Energy Saving
Content
First Prize
Textile
WELSPUN INDIA LIMITED
Vapi, Distt. Valsad (Gujarat)
Unit Profile
Welspun India Limited (WIL) is the Flagship company of Welspun Group with an enterprise value of U.S. $ 3 billion. WIL is ISO 9001:2000, 14001 and SA 8000 certified company. WIL is a composite textile mill producing Cotton Yarn, Terry Towels and Rugs for international market. Welspun India Ltd. is one of the largest Home Textiles producers in Asia and amongst the top 4 producers of Terry Towels in the world. WIL is located at village Morai in Valsad district, Gujarat State. WIL annual sales turnover for year 2009-2010 was Rs. 681.881 crores.
Energy Consumption
The continuous implementation of various energy conservation measures being ongoing practice, there is steady decline of specific energy consumption. Last three years specific energy consumption figure are shown below, which depicts continual reduction in specific energy consumption over last two years due to plant’s sustained efforts with the implementation of various energy conservation measures and ideas to increase efficiency of equipments.
307
Power Consumption Vs Production (kWh/Mt)
4000.00
3000.00
2665.00
2538.66
2390.00
2000.00
1000.00
0.00 Ration Kwh/MT
2007-08 2665.00
2008-09 2538.66
2009-10 2390.00
Energy Conservation Measures
Major Projects Implemented for Energy conservation during the Year 2009-2010
1. Power Saving on Refrigerent Air Dryers on ZH - 10000 Compressor
Replaced 2 nos electrically heated air dryers with 2 Nos Refrigerant Air Dryer on Compressor ZH-10000 Power saved Cost saved Investment = 4738 kWh / day = Rs 74.08 Lakhs/Annum = Rs 34.12 Lakhs, Pay back period = 3 Months
308
2. Chilled Water generation from Waste Exhaust Gas, Total Chilled water generation = 16490 TR /Day
Power Saved Gas equivalent of power saved = 11543 kWh / Day = 2850 SCM / Day
VAC Installed on Exhaust of Gas DG Set to recover waste Heat
3. Energy Saving through Condensate Water Recovery
Condensate water recovery = 419000 Ltr / Day. Gas equivalent of energy saved = 2815 SCM / Day
Condensate Recovery System
309
4. Power Saving on Autoconer
Autoconer 338 suction fan drive motors up gradation with negative pressure sensor Power saved Cost saved Investment Pay back period = = = = 384 kWh / day Rs 6.0 Lakhs/Annum Rs 2.95 Lakhs 2.2 Months
VFD provided on Auto Conner waste removal system to work on set pressure
5. Power Saving on Pumping Station
Pump House: Installed closed loop VFD based pumping system for energy reduction Power saved Cost saved = 282 kWh / day = Rs 4.4 Lakhs / Annum.
Provided Pressure feedback on VFD to maximum utilization of pumping station as per Process needs with Energy saving aspects.
Pumps
Drive Panel to Maintain Set Pressure
310
Energy Conservation Policy
We, at Welspun are committed to adopt energy conservation measures in all our processes, activities, products and services. We shall strive to improve the energy consumption. We are committed to optimally utilise the various forms of energy in a cost - effective manner for conservation of precious energy resources. We shall seek to achieve our energy conservation objectives by continuing to improve on the efficiency of our machines, processes, infrastructure and Communication & Information systems. We shall invest in good energy management & energy efficient technologies as they become available. We will also seek to reduce our carbon emissions by investing in low carbon energy options such as renewable energy etc. where-ever possible in line to our commitment towards use of Green Technologies for a safe and clean future.
Environmental Policy
We at Welspun India Ltd., manufacturing cotton yarn, terry towels and toweling fabrics, commit ourselves to continual and sustainable improvement of environmental management of all our activities and products. We shall strive to meet the applicable environmental legislation, regulation and other legal requirements. We commit to set environmental objectives and targets and implement environmental programs to mitigate environmental impacts of our activities. We shall continue to improve our environmental performance through: Optimizing use of natural resources, electrical energy, fuel, water & chemicals. Encourage recycling of unavoidable wastage Training employees for environmental responsibilities Providing safe working environment to produce safe and legal products
311
Second Prize
Textile
RAYMOND LIMITED
Tal. Pardi, Distt. Valsad (Gujarat)
Unit Profile
Raymond Limited under the leadership of JK Group is undoubtedly Number One in the Indian Textile Industry. It comprises of four units. Vapi unit established in 2006 in Khadki village is around 28 km south of the district headquarter city of Valsad, it is surrounded by Union Territories of Daman on the west and by Dadra and Nagar Haveli on the east. The location advantages of Raymond Textile Unit at Vapi are: Situated on NH # 8 and near to Industrial Hub Proximity to Mumbai / Thane The plant was commissioned in THREE phases. Ist phase was commissioned on 30th March, 2006. IInd phase was commissioned on 17th January,2007 and the IIIrd phase was commissioned on 5th March,2009. Currently, the unit is engaged in manufacturing of Premium Worsted Suiting Fabric, and is equipped with State of the art technology with Hi-tech machineries viz. Warping equipment from Switzerland, Weaving machines from Belgium, Finishing machines, Automatic drawing-in and other machines from Italy to produce 14 million meter fabric / annum.
