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V S Iyer (Sr. VP- Operation) S G Panse (Plant Head) C P Pachpande (Energy Mgr.)
19th National Award for Excellence in Energy Management
Participating Team For…
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– Various Plant Locations
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– Some Of The Plants
Silvassa
Nasik
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About Sinnar Plant
- Established in 2004 , Area – 20,000 Mtr²- Capacity- 8520 MT/Year
Process - Plastic Injection Moulding And ROTO Moulding
Equipment - Wide Range of 600 T to 3000 T Injection
Moulding m/c’s AND Two ROTO Moulding m/c’s.
PRODUCTS – Plastic Furniture ,Crates, Pallets & Waste Bins
& Roto Moulded Road Safety Barrier, Milk Can, Ice Box,
Pallets.
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• Material Handling Equipments…. And Road Safety
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• Crates , Bins , Milk Cans and Pallets
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66118315 7885 8428
0.86
0.73
0.640.60
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
2014-15 2015-16 2016-17 2017-18
SINNAR - Specific Electrical Energy Consumption Trend - YEARLY
Year
ly T
on
nag
e
Yearly Unit/Kg Trend
Un
it/K
g
11
666 703
1051
1317
9570
115318274 8350
0
2000
4000
6000
8000
10000
12000
14000
0
200
400
600
800
1000
1200
1400
2014-15 2015-16 2016-17 2017-18
SINNAR - Specific Energy Consumption Trend LPG for ROTO - YEARLY
Year
ly T
on
nag
e
Yearly Tonnage Vs SEC KJ/Kg Trend
KJ/
Kg
2014-15
2015-16
2016-17
2017-18
1 Diesel m/c
Added 1 More Diesel m/c
Convert 1 to LPG
Replaced 2nd with LPG
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Title of ProjectInitiated in Year
YEARLY SAVINGS
Investment (Lakh INR)
Payback (months)Electrical
(Lakh kWh)
Cost(Lakh INR)
Reducing SEC with Gear Motor & VFD installation in SIMD-1,2 &12 m/c
2015-16 10.20 83 98 14
Cooling tower Submercible Pump replaced by Mono block 5 star Pumps
2015-16 0.32 3 1 4
Unit/Kg reduction in Grinding m/c by Staggered Rotor Installation
2015-16 0.20 2 1 6
Projects with ZERO INVESTMENT
Reduction in SEC by optimisation of machine cycle time in SIMD-13
2015-16 1.26 9.03 0
Reduction in SEC by optimisation of machine cycle time in SIMD-12
2015-16 2.8 21.75 0
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Title of ProjectInitiated in Year
YEARLY SAVINGS
Investment (Lakh INR)
Payback (months)Electrical
(Lakh kWh)
Cost(Lakh INR)
Reciprocating AIR Compressor replaced with Energy efficient Screw type air
compressor2016-17 0.17 1 3 23
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Title of ProjectInitiated in
Year
YEARLY SAVINGSInvestment
(Lakh INR)
Payback
(Years)Electrical
(Lakh kWh)
Cost
(Lakh INR)
Installation of Servo Injection Molding m/c 2017-18 14.47 109 616 5.7
Installation of Screw Chiller -63 TR 2017-18 1.87 13 22 1.7
Installation of Rooftop SOLAR - 400KW 2017-18 5.74 43 225 5.2
Projects with ZERO INVESTMENT Kwh Saved Rs.Saved
Cooling Tower Fan Blade Angle Setting 2017-18 42048 315360 0 0
Water Saving
Lac LtrRs.Saving
Cooling Tower Fan Blade Angle Setting 2017-18 22 59720 0 0
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Title of ProjectInitiated in
Year
YEARLY SAVINGSInvestment (Lakh INR)
Payback (Years)
Electrical (Lakh kWh)
Cost(Lakh INR)
Installation of Screw Chiller -63 TR 2017-18 1.87 13 22 1.7
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Title of ProjectInitiated in
Year
YEARLY SAVINGSInvestment (Lakh INR)
Payback (Years)
Electrical (Lakh kWh)
Cost(Lakh INR)
Installation of Rooftop SOLAR - 400KW 2017-18 5.74 43 225 5.2
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Renewable Energy…Solar Power Generation ....
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Title of ProjectInitiated in
Year
YEARLY SAVINGS
Investment
(Lakh INR)
Payback
(Years)Electrical
(Lakh kWh)
Cost
(Lakh INR)
Projects with ZERO INVESTMENT Kwh Saved Rs.Saved
Cooling Tower Fan Blade Angle Setting 2017-18 42048 315360 0 0
Water Saving
Lac LtrRs.Saving
Cooling Tower Fan Blade Angle Setting 2017-18 22 59720 0 0
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Renewable Energy – Generation Lac KWh
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One Tree Absorbs 22 Kg CO² in a year.
6914
550
1246
2071
3047
0
1000
2000
3000
4000
5000
6000
7000
8000
Cumulative 2014-15 2015-16 2016-17 2017-18
Absorbtion of CO2 – in Tons
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1. Used PEPSI-COKE Crates purchased from OEMs/Bottling plants for
Recycling with Mutual Understanding.
2. New Crates are Supplied to Nearby Bottlers, and exchanged with Old ones
with lesser processing cost.
