11.93

We don’t have colony2008-09 6882 650 10.52009-10 6898 693 9.92010-11 6936 754 9.2

Per capita Water Consumption

2007-08 2008-09 2009-10 2010-110

100200300400500600700800

500

650 693754

11.9 10.6 9.9 9.2

Avg. Employee per dayPer Captia Domestic water consumption

• By Photo sensing water flush system in Toilet.

• Installation of Press types water tapes.

• Reduction in water consumption by providing overhead tank in place of pressurized water

• Posters.

Monitoring & Reporting SystemsDaily monitoring Report _ MIS

Monitoring & Reporting SystemsDaily monitoring Report _ MIS

Year 2010-2011

Month RO Permeate Recycled to Cooling tower make

Up in KL/Month

Apr-10 2320

May-10 2862

Jun-10 2962

Jul-10 2697

Aug-10 2255

Sep-10 2850

Oct-10 2736

Month RO Permeate Recycled to Cooling tower make Up in

KL/Month

Nov-10 2360

Dec-10 3652

Jan-11 3555

Feb-11 3176

Mar-11 2659

Total 34084

Avg/Day 95

Monitoring & Reporting SystemsMetering & Recording

KIADB main incoming meter

Water meter after treatment Utility Feed inlet meter

Utility Effluent inlet to RO system meter DM Plant outlet meter Log book

10 additional meter was installed in new locations for better monitoring & control on water consumption pattern.

Last 3 yrs Water Conservation Projects

Sl No

Title of Water Saving project implemented

Year of Imple

mentation

Annual Water Savings

Invest. Made

Planned date of

completion

Actual date of completion

m3 Rs. Lakhs Rs. Lakhs

1 Recycling of RO Permeate toCooling tower makeup 2008 22131 2.65 175 2009 Completed and

is on going

2 Rain water Harvesting - Roof Top 2008 7219 - 1.2 2008

Completedand is ongoing,water Recharge pits

3Recycling ofSRP condensateto Scrubber solution makeup

2009 360 0.043 NIL 2009 Completed and is on going

4Utilization of RO permeate or IncineratorScrubber solution preparation

2008 1500 0.18 NIL 2009 Completed and is on going

Last 3 yrs Water Conservation Projects

Sl No

Title of Water Saving project implemented

Year of Implementation

Annual Water

SavingsInvest. Made

Planned date of

completion

Actual date of completion

m3 Rs. Lakhs

Rs. Lakhs

5Implementationof CIP ( Clean In Place) system

2009 5040 11.0 2.5 2009 Completed and is on going

6Water Seepage arresting in Fire Hydrant system

2010 2160 11.0 1.0 2010 Completed and is on going

7 Steam Economy improvement in TEE 2010 1380 48.0 1.0 2010 Completed and

is on going

8 Flash steam recovery at ETP 2010 504 12.0 10 2010 Completed and

is on going

ZERO LIQUID DISCHARGE –ETP

PCTP StripperTEE

FCE

ATFDInorganic cakeBTP

RO Cooling TowerB/d

Concentrate

Effluent from the plant

Equalization & Neutralisation

Clarifloculation

Multiple Effect Evaporator

Sludge from filter pressFiltrate

Biological Treatment Plant

Pressure Sand Filter

Reverse Osmosis Plant

CT Blow down

Sludge

Reject

Permeate

Cooling Tower Makeup

Condensate

Ash to Secure land fill

Stationary Pyrolyser 1, & 2

Drum Pyrolyser 1,2 & 3

Spray Dryer

Cyclone Separator

Venturi Scrubber

Droplet Separator

Stack (50 m)

Treated Gas

Post Combustion Chamber

ATFD + Scrubber

StripperIncinerable Hazardous waste

Liquid Treatment

Solid Treatment

• Zero liquid discharge

• All Solid Wastes Incinerated

• All gases treated to meet prescribed norms

Zero Liquid Discharge

Forced Cir. Evaporator

ZERO LIQUID DISCHARGE –ETP

1) Recycling of RO Permeate to Cooling Tower

Title of Water Saving project implemented

Year of Implemen

tation

Annual Water

Savings FY 2010-11

m3

Recycling of RO Permeate to Cooling tower makeup 2008 34,084

2) Rain Water Harvesting - From Roof Top

3) Flash steam Recovery at Effluent treatment plant

In effluent treatment plant, for concentrating the effluent, it is drying in FCE, ATFD. Steam is a used for evaporation. The condensates is recycled as boiler feed water.

Flash steam generation from these condensate is about 75 kg/hr @ 0.2 bar. This will reduce equivalent make up water addition in boiler.

The annual water consumption reduction by this project is 504 KL.

4) Steam Economy Improvement in TEE

Design / Target : 0.270 kg of steam / Lt of water evaporation

Baseline Steam Economy 0.323 kg of steam / Lt of water evaporation

Present Steam Economy 0.256 kg of steam / Lt of water evaporation

Present water Evaporation 1700 KL/month Steam reduction 1380 tons/yrEquivalent Water reduction 1380 KL/yrAnnual Financial Savings 48.0 Rs Lac

The annual water reduction by this project is 1380 KL.