312
Energy Consumption
Consumption profile for the last 3 years
Energy Conservation Commitment, Policy and Set-Up
Raymond Ltd. (Textile Division), Vapi involved in the production of high quality Polyester Wool and Polyester Viscose blended fabric, are committed to demonstrate excellence in Energy Management Performance on a continual basis.
Energy Conservation Plans and Targets for the year 2010-11
Implementation of Drives in Air Washer Towers. 4 nos. of 37KW VFD 2 nos. 30KW VFD 2 nos. 22KW VFD 1 nos. 11KW VFD
Energy Conservation Measures Implemented in 2009-10
Energy Conservation Achievements
313
314
315
316
Environment and Safety
The Plant has been recommended for ISO 14001:2004 & OHSAS 18001:2008 Certification The World Environment day, Safety Day and the Energy Conservation Day are celebrated with full enthusiasm without fail every year. The Plant have identified major accident hazards and taken adequate step for Prevention and Control and provided information, training, and equipment to the persons working at the site. Company Management encouraging personnel to use protective equipment like ear plugs, safety goggles, safety shoes etc.
317
Second Prize
Textile
BOMBAY RAYON FASHIONS LIMITED YARN DYEING
Doddaballa Pura, Bangalore (Karnataka)
Unit Profile
Bombay Rayon Fashions Limited - Bangalore unit is a Composite unit of Bombay Rayon group of companies. This unit was established in the year of 2006-07 with 3.5 tons capacity of yarn dyeing, 104 looms with the capacity of 30000 mtrs/day, and wet processing 1.16 lakhs mtrs/day.
The Bombay Rayon group comes into existence in 1986. The commencement of garment division of the group begin in 2001. The group sets up 7-garment manufacturing facilities in Bangalore with 7000 machines. Presently the Bombay Rayon Fashions Limited, manufacturing the fabric quantity of 90 million meters/ annum, and garment manufacturing facilities of 40 million garments/annum with in house laundry, printing, embroidery. Total of 35000 employees were employed in entire group. Its turn over for the year 2008-09 was USD350 million and for the year 2009-10 USD425 million.
318
Details of actual Consumption / production for the period 20082009 & 2009 – 2010 Weaving
Period 2008-09 2009-10 Actual Production in tones 1860.919 2087.729 Actual Coal consumption in tones 2056.60 1834.00
Yarn Dyeing
Period Production in tones 977.903 1076.808 Actual coal consumption in tones 3290.60 2934.43 Actual power consumption in kWh 3297629 3548403
2008-09 2009-10
Energy Conservation: Saving Details Weaving
Sl. No. Period Fabric prodn. in Tonnes Coal consumed in tonnes Coal in tones / tonne of fabric Coal Saving in tones / tonne of fabric 0.23 Cost % Saving saving in lakh Rs. For the period 2009 -2010 20.65 21%
1 2
2008 - 2009 2009 - 2010
1860.918 2087.729
2056 1834
1.10483105 0.87846656
Fuel saving for steam generation in tones [Coal] = 480.18 tons
1. 2. Savings achieved due to fuel additive used for increasing the fuel efficiency. Grouping of similar items for running the warp sheet in sizing machine.
Yarn Dyeing -Power saving
Sl. No. Period Dyed Power Yarn prodn. consumed in Tonnes in kWh Power in kWh / tonne of dyed Yarn Power saving in kWh / tonne of Dyed Yarn 76.84 Cost % Saving saving in lakh Rs. For the period 2009 -2010 4.23 7.14%
1 2
2008 - 2009 2009 - 2010
977.903 1076.808
3297629 3548403
3372.14 3295.30
319
1. 2.
Operating time reduced due to optimization of process sequence Optimization of capacity utilization
Yarn Dyeing -Coal saving
Sl. No. Period Dyed Coal Yarn prodn. consumed in Tonnes in tonnes Coal in tones / tonne of Dyed Yarn Coal Saving in tones / tonne of Dyed Yarn 0.63 Cost % Saving saving in lakh Rs. For the period 2009 -2010 29.17 18.75%
1 2
2008 - 2009 2009 - 2010
977.903 1076.808
3290.6 2934.43
3.36 2.73
1. 2. 3.
