UNILEVER INDIA EXPORTS LIMITED - Knowledge Platform · UNILEVER INDIA EXPORTS LIMITED Kandla (Gujarat) Unit Profile Kandla Factory is situated in the Special Economic Zone and 9 kms

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First Prize

Consumer Goods Manufacturing

UNILEVER INDIA EXPORTS LIMITED

Kandla (Gujarat)

Unit Profile

Kandla Factory is situated in the Special Economic Zone and 9 kms away from the

port. The factory has been operating since its commissioning from April 1982 for the

past 32 years. It has a site area of 81,000 square meters in the built up area of

41,000 square meters. The Plant started in 1982 with all support from government

for clearance and licenses.

The unit has also worked upon jointly to build ownership by imparting training,

multi-skilling and soft skill development programs to enhance their capability to take

up higher responsibilities.

The Unit is in the proximity of the port and caters to countries in the UAE, Iran,

Singapore, Netherlands, Turkey and is handling more than 300 SKU’s and more than

90 formulations in a year. This factory currently produces various Personal Care

products for exports namely Ponds, Lifebuoy shampoo, Signal, Pepsodent, Close-

up, Aim toothpaste, Fair & Lovely and Dove cream, etc to name a few.

Energy Consumption

Year on year reduction in energy consumption is reflected below -

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Energy Conservation Measures Taken

• Installation of Eco Friendly 5 TR chiller

• Installation of Eco Friendly Screw type Energy

Efficient Chiller 110 TR replacement of

Reciprocating 120 TR chiller

• Installation of Energy Recovery Unit from Air

Compressor

• Installation of Double Stage Water Ring vacuum

Pump for replacement of Single Stage Vacuum

pump

• Condensate Recovery

• Elimination of Steam usage in DM pasteurization Tank by

using Hot water Generator

• Replacement of CFL 2 x 36 W in to LED 1 x 36 W 50

sets

• Installation of Natural Draft Cooling Tower along with

existing induced draft cooling tower

• Apply Heat resistant Insulation for all exposed lines &

Replacement of damaged insulation

• Energy Reduction through various in-house kaizens,

Conservation Campaigns & Environmental Awareness

Program for leakage identifications and mitigations

• Installation of Blow on/off Sensors on packing line to

reduce Compressed Air Consumption

• Rerouting of Steam line, Hot water pipeline & Removal of unwanted steam lines

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Second Prize

Consumer Goods Manufacturing

HINDUSTAN UNILEVER LIMITED

Rajpura (Punjab)

Unit Profile

HUL, Rajpura unit is 35 yrs old and has approx 600 employees working in it. The

factory has two plants serving the categories of Foods and Home Care (Laundry). It

has facilities to manufacture Spray dried detergent powder, Ketchup, Jam, and

Mayonnaise with annual capacity of 90000 metric tons.

Every year, the company takes initiatives in the field of energy saving for power &

fuel consumption based on previous year consumption & available opportunities for

energy conservation. Significant amount is being invested to improve upon energy

efficiency by using innovative & latest technology. Renewable resources are also

being used as much as possible. Under this initiative, Biomass fuel is being used in

place of fossil fuel in our Steam generating Boiler.

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Energy Consumption

Energy Conservation Measures Taken

S. No. Project Description Annual Saving (INR Lakh)

Investment (INR Lakh)

1. Steam elimination in NSD plant 51.94 18

2. Steam generation Efficiency Improvement 40.49 14

3. Online Brix meter 16.35 11

4. VFD for air compressor 8.11 8

5. AHU duct combinations in pulp & sugar and Mayo & Jam area

6.25 3

6. Replacement of inefficient pumps with energy efficient pumps

4.35 4.5

7. Motors replacement with Energy Efficiency

IE 3 motors

4.28 4.5

8. Shifting of condenser of vacuum pans to ground floor (reduction of motor sizing)

3.5 3

9. LED Lights for the street light & pathways 2.2 10

10. Conveyors automation 1.23 1.1

11. Removal of one pump motor 1.1 0.8

Total 139.6 77.9

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Project 1: Steam Elimination in NSD plant