5) Water Seepage arresting in Fire Hydrant System

Annual Water reduction by Fire Hydrant seepage arresting was 2160 KL. And this also reduce the nallah treatment water generation & cost.

6) EFFLUENT STREAM SEGREGATION - APPROACH

Segregate streams

Characterize streams

Categorize stream

C1 streams (Lean streams)0<COD<10000 ppm0<TDS<5000 ppm

C2 streams (Concentrated streams)10000<COD<80000 ppmTDS>5000 ppm

Out sourcing opportunities

RO/STP/BTP

C3 streams (Highly concentrated )COD>80000 ppm

PCTP

Material balance

Site water balance

Identify / Quantify streams

Streams will technically be reviewed to recover organics/ outsourcing

Controlled reception of effluent through magnetic flowmeter

Agree upon quantities with concerned generators

C1 streams

Lean streams0<COD<10000 ppm0<TDS<5000 ppm

1. Steam condensate2. Wash basin3. Eye wash4. Floor cleaning5. Utility effluent

EFFLUENT CATEGORY

C3 streams

Highly Concentrated COD>80000 ppm

1. Process effluent

C2 streams

Concentrated streams10000<COD<80000 ppmTDS>5000 ppm

1. Process effluent2. Equipment

washing

EFFLUENT PIT CATEGORY

P-2 lean & Conc. Effl. pit P-4 Conc. Effl. pit

7) SEWAGE TREATMENT PLANT – 100KLD

8) Clean In Place (CIP) at, High Pr. Jet cleaning for all process Equipment

8) Clean In Place (CIP) at, High Pr. Jet cleaning for all process Equipment

Annual Water reduction by CIP is 5040 KL and corresponding Effluent load.Financial Benefits is Rs 11.0 Lac.

FY 10-11 - Project Summary

Sl No Title of Water Saving project implemented

Annual Water Savings Invest. Made

m3 Rs. Lakhs Rs. Lakhs

1 Water Seepage arresting in Fire Hydrant system 2160 11.0 1.0

2 Steam Economy improvement in TEE 1380 48.0 1.0

3 Flash steam recovery at ETP 504 12.0 10.0

Total 4,044

Specific planned step for futurity preservation of Environment

1. New Domestic Effluent Treatment Plant

2. Green Chemistry

• Existing 20 KLD STP was expanded to 100 KLD capacity in view with increase in No. of employees.

• Treated water is used in Gardening in place of fresh water.

Specific planned step for futurity preservation of Environment

3. Pressure Swing Absorption

• Removal of Moisture from Solvents • Improving Solvent Recovery • Reduction in VOC.

4. Environmental Friendly Innovative Design of New Plant

Specific planned step for futurity preservation of Environment

5. Improved Effluent Management

6. Installation of New Incinerator for better environment friendly solid disposal.7. Installation of New TEE, FCE, ATFD is under progress for treating the proposed

increasing effluent load.

Stripper

Powder Transfer System (PTS) Installation

Eliminate Powder dust to atmosphere and help in maintaining Healthy Environment

Certificates

OHSAS 18001:2007 ISO 14001:2004

Initiatives taken awareness to Company employees

1. Internal Team meeting & Awareness training

Initiatives taken awareness to Company employees & nearby Community

3. Awareness program to Local community on water conservation at Kallahalli Village

2. Awareness Posters

Initiatives taken awareness to nearby Community

Before Cleaning the drinking water tank at Kallahalli Village

After Cleaning the drinking water tank & facility Upgraded at Kallahalli village

Pure it - Water Filter to Anganawadi centre at

Kallahalli

1. Drinking Water Facility implementation at Korehundi School, Nanjangud

Initiatives taken awareness to nearby Community

2. Water Facility to Kallahalli Village

Targeting anti pollution drives against ground and surface water pollution

Jubilant Life Sciences Ltd (JLSL) took a plantation campaign to plant more trees inside the premises and tree saplings across premises as shown in below

Sri. A.S.Sadashivaiah, Chairman, KSPCB planting the sapling at site

Targeting anti pollution drives against ground and surface water pollution

JLSL took a plantation campaign to plant more trees inside the premises and tree saplings across premises as shown in below

Sri. Mr.Somappa, TAC Member, KSPCB planting the sapling at site

Targeting anti pollution drives against ground and surface water pollution

JLSL took a plantation campaign to plant more trees inside the premises and tree saplings across premises as shown in below

JLSL employees planting saplings at site Crops grown with STP water

Mr. B. Mitra Sr.V.P. (O)receiving Golden Peacock Award 2010 from Dr Ola Ullsten, Former Prime Minister of Sweden and Dr. Madhav Mehra, President, World Council for Corporate Governance at National Liberal Club, London on 29th July, 2010

7th National Award for Excellence in Water Management 2010 organised by CII – Godrej Green Business Centre at CII – Godrej Green Business Centre, Hyderabad

Awards

Awards

CII’s National Award for Excellence in Water Management 2011, 25th November 2011, Jaipur

Description Source of Water* (Kabini River)

Cost of Water (Rs/m3)

Raw Water Supply by KIADB 24/-

Final treated water - 3,040/-

COST OF WATER AS APPLICABLE TO JUBILANT

Thank you