Savings achieved due to fuel additive used for increasing the fuel efficiency. Operating time reduced due to optimization of process sequence Optimization of capacity utilization
Integrated Policy for SA 8000, ISO 14001 & ISO 9001
We at BOMBAY RAYON FASHIONS LIMITED are committed to delight our external & internal stakeholders by integrating our initiatives on Quality, Environment and Social Accountability. We shall realize this commitment through: Manufacture & supply of high quality Fabrics by employing quality, environmental & social accountability practices compliant with relevant standards. Compliance to applicable statutory, regulatory and industry codes of conduct including international standards & instruments. Continual improvement of organisation’s performance through consistent monitoring & review of policy. Ensuring of dissemination & adoption of good quality. Environmental & social accountability practices among suppliers. Conservation of resources through reduction of waste, recycling and prevention of pollution. Continually improve the effectiveness of Quality, environmental and social accountability management systems.
320
Certificate of Merit
Textile
RAYMOND LIMITED
Jalgaon (Maharashtra)
Unit Profile
Incorporated in 1925, Raymond is the leading, integrated producer of worsted suiting fabric in the world, with a capacity of producing 33 million meters of wool & wool-blended fabrics. A pioneer in the textile and men's apparel business, in India, with a turnover of over USD 600 Million, The Group has six, state-of -the art textile plants and four garmenting factories, in India and Europe. The Raymond Group has already marked its presence in the global arena with partnerships with leading European manufacturers of carded woolens, fine shirting fabrics and specialty Denim. In addition, the Group has business interests in readymade garments, designer wear, Cosmetics & toiletries, engineering files and tools, prophylactics and air charter operations. Moving up the value chain. Raymond Ltd Jalgaon division is one of the 4 Textile units established in year 1979 with manufacturing capacity of 54 lakh meters per annum of worsted suiting. Worsted division manufacturing Worsted Suiting fabric with polyester-wool and polyester-viscose blends. Turnover of Jalgaon unit was Rs 7277 lakh for previous year. Raymond Ltd. Jalgaon is ISO9001, 14001 and OHSAS certified company.
Energy Consumption
Year Electrical Energy Consumption Electrical Energy Savings Achieved Lakh Rs./ annum % Savings achieved/ Energy Cost of Prev. year (vi)/(ii)x100 4.81% 6.14%
Total Energy Specific % Reduction Lakh Electrical Cost Energy in Specific kWh / Energy (Rs. Lakhs/ Consumption Energy annum Consumption year) kWh / Consumption kWh/annum tonne over 08-09 (i) (ii) (iii) (iv) (v) 2008-09 2009-10 117.45 112.10 520.84 496.60 8881.11 8234.36 ---7.28% 5.66 6.86
(vi) 25.07 30.51
321
Specific Electrical Energy Consuption
9000 8800
KWH/000pick
8600 8400 8200 8000 7800 2008-2009 2009-2010
8881.11 8234.36
Year
It is evident from above graph and table that specific electrical energy consumption of Raymond unit is showing reducing trend in last two years as a result of continuous efforts in the direction of energy conservation.
Energy Conservation Achievements for the year 2009-10 1) Optimum Utilization of A.C. Plant Capacities by installation of VFD’s for blowers & pumps
Project background: - It was observed that 7 No. of A.C. plants are running full capacities in winter season also when it is not required due to favorable atmospheric conditions. Unit could either run A.C. Plants or shut down them completely. Variation in speed of blowers as per requirement was not possible as there were no drive control for speed variation to cope up the demand and save energy. To overcome this obstruction unit decided to install Variable Frequency Drives for all 10 No. of Air Blowers & Water spray pumps of A.C. Plants. After installation of V.F.D’s and maintenance of required conditions inside departments unit could achieve power saving. Before: - Power consumption of 7 no. of A.C. plant as monitored by energy meter before implementation of this project was 24.04 Lakh kWh / Annum. After: - After installations of drives in blowers and spray pumps unit could able to control the speed of the supply blowers as well as working of spray pumps to maintain the desired conditions in the departments for production purpose and reducing the power consumption. Power consumption of 7 no. of A.C. plant as monitored by energy meter after implementation of this project is 22.28 Lakh kWh / Annum. Savings achieved: - Difference in power consumption before & after implementation of this project. = (24.04-22.28) Lakh kWh / Annum. = 1.76 Lakh kWh / Annum Or Rs 7.75 Lakh / Annum— @ Rs 4.43 / kWh 322
Payback Period: - Investment incurred for this project / Savings achieved = (7.75 / 9.25) Lakh Rs = 8 months
2) Installation of Compressed Air pressure Booster for winding machines
Project background: - It was observed that only few machines in production line require high pressure for their operation up to 6.5 kg /sq cm. While remaining machines can operate at considerably low air pressure around 5.0 kg. For this few machines requiring high air pressure unit have to generate compressed air at high pressure. So unit installed compressed air pressure booster for this winding machines in 5700 Spinning department & reduced generation pressure setting by 0.5 kg / sq cm from 6.5 kg / sq cm to 6.0 kg / sq cm. This compressed air pressure booster is a mechanical device which further compresses air to give double output pressure. If unit give input of 3.5 kg/ sq cm pressure than unit get continuous output of 7.0 kg / sq cm. This reduction in pressure setting at generating compressor resulted in to increase in unloading time of compressor & thus added to power saving. Before: - Power consumption of Air compressors before installation of Air pressure boosters as monitored by energy meter was 11.00 Lakh kWh / Annum. After: - Power consumption of Air compressors after installation of Air pressure boosters as monitored by energy meter is 10.52 Lakh kWh / Annum. Savings achieved: - Difference in power consumption before & after implementation of this project. = (11.00-10.52) Lakh kWh / Annum. = 0.48 Lakh kWh / Annum Or Rs 2.10 Lakh / Annum— @ Rs 4.43 / kWh Payback Period: - Investment incurred for this project / Savings achieved = (1.25 / 2.10) Lakh Rs = 7 months.