In powder plant NSD slurry is prepared in crutcher with the help of steam to achieve

the temperature of 80-85 degree centigrade. The reaction between sulphonic acid

and caustic is exothermic. The normal drum and paddle type agitator was replaced

with Lightning agitator which has given a better mixing and as a result detergent

slurry achieved the desired temperature without use of steam

Steam Saved : 1320 Tons

Savings (INR) : 51.94 Lakh

Investment : 18 Lakh

Project 2: Steam generation efficiency improvement & reduction in usage

Rajpura factory has oil fired boiler of 8 TPH in 2102 – 13. The steam generation was

11.2 Ts per ton of furnace oil. Unit has taken the various initiatives to improve the

generation efficiency and reduction in usage. Few of them are on line oxygen

monitoring (maintaining – oxygen level – 3.5 – 5%), Condensate recovery PPPPU

unit installed, Derating of boiler from 8 TPH to 3 TPH (Small blower, flexibility in

nozzle size), Online dosing of boiler chemicals etc.

Steam to fuel ratio improvement : 11.7 to 13.1 T/T (11.8 %)

Energy cost saving : Rs 40 Lakh

Investment : Rs 10 Lakh

Project: 3: Online brixmeter

In Jam manufacturing process, Brix (sugar concentration) is checked in QC lab

which takes about 10 - 15 minutes per sample check. During this time steam,

agitator and pumps are on. Therefore online brixmeter installed in the process,

consequently reduction of steam and power consumption

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Energy cost saving : Rs 16.35 Lakh


Project: 4: VFD for the air compressors

Rajpura unit is having air compressors of 10 m3/hr with

loading ~ 70-80% and consuming 55 kW per hour. A VFD

of 75 HP was put on the motor which has given the

saving of 9 kWh per hour.

Annual electrical energy saved : 77760 units

Energy cost saving : Rs 6 Lakh

Investment : Rs 4.5 Lakh

Project 5: Interconnecting of AHU ducts between Pulp, Sugar, Mayonnaise

& Jam manufacturing areas

HVAC is the major source of electric consumption. To reduce the energy

consumption the Unit has carried out the chilled water temperature control system

automation. Interconnection of ducts at two locations also helped in balancing the

air flow consequently saving energy



Investment : 3 Lakh

Project 6 : Replacement of inefficient pumps with Energy efficient pumps

An energy audit was carried out for the pumps in utility

and saving potential evaluated. 5 nos. of pumps were

replaced with Energy efficient pumps with lower

ratings.




Project 7: Normal motors replaced with Energy Efficiency IE 3 motors

Factory had no. of old motors which were energy inefficient and re-winded twice or

more. These motors were identified and replaced with Energy efficient IE3 motors.




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Project 8: Shifting of condenser of Vacuum Pans to ground floor in Jam

manufacturing

The water condenser for the Jam process is located

at height of 6 meter from ground floor. A pump of 30

HP is being used to supply the water to these

condensers irrespective of the nos. of condenser in

operation. These condensers brought down at ground

floor and pump with 3 HP motor provided for

Individual condenser.



Investment : 3 Lakh

Project 8: LED Lights

Normal lights replaced with the LED lights at Shop floor and packing hall and offices.

Total 55 nos. of lights were replaced with the LED lights



Investment : 10 Lakh

Project 10: Conveyors automation

CPD packing hall in Foods plant has various conveyors which are being used for

transfer of semi finished and finished product. These conveyors were running

continuously even when not required. The conveyors were automated with the help

of sensors and interlocks.




Project 11: Removal of pump and motor in utility

The Mayonnaise manufacturing process requires chilled water of 7 °C. For this a

chiller and hot well / cold well pumps were provided. The water circuit was modified

and one pump with motor (10 HP) eliminated from the process.




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UNILEVER INDIA EXPORTS LIMITED - Knowledge Platform · UNILEVER INDIA EXPORTS LIMITED Kandla (Gujarat) Unit Profile Kandla Factory is situated in the Special Economic Zone and 9 kms