KCMMF Ltd.

CENTRAL PRODUCTS DAIRYALLEPPEY

WELCOME TO THE WELCOME TO THE

PRESENTATION OF TOTAL PRESENTATION OF TOTAL

ENERGY MANAGEMENTENERGY MANAGEMENT

GENERAL INFORMATION

�Started in 1974, Capacity: 2000 LPD

�Expanded to: 60,000 LPD on Dec 1987

�Aseptic Packing station commissioned on Dec 1988

�Milk Powder Factory commissioned on Sep 1996

� Capacity enhanced to 1,00,000 LPD in 2005

�Mango Juice Production Started in Pet Bottles on 2007.

PRODUCTS HANDLED

�� TONED MILKTONED MILK

�� DOUBLE TONED DOUBLE TONED

MILKMILK

�� CURD CURD

�� GHEEGHEE in 2 Brandsin 2 Brands

�� PEDAPEDA

�� STERILIZED STERILIZED

FLAVOURED MILKFLAVOURED MILK

�� MANGO DRINKMANGO DRINK in in

Tetra packs & Pet Tetra packs & Pet

Bottles.Bottles.

�� DAIRY WHITENERDAIRY WHITENER

AVERAGE MILK HANDLED

2009

0

500000

1000000

1500000

2000000

2500000

3000000

JA N . MAR. MAY. JULY SEP. N OV.

Av. MilkHandled (lts)per day

PRODUCTION DETAILS

CURD 2009

0

10000

20000

30000

40000

50000

60000

70000

JAN. MAR. MAY. JULY SEP. NOV.

KGS

PRODUCTION DETAILS

CURD 2009

0

5000

10000

15000

20000

25000

30000

APR MAY JUN JUL AUG SEP

KGS

PRODUCTION DETAILS

GHEE

0

5000

10000

15000

20000

25000

JAN MAR. MAY JULY SEP. NOV.

KGS

PRODUCTION DETAILS

MILMA PLUS 2009

0

10000

20000

30000

40000

50000

60000

70000

JAN MAR MAY JUL SEP NOV

BOTTLESB

PRODUCTION DETAILS

MILMA MANGO 2009

0

1000

2000

3000

4000

5000

6000

APR MAY JUN JUL AUG SEP

TRAYS

ENERGY CONSUMPTION

DETAILS FURNACE OIL

(2009)

20000

20500

21000

21500

22000

22500

23000

JAN. MAR. MAY. JULY SEP. NOV.

LTR

ENERGY CONSUMPTION

DETAILS POWER(2009)

0

20000

40000

60000

80000

100000

120000

JAN. MAR. MAY. JULY SEP NOV.

KWH

ENERGY EXPENCE DETAILS

POWER(2009)

0

50000

100000

150000

200000

250000

300000

350000

400000

450000

JAN MAR MAY JUL SEP NOV

Rs

UNIT COST-,FURNACE OIL,ELC

(2009)

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

JAN. MAR. MAY. JULY SEP. NOV.

FURNACE OIL(Rs)

ELC(Rs)

3-D Column 3

PRODUCTION

COMPARISON MILK

22000000

23000000

24000000

25000000

26000000

27000000

28000000

29000000

2007 2008 2009

LTR

PRODUCTION COMPARISON

GHEE

0

20000

40000

60000

80000

100000

120000

140000

160000

180000

2007 2008 2009

KGS

PRODUCTION COMPARISON

CURD

0

100000

200000

300000

400000

500000

600000

700000

2007 2008 2009

PACKETS

PRODUCTION COMPARISON

MILMA PLUS

0

100000

200000

300000

400000

500000

600000

2007 2008 2009

BOTTLES

ENERGY CONSUMPTION

850000

900000

950000

1000000

1050000

1100000

1150000

2007 2008 2009

ELECTRICTY

ENERGY CONSUMPTION

160000

170000

180000

190000

200000

210000

220000

2007 2008 2009

FURNACE OIL

FURNACE OIL

ENERGY EXPENSE

DETAILS

0

500000

1000000

1500000

2000000

2500000

3000000

3500000

4000000

4500000

5000000

2007 2008 2009

ELECTRICTY

ENERGY EXPENSE

DETAILS

0

50000

100000

150000

200000

250000

2007 2008 2009

FURNACE OIL

Energy Saving activities

undertaken

� We have replaced 4 sachet filling machines with mechanical filling machines.

� Only one Ammonia Compressor is being used in dairy

� The Head cooling water from Air Compressor diverted to Boiler feed & sump of Ammonia Condenser

SAVING ACTIVITIES cont..SAVING ACTIVITIES cont..

�30 T capacity refrigeration plant of MPF is not

being operated in this flush season due to

sufficient ice obtained from our Dairy

refrigeration plant for MPF use also. This was

achieved by maintaining 100 % efficiency in

the Dairy refrigeration plant after some

modification.

SAVINGS

� The temperature of Pasteurization was reduced from 790C to 780C.

� It will be further reduced to 770C in the next phase

� Installation of 4 mechanical filling machines has saved Rs. 2000 per day in power cost

� Due to non operation of 2nd Compressor, the energy cost saved Rs. 40,000 / month & non operation of MPF refrigeration plant during flush season 15 KWH energy saved every operational day

COMPARISON OF REFRGN

HOURS

7000

7200

7400

7600

7800

8000

8200

8400

8600

2007

2008

2009

ENERGY SAVING OPPERTUNITIESWITH INVESTEMENT

(A)Boiler

1 Installation of new Water Pump and

Furnace oil Pump

2 Replacing the insulations of Boiler and

Connected steam line

3 Installation of flow meter for oil and feed

water

4 Utilization of fuel gas temp for feed water

heating.

(B) STEAM LINES

1 providing Insulations on identified Area

2 Replace Steam traps with Good quality Steam traps.

(C) GHEE Vat.

Replace Thermo dynamic steam trap with Ball float steam trap.

(D ) REFRIGERATION

Providing separate Energy meter to the Ref: plant to monitor the Power consumption

(A) BOILER

Utilization of head cooling water from

Air compressor in feed water ( 48 0c )

ENERGY SAVING

OPPORTUNITIES

WITHOUT INVISTEMENT

Energy Mngmt CommitteeEnergy Mngmt Committee

� K P Rajan – Manager & Chairman

� V Unnikrishnan – A.M(P&M) & Energy Manager

� V.S. Murukan- QCO

� Rajive Zachariah – Asst. Manager

� K Raveendran – Refgn Mechanic

� C S Chandralal – Boiler Operator

Energy Mngmt CommitteeEnergy Mngmt Committee

� V Unnikrishnan – Electrician

� Satheesan – Fitter

� K C Joseph – Plant Operator

� V K Manoharan – Plant attender

Proposed Ivestments

� Lightings to be changed to CFL.

� Continuous ghee packing machine to be purchased saving upto 80 labour hours daily

� Pasteurizer plant to be replace with a higher Capacity including Homogenizer.