3) Installation of Energy efficient Tubes fittings at TFO section of Spinning Department
Project background:- In Spinning TFO department earlier 70 nos. of Tube fittings of double rod having wattage 36 each were used for lighting purpose. This double fitting were replaced with energy efficient Asian make single tube having wattage 28 with mirror reflector. This project has been implemented without affecting illumination level required for caring out production activities in that Area. Before: - Power consumption of Lighting meter as monitored by energy meter after implementation of this project is 7.13 Lakh kWh / Annum.
323
After: - Power consumption of Lighting meter as monitored by energy meter before implementation of this project was 7.54 Lakh kWh / Annum. Savings achieved: - Difference in power consumption before & after implementation of this project. = (7.54- 7.13) Lakh kWh / Annum. = 0.41 Lakh kWh / Annum Or Rs 1.80 Lakh / Annum— @ Rs 4.43 / kWh Payback Period: - Investment incurred for this project / Savings achieved = (1.25 / 1.80) Lakh Rs = 8 months.
4) Power saving due to optimum utilization of capacities of Spinning production machines & proactive maintenance.
Project background: - It was observed that many a time production machines of spinning department are partially loaded due to constraints in production programs. A monitoring system was developed after brain storming with production & planning people to utilize best of machine capacities. Also a due consideration was given to do proactive maintenance which involved periodic motor checking, gearbox checking, belt tension & general lubrication of machines. As a effect of above measures a fair reduction in power consumption of machines is achieved as compared to previous year. Before: - Power consumption of spinning machines as monitored by energy meter before implementation of this project was 41.32 Lakh kWh / Annum. After: - Power consumption of spinning machines as monitored by energy meter after implementation of this project was 38.51 Lakh kWh / Annum. Savings achieved: - Difference in power consumption before & after implementation of this project. = (41.32-38.51) Lakh kWh / Annum. = 2.81 Lakh kWh / Annum Or Rs 12.44 Lakh / Annum— @ Rs 4.43 / kWh.
5) Power saving due to optimum utilization of capacities of Weaving production machines & proactive maintenance.
Project background: - A monitoring system was developed after brain storming with production & planning people to utilize best of machine capacities. Also a due consideration was given to do proactive maintenance which involved periodic motor checking, gearbox checking, belt tension & general lubrication of machines. As a effect of above measures a fair reduction in power consumption of machines is achieved as compared to previous year. Before: - Power consumption of weaving machines as monitored by energy meter before implementation of this project was 22.05 Lakh kWh / Annum.
324
After: - Power consumption of weaving machines as monitored by energy meter after implementation of this project was 20.63 Lakh kWh / Annum. Savings achieved: - Difference in power consumption before & after implementation of this project. = (22.05-20.63) Lakh kWh / Annum. = 1.42 Lakh kWh / Annum Or Rs 6.29 Lakh / Annum— @ Rs 4.43 / kWh
6) Thermal Energy saving by optimum utilization of machine capacity & leakages monitoring
Description of the energy conservation measure: At yarn conditioning machine following steps are taken to conserve thermal energy. 1) Optimum utilization of machine by operating on programmer. 2) Regular checking & rectifying steam leakages from flange joints & valve glands. 3) Monitoring of steam trap working of header & service line. 4) Maintaining insulation quality of machine body. Before: - Furnace Oil consumption of Yarn conditioning machines before implementation of this project was 36.70 kL / Annum. After: - Furnace Oil consumption of Yarn conditioning machines after implementation of this project was 36.18 kL / Annum. Savings achieved: - Difference in Furnace Oil consumption before & after implementation of this project. = (36.70-36.18) KL / Annum. =0 .52 KL / Annum. Or Rs 0.13 Lakh / Annum— @ Rs 26700 / KL
325
Textile
WELSPUN INDIA LIMITED
Vapi, Distt. Valsad (Gujarat)
Unit Profile
Welspun India Limited (WIL) is the Flagship company of Welspun Group with an enterprise value of U.S. $ 3 billion. WIL is ISO 9001:2000, 14001 and SA 8000 certified company. WIL is a composite textile mill producing Cotton Yarn, Terry Towels and Rugs for international market. Welspun India Ltd. is one of the largest Home Textiles producers in Asia and amongst the top 4 producers of Terry Towels in the world. WIL is located at village Morai in Valsad district, Gujarat State. WIL annual sales turnover for year 2009-2010 was Rs. 681.881 crores.