PEPSI-COKE Crates Recycling
- 2017-18Qty
Old Used Pepsi-Coke Crates
Collected from OEM/Bottelers700 Ton
Finally Actual Cost Saved 485 Lacs
CO² Emmision Saved in Tons 159 Tons
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Title of ProjectInitiated in
Year
YEARLY SAVINGSInvestment (Lakh INR)
Payback (Years)
Electrical (Lakh kWh)
Cost(Lakh INR)
Transportation 2017-18 14.47 109 616 5.7
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Increasing Length of Truck Body
within norms And Rearranging
Stacks, Helped …Pune to Sinnar Transport BEFORE AFTER
No of Pallets in Truck 180 220
No of Trucks for 1 Lac Pallets 568 464
Nos Of Trips Saved in 2017-18 104
Rs. Saved in Lacs 4.95
CO² Emmision Saved in Tons 8.89
Sinnar To Pimpalgaon Transport BEFORE AFTER
No of Crates in Truck 850 900
No of Trucks for 1 Lac Crates 117 111
Nos Of Trips Saved in Year for 40Lac 240
Rs. Saved in Lacs 5.76
CO² Emmision Saved in Tons 12.4
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Team work, Employee Involvement & Monitoring
1.Daily monitoring system – DIS Report
1 3 4 5 3 4 5 3 4 5 7 8 9 10 11 12
DATE SUMMERY (IMD) SUMMERY (Roto)SUMMERY (Overall
IMD+Roto+Utility) (0.79)
Main meter
Reading
SIMD 1A (MGN-660T)
(Base Line- 0.76)
TOTAL IMD
TONNAGE
Total Units
(IMD) (kwh)
Unit/Kg
IMD
TOTAL Roto
TONNAGE
Total Units
(Roto)(kwh)
Unit/Kg
Roto
TOTAL
IMD+Roto
TONNAGE
Total Units
(IMD+Roto+
Light+utility)
(kwh)
Unit/Kg
IMD+Roto
+Utility
Meter
Reading
Diff.Units
(Kwh)
Meter
Reading
Diff.Units
(Kwh)
Total Wt.in
Kg Unit/Kg
30-Jun-2018 2078747 200913
1-Jul-2018 31545 18145 0.58 2262 860 0.38 33807 21413 0.632080014
19005 202593 1680 3088 0.54
2-Jul-2018 31815 18615 0.59 2746 930 0.34 34561 21588 0.622081317
19545 204312 1719 3081 0.56
3-Jul-2018 26797 14650 0.55 2230 800 0.36 29027 18480 0.642082347
15450 205965 1653 2971 0.56
4-Jul-2018 25240 14925 0.59 2770 780 0.28 28010 17629 0.632083394
15705 207372 1407 2447 0.57
5-Jul-2018 25233 16445 0.65 3129 880 0.28 28362 18826 0.662084549
17325 208365 993 1273 0.78
6-Jul-2018 23280 15680 0.67 2958 880 0.30 26238 18350 0.702085653
16560 209580 1215 1574 0.77
7-Jul-2018 21300 14275 0.67 2617 770 0.29 23917 16214 0.682086656
15045 210767 1187 1560 0.76
8-Jul-2018 23171 14925 0.64 3479 960 0.28 26650 17885 0.67 2087715 15885 211724 957 1146 0.84
9-Jul-2018 14411 10690 0.74 2885 890 0.31 17296 12552 0.732088487
11580 212588 864 1243 0.70
10-Jul-2018 21884 14885 0.68 2929 850 0.29 24813 16695 0.672089536
15735 213631 1043 1860 0.56
11-Jul-2018 17897 14685 0.82 2675 900 0.34 20572 16362 0.802090575
15585 214765 1134 1947 0.58
2. Qtrly Review meetings are Chaired by Plant Head & MRR.
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Team work, Employee Involvement & Monitoring
( in Lacs )
Capex Summery in Lacs Rs. PON HOS SIN VAS Total
2017-18 - CAPEX
1 Plant and Machinery 37.45 486.90 629.8 207.10 1361.3
2 Factory Equipment-Tools 2.00 0.90 0.3 0.00 3.2
3 Capital Spares 16.8 120 112.1 31 280.1
4 Energy saving 453 679 454.0 453 2039.0
5 Computers 1.67 1.50 1.7 11.04 15.9
6 Vehicles 1.50 18.00 19.5
7 Imports - Capital Spares 659 86.0 745.0
Total--> 511 1949 1284 720 4464
OPEX
8 Factory building 61.0 12.26 1.5 26.55 101.3
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PROJECT : THEME : QMS
MONTH : DEPT : IMD TR
Initiator Team Member Team Member Team Member Team Member Team Member
Mr. Sanjay Mhasalkar Mr.Ritesh Ambekar Mr.Ravi Chaudhary Mr.Mahesh Tayde Mr.Nitin Barate Mr.Tejas Sonawane
V 30 WINNERS SERIES 2017Pallet Rod Insert Machine
March: 2018
BEFORE AFTER
NKL SINNAR
PAIN AFTER ACTION GAIN1. Manual rod inserted in pallet.
2. Taking time to insert rod in pallet.
3. 2-4 manpower involve in rod insertion.
4.Chance of pallet damage in manual
inserting rod in pallet.
1. Make Hydraulic press rod insert machine.
2. Remove manual rod insert practice.
1. Save man power to insert rod in pallet.
2. Fast pallet formation.
3. Reduce the risk of pallet damage in
manual rod inserting.
4. Time saving and full automation
machine.
5. Projects implemented by V-30 Winner- Workers and Supervisor level
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Implementation of ISO 50001/Green Co
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ISO:9001Manufacturing
Excellence AwardISO:14001
ISO:50001
OHSAS:18001
National Energy Conservation AwardISO:50001
Any other awards, acknowledgement - Major achievements etc
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