Energy Consumption
The continuous implementation of various energy conservation measures being ongoing practice, there is steady decline of specific energy consumption. Last three years specific energy consumption figure are shown below, which depicts continual reduction in specific energy consumption over last two years due to plant’s sustained efforts with the implementation of various energy conservation measures and ideas to increase efficiency of equipments.
307
Power Consumption Vs Production (kWh/Mt)
4000.00
3000.00
2665.00
2538.66
2390.00
2000.00
1000.00
0.00 Ration Kwh/MT
2007-08 2665.00
2008-09 2538.66
2009-10 2390.00
Energy Conservation Measures
Major Projects Implemented for Energy conservation during the Year 2009-2010
1. Power Saving on Refrigerent Air Dryers on ZH - 10000 Compressor
Replaced 2 nos electrically heated air dryers with 2 Nos Refrigerant Air Dryer on Compressor ZH-10000 Power saved Cost saved Investment = 4738 kWh / day = Rs 74.08 Lakhs/Annum = Rs 34.12 Lakhs, Pay back period = 3 Months
308
2. Chilled Water generation from Waste Exhaust Gas, Total Chilled water generation = 16490 TR /Day
Power Saved Gas equivalent of power saved = 11543 kWh / Day = 2850 SCM / Day
VAC Installed on Exhaust of Gas DG Set to recover waste Heat
3. Energy Saving through Condensate Water Recovery
Condensate water recovery = 419000 Ltr / Day. Gas equivalent of energy saved = 2815 SCM / Day
Condensate Recovery System
309
4. Power Saving on Autoconer
Autoconer 338 suction fan drive motors up gradation with negative pressure sensor Power saved Cost saved Investment Pay back period = = = = 384 kWh / day Rs 6.0 Lakhs/Annum Rs 2.95 Lakhs 2.2 Months
VFD provided on Auto Conner waste removal system to work on set pressure
5. Power Saving on Pumping Station
Pump House: Installed closed loop VFD based pumping system for energy reduction Power saved Cost saved = 282 kWh / day = Rs 4.4 Lakhs / Annum.
Provided Pressure feedback on VFD to maximum utilization of pumping station as per Process needs with Energy saving aspects.
Pumps
Drive Panel to Maintain Set Pressure
310
Energy Conservation Policy
We, at Welspun are committed to adopt energy conservation measures in all our processes, activities, products and services. We shall strive to improve the energy consumption. We are committed to optimally utilise the various forms of energy in a cost - effective manner for conservation of precious energy resources. We shall seek to achieve our energy conservation objectives by continuing to improve on the efficiency of our machines, processes, infrastructure and Communication & Information systems. We shall invest in good energy management & energy efficient technologies as they become available. We will also seek to reduce our carbon emissions by investing in low carbon energy options such as renewable energy etc. where-ever possible in line to our commitment towards use of Green Technologies for a safe and clean future.
Environmental Policy
We at Welspun India Ltd., manufacturing cotton yarn, terry towels and toweling fabrics, commit ourselves to continual and sustainable improvement of environmental management of all our activities and products. We shall strive to meet the applicable environmental legislation, regulation and other legal requirements. We commit to set environmental objectives and targets and implement environmental programs to mitigate environmental impacts of our activities. We shall continue to improve our environmental performance through: Optimizing use of natural resources, electrical energy, fuel, water & chemicals. Encourage recycling of unavoidable wastage Training employees for environmental responsibilities Providing safe working environment to produce safe and legal products
311
Second Prize
Textile
RAYMOND LIMITED
Tal. Pardi, Distt. Valsad (Gujarat)
Unit Profile
Raymond Limited under the leadership of JK Group is undoubtedly Number One in the Indian Textile Industry. It comprises of four units. Vapi unit established in 2006 in Khadki village is around 28 km south of the district headquarter city of Valsad, it is surrounded by Union Territories of Daman on the west and by Dadra and Nagar Haveli on the east. The location advantages of Raymond Textile Unit at Vapi are: Situated on NH # 8 and near to Industrial Hub Proximity to Mumbai / Thane The plant was commissioned in THREE phases. Ist phase was commissioned on 30th March, 2006. IInd phase was commissioned on 17th January,2007 and the IIIrd phase was commissioned on 5th March,2009. Currently, the unit is engaged in manufacturing of Premium Worsted Suiting Fabric, and is equipped with State of the art technology with Hi-tech machineries viz. Warping equipment from Switzerland, Weaving machines from Belgium, Finishing machines, Automatic drawing-in and other machines from Italy to produce 14 million meter fabric / annum.
312
Energy Consumption
Consumption profile for the last 3 years
Energy Conservation Commitment, Policy and Set-Up
Raymond Ltd. (Textile Division), Vapi involved in the production of high quality Polyester Wool and Polyester Viscose blended fabric, are committed to demonstrate excellence in Energy Management Performance on a continual basis.
Energy Conservation Plans and Targets for the year 2010-11
Implementation of Drives in Air Washer Towers. 4 nos. of 37KW VFD 2 nos. 30KW VFD 2 nos. 22KW VFD 1 nos. 11KW VFD
Energy Conservation Measures Implemented in 2009-10
Energy Conservation Achievements
313
314
315
316
Environment and Safety
The Plant has been recommended for ISO 14001:2004 & OHSAS 18001:2008 Certification The World Environment day, Safety Day and the Energy Conservation Day are celebrated with full enthusiasm without fail every year. The Plant have identified major accident hazards and taken adequate step for Prevention and Control and provided information, training, and equipment to the persons working at the site. Company Management encouraging personnel to use protective equipment like ear plugs, safety goggles, safety shoes etc.
317
Second Prize
Textile
BOMBAY RAYON FASHIONS LIMITED YARN DYEING
Doddaballa Pura, Bangalore (Karnataka)
Unit Profile
Bombay Rayon Fashions Limited - Bangalore unit is a Composite unit of Bombay Rayon group of companies. This unit was established in the year of 2006-07 with 3.5 tons capacity of yarn dyeing, 104 looms with the capacity of 30000 mtrs/day, and wet processing 1.16 lakhs mtrs/day.
The Bombay Rayon group comes into existence in 1986. The commencement of garment division of the group begin in 2001. The group sets up 7-garment manufacturing facilities in Bangalore with 7000 machines. Presently the Bombay Rayon Fashions Limited, manufacturing the fabric quantity of 90 million meters/ annum, and garment manufacturing facilities of 40 million garments/annum with in house laundry, printing, embroidery. Total of 35000 employees were employed in entire group. Its turn over for the year 2008-09 was USD350 million and for the year 2009-10 USD425 million.
318
Details of actual Consumption / production for the period 20082009 & 2009 – 2010 Weaving
Period 2008-09 2009-10 Actual Production in tones 1860.919 2087.729 Actual Coal consumption in tones 2056.60 1834.00
Yarn Dyeing
Period Production in tones 977.903 1076.808 Actual coal consumption in tones 3290.60 2934.43 Actual power consumption in kWh 3297629 3548403
2008-09 2009-10
Energy Conservation: Saving Details Weaving
Sl. No. Period Fabric prodn. in Tonnes Coal consumed in tonnes Coal in tones / tonne of fabric Coal Saving in tones / tonne of fabric 0.23 Cost % Saving saving in lakh Rs. For the period 2009 -2010 20.65 21%
1 2
2008 - 2009 2009 - 2010
1860.918 2087.729
2056 1834
1.10483105 0.87846656
Fuel saving for steam generation in tones [Coal] = 480.18 tons
1. 2. Savings achieved due to fuel additive used for increasing the fuel efficiency. Grouping of similar items for running the warp sheet in sizing machine.
Yarn Dyeing -Power saving
Sl. No. Period Dyed Power Yarn prodn. consumed in Tonnes in kWh Power in kWh / tonne of dyed Yarn Power saving in kWh / tonne of Dyed Yarn 76.84 Cost % Saving saving in lakh Rs. For the period 2009 -2010 4.23 7.14%
1 2
2008 - 2009 2009 - 2010
977.903 1076.808
3297629 3548403
3372.14 3295.30
319
1. 2.
Operating time reduced due to optimization of process sequence Optimization of capacity utilization
Yarn Dyeing -Coal saving
Sl. No. Period Dyed Coal Yarn prodn. consumed in Tonnes in tonnes Coal in tones / tonne of Dyed Yarn Coal Saving in tones / tonne of Dyed Yarn 0.63 Cost % Saving saving in lakh Rs. For the period 2009 -2010 29.17 18.75%
1 2
2008 - 2009 2009 - 2010
977.903 1076.808
3290.6 2934.43
3.36 2.73
1. 2. 3.
Savings achieved due to fuel additive used for increasing the fuel efficiency. Operating time reduced due to optimization of process sequence Optimization of capacity utilization
Integrated Policy for SA 8000, ISO 14001 & ISO 9001
We at BOMBAY RAYON FASHIONS LIMITED are committed to delight our external & internal stakeholders by integrating our initiatives on Quality, Environment and Social Accountability. We shall realize this commitment through: Manufacture & supply of high quality Fabrics by employing quality, environmental & social accountability practices compliant with relevant standards. Compliance to applicable statutory, regulatory and industry codes of conduct including international standards & instruments. Continual improvement of organisation’s performance through consistent monitoring & review of policy. Ensuring of dissemination & adoption of good quality. Environmental & social accountability practices among suppliers. Conservation of resources through reduction of waste, recycling and prevention of pollution. Continually improve the effectiveness of Quality, environmental and social accountability management systems.
320
Certificate of Merit
Textile
RAYMOND LIMITED
Jalgaon (Maharashtra)
Unit Profile
Incorporated in 1925, Raymond is the leading, integrated producer of worsted suiting fabric in the world, with a capacity of producing 33 million meters of wool & wool-blended fabrics. A pioneer in the textile and men's apparel business, in India, with a turnover of over USD 600 Million, The Group has six, state-of -the art textile plants and four garmenting factories, in India and Europe. The Raymond Group has already marked its presence in the global arena with partnerships with leading European manufacturers of carded woolens, fine shirting fabrics and specialty Denim. In addition, the Group has business interests in readymade garments, designer wear, Cosmetics & toiletries, engineering files and tools, prophylactics and air charter operations. Moving up the value chain. Raymond Ltd Jalgaon division is one of the 4 Textile units established in year 1979 with manufacturing capacity of 54 lakh meters per annum of worsted suiting. Worsted division manufacturing Worsted Suiting fabric with polyester-wool and polyester-viscose blends. Turnover of Jalgaon unit was Rs 7277 lakh for previous year. Raymond Ltd. Jalgaon is ISO9001, 14001 and OHSAS certified company.
Energy Consumption
Year Electrical Energy Consumption Electrical Energy Savings Achieved Lakh Rs./ annum % Savings achieved/ Energy Cost of Prev. year (vi)/(ii)x100 4.81% 6.14%
Total Energy Specific % Reduction Lakh Electrical Cost Energy in Specific kWh / Energy (Rs. Lakhs/ Consumption Energy annum Consumption year) kWh / Consumption kWh/annum tonne over 08-09 (i) (ii) (iii) (iv) (v) 2008-09 2009-10 117.45 112.10 520.84 496.60 8881.11 8234.36 ---7.28% 5.66 6.86
(vi) 25.07 30.51
321
Specific Electrical Energy Consuption
9000 8800
KWH/000pick
8600 8400 8200 8000 7800 2008-2009 2009-2010
8881.11 8234.36
Year
It is evident from above graph and table that specific electrical energy consumption of Raymond unit is showing reducing trend in last two years as a result of continuous efforts in the direction of energy conservation.
Energy Conservation Achievements for the year 2009-10 1) Optimum Utilization of A.C. Plant Capacities by installation of VFD’s for blowers & pumps
Project background: - It was observed that 7 No. of A.C. plants are running full capacities in winter season also when it is not required due to favorable atmospheric conditions. Unit could either run A.C. Plants or shut down them completely. Variation in speed of blowers as per requirement was not possible as there were no drive control for speed variation to cope up the demand and save energy. To overcome this obstruction unit decided to install Variable Frequency Drives for all 10 No. of Air Blowers & Water spray pumps of A.C. Plants. After installation of V.F.D’s and maintenance of required conditions inside departments unit could achieve power saving. Before: - Power consumption of 7 no. of A.C. plant as monitored by energy meter before implementation of this project was 24.04 Lakh kWh / Annum. After: - After installations of drives in blowers and spray pumps unit could able to control the speed of the supply blowers as well as working of spray pumps to maintain the desired conditions in the departments for production purpose and reducing the power consumption. Power consumption of 7 no. of A.C. plant as monitored by energy meter after implementation of this project is 22.28 Lakh kWh / Annum. Savings achieved: - Difference in power consumption before & after implementation of this project. = (24.04-22.28) Lakh kWh / Annum. = 1.76 Lakh kWh / Annum Or Rs 7.75 Lakh / Annum— @ Rs 4.43 / kWh 322
Payback Period: - Investment incurred for this project / Savings achieved = (7.75 / 9.25) Lakh Rs = 8 months
2) Installation of Compressed Air pressure Booster for winding machines
Project background: - It was observed that only few machines in production line require high pressure for their operation up to 6.5 kg /sq cm. While remaining machines can operate at considerably low air pressure around 5.0 kg. For this few machines requiring high air pressure unit have to generate compressed air at high pressure. So unit installed compressed air pressure booster for this winding machines in 5700 Spinning department & reduced generation pressure setting by 0.5 kg / sq cm from 6.5 kg / sq cm to 6.0 kg / sq cm. This compressed air pressure booster is a mechanical device which further compresses air to give double output pressure. If unit give input of 3.5 kg/ sq cm pressure than unit get continuous output of 7.0 kg / sq cm. This reduction in pressure setting at generating compressor resulted in to increase in unloading time of compressor & thus added to power saving. Before: - Power consumption of Air compressors before installation of Air pressure boosters as monitored by energy meter was 11.00 Lakh kWh / Annum. After: - Power consumption of Air compressors after installation of Air pressure boosters as monitored by energy meter is 10.52 Lakh kWh / Annum. Savings achieved: - Difference in power consumption before & after implementation of this project. = (11.00-10.52) Lakh kWh / Annum. = 0.48 Lakh kWh / Annum Or Rs 2.10 Lakh / Annum— @ Rs 4.43 / kWh Payback Period: - Investment incurred for this project / Savings achieved = (1.25 / 2.10) Lakh Rs = 7 months.
3) Installation of Energy efficient Tubes fittings at TFO section of Spinning Department
Project background:- In Spinning TFO department earlier 70 nos. of Tube fittings of double rod having wattage 36 each were used for lighting purpose. This double fitting were replaced with energy efficient Asian make single tube having wattage 28 with mirror reflector. This project has been implemented without affecting illumination level required for caring out production activities in that Area. Before: - Power consumption of Lighting meter as monitored by energy meter after implementation of this project is 7.13 Lakh kWh / Annum.
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After: - Power consumption of Lighting meter as monitored by energy meter before implementation of this project was 7.54 Lakh kWh / Annum. Savings achieved: - Difference in power consumption before & after implementation of this project. = (7.54- 7.13) Lakh kWh / Annum. = 0.41 Lakh kWh / Annum Or Rs 1.80 Lakh / Annum— @ Rs 4.43 / kWh Payback Period: - Investment incurred for this project / Savings achieved = (1.25 / 1.80) Lakh Rs = 8 months.
4) Power saving due to optimum utilization of capacities of Spinning production machines & proactive maintenance.
Project background: - It was observed that many a time production machines of spinning department are partially loaded due to constraints in production programs. A monitoring system was developed after brain storming with production & planning people to utilize best of machine capacities. Also a due consideration was given to do proactive maintenance which involved periodic motor checking, gearbox checking, belt tension & general lubrication of machines. As a effect of above measures a fair reduction in power consumption of machines is achieved as compared to previous year. Before: - Power consumption of spinning machines as monitored by energy meter before implementation of this project was 41.32 Lakh kWh / Annum. After: - Power consumption of spinning machines as monitored by energy meter after implementation of this project was 38.51 Lakh kWh / Annum. Savings achieved: - Difference in power consumption before & after implementation of this project. = (41.32-38.51) Lakh kWh / Annum. = 2.81 Lakh kWh / Annum Or Rs 12.44 Lakh / Annum— @ Rs 4.43 / kWh.
5) Power saving due to optimum utilization of capacities of Weaving production machines & proactive maintenance.
Project background: - A monitoring system was developed after brain storming with production & planning people to utilize best of machine capacities. Also a due consideration was given to do proactive maintenance which involved periodic motor checking, gearbox checking, belt tension & general lubrication of machines. As a effect of above measures a fair reduction in power consumption of machines is achieved as compared to previous year. Before: - Power consumption of weaving machines as monitored by energy meter before implementation of this project was 22.05 Lakh kWh / Annum.
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After: - Power consumption of weaving machines as monitored by energy meter after implementation of this project was 20.63 Lakh kWh / Annum. Savings achieved: - Difference in power consumption before & after implementation of this project. = (22.05-20.63) Lakh kWh / Annum. = 1.42 Lakh kWh / Annum Or Rs 6.29 Lakh / Annum— @ Rs 4.43 / kWh
6) Thermal Energy saving by optimum utilization of machine capacity & leakages monitoring
Description of the energy conservation measure: At yarn conditioning machine following steps are taken to conserve thermal energy. 1) Optimum utilization of machine by operating on programmer. 2) Regular checking & rectifying steam leakages from flange joints & valve glands. 3) Monitoring of steam trap working of header & service line. 4) Maintaining insulation quality of machine body. Before: - Furnace Oil consumption of Yarn conditioning machines before implementation of this project was 36.70 kL / Annum. After: - Furnace Oil consumption of Yarn conditioning machines after implementation of this project was 36.18 kL / Annum. Savings achieved: - Difference in Furnace Oil consumption before & after implementation of this project. = (36.70-36.18) KL / Annum. =0 .52 KL / Annum. Or Rs 0.13 Lakh / Annum— @ Rs 26700 / KL
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