© Confederation of Indian Industry
ANJAN MAJI – FACTORY MANAGERBALAKRISHAN – ENGG MANAGER
UNILEVER INDIA EXPORTS LIMITED INSTANT TEA FACTORY
ETAH
© Confederation of Indian Industry
Brief introduction on Unit
Location : Etah, India (UP)
Year of establishment : 1996
Built in capacity : 1100 Tons
Product : Instant tea powder for Lipton Ice tea premix
Variants : CWS (Cold water soluble)
Green Tea, Evian Brite and Saint Brite
HWS (Hot water soluble) HIT
Key Technology : 3 stage extraction process with spray dryer
: SCADA application for Process automation& control
One of the 3 Unilever sites of Instant Tea across the world contributing to 27% of Unilever’s tea powder supply in 2017
© Confederation of Indian Industry
Brief introduction – Instant Tea Process
3 Stage Extraction
TEA SPENT
TROLLEY
SPRAY
DRYER
PACKING
PUMP
1st EVAPORATOR
2nd EVAPORATOR
HOT LIQUOR
INSOLUBLES
SEPARATION
COLD LIQUOR
INSOLUBLES
SEPARATION
GLYCOL
PHE
For cooling
Tea Waste WaterIndirect
Steam
Te
a L
iqu
or
Te
a
sp
en
t
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Sp. Power Consumption Trend
3963
3627
3362
3000
3500
4000
2015-16 2016-17 2017-18
Specific Energy Cons.KWH/Ton
▪ Energy Efficient Motor (IE3) & Pump installation▪ Pump capacity optimization based on requirement▪ Replacement with Planetary gearbox▪ VFD for compressor & 11KVA Express feeder▪ ATB in Chiller, Combined Cooling tower and Diffused Aerator▪ Productivity improvement through yield increase in process
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Sp. Thermal Energy Consumption trend
73731
68540
57454
40000
60000
80000
2015-16 2016-17 2017-18
Specific Thermal Energy (KJ/Kgs)
▪ Evaporation ratio improvement in Boiler▪ Auto Steam cutoff valves in all process equipment▪ In Boiler – O2 Analyzer, Sonic soot blower, Auto blow down & 3D
Element controller ▪ Servo Based Burner for HAG▪ HAG Flue gas Heat recovery
© Confederation of Indian Industry
Bench Mark with Ceytea plant Power (Sri Lanka)
Plant : Ceytea Instant Tea Plant – Sri Lanka
Location : Sri Lanka
Built in capacity : 3500 Tons
Product : Instant tea powder for Lipton Ice tea premix
Variants : CWS (Cold water soluble)-Saint Brite and Dark
Key Technology : 3 stage extraction process with spray dryer
: SCADA application for Process automation& control
Spec. Power per Ton : 2076 KW/Ton
Spec. Steam per Ton : 15.75 tons of steam/Ton
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2076335 265
245 245 196
3362
0
2000
4000
Spec. Power Reduction water Map KWH/Ton
CEYTEA - 2076 KWH/Ton
Etah - 3362 KWH/Ton
0400800
1200
210558
229 100612
35215
475976
373 171
921428
18
Electrical Energy Bench Mark Etah vs Ceytea
CEYTEA - 2076 KWH/Ton Etah - 3362 KWH/Ton
Spec. Power - Gap & Road Map
© Confederation of Indian Industry
Spec. Thermal Energy - Gap & Road Map
CEYTEA - 15.8 Ton of steam/TonEtah - 20.7 Tons of steam/Ton
05101520 1.2
8.2 3.2 0.6 0.6 0.8 1.21.5
11.6 5.4 0.6 0.4 0 1.2
Thermal Energy Bench Mark Etah vs Ceytea
CEYTEA - 15.8 Ton of steam/Ton Etah - 20.7 Tons of steam/Ton
15.8
1.8 0.80.8 0.8
0.7
20.7
10
15
20
Spec.Steam Reduction water flow chart Tons/Ton
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Energy Saving projects implemented in FY 2015-16
Title of the project
Annual ele cost savings (Rs Mn)
Annual thermal
cost savings (Rs Mn)
Total Annual savings
Investment made
Payback in
Months
Boiler Evaporation ratio improvement
0 1.45 1.45 1.85 15
SABD Project - 2015 ( Planetary gearbox, VFD for air compressor & Cooling tower, DE system, auto steam cutoff valve)
1.35 0 1.35 3 26
11KVA Express Feeder 0 10.2 10.2 9.4 11
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Energy Saving projects implemented in FY 2016-17
Title of the project
Annual ele cost savings (Rs Mn)
Annual thermal
cost savings (Rs Mn)
Total Annual savings
Investment made
Payback in
Months
Energy Efficient Motor in Plant 0.84 0 0.84 1.1 16Energy Efficient Pumps in plant 0.8 0 0.8 1.2 18
SABD Projects - Thermal Energy Reduction - Online Flue gas Analyzer and synchronizing with FD & PA fan & Fuel feeder, Steam optimization throught the plant by installaling Flow meter, Traps & Moistire separator in header,
0 5.3 5.3 7.6 16
3D Element controller in Boiler 0 0.5 0.5 0.8 19
Yield Improvement - Back pressure plate, Tea water Ratio, Online flushing of screw, MF meter
0.7 2.23 2.93 3.7 15
© Confederation of Indian Industry
Energy Saving projects implemented in FY 2017-18
Title of the project
Annual ele cost savings (Rs Mn)
Annual thermal
cost savings (Rs Mn)
Total Annual savings
Investment made
Payback in
Months
Pump Optimization to reduce Power
0.72 0 0.72 1.5 25
Boiler Efficiency Improvement 0 1.7 1.7 2.6 18
Combined Cooling tower 1.1 1.1 1.1 2.5 25
SABD projects - Servo based Burner, Steam control valves, ATB system in Chiller etc
0.72 2.1 2.82 4 16
HAG Flue Gas heat recovery system 0 2.6 2.6 3.5 16
Diffused Aerator in ETP 0.67 0 0.67 1.85 26
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Energy Savings Projects
➢ IMPROVED THE POWER FACTOR FROM
0.97 TO .984
➢ INSTALLED PREMIUM LEVEL EFFICIENCY
MOTORS
➢ OPTIMIZED THE UTILITY LOAD BY
RUNNING OPTIMIZED CAPACITY
EQUIPMENT’S, CHILLER, AIR COMPRESSOR
© Confederation of Indian Industry
ON/OFF level control gives sudden volumes of sub-cooled water in the boilers steaming capacity, which results in large excursions in the boiler water temperature, drum level and pressure. These excursions reduce boiler steam efficiency by sub-cooling the boiler feed water for the sudden mass/heat upset
❑110% Excess air ❑11-12 % of O2 level❑3-4% Combustion
efficiency improvement ❑Black smoke reduction
❑Boiler was tunes at 3.3 TPH.
❑Screw feeder and FD fan tuned at 4.2 TPH.
❑Combustion efficiency improvement.
Energy Savings Projects
3D
ELEMENT
Oxygen
Analyzer
SC Feeder
tuning @4 .2
TPH
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Energy Savings Projects
❑Increased feed water temperature up to 96 deg.
❑Automatic temperature control system installation at APV tank.
FEED WATER
TEMP INCREASE
TEMPERATURE
CONTROL SYSTEM
AT APV
❑Excess heated water went out.
❑Was maintaining the TDS 2500 PPM
❑Maintain cosinsistly 11 bar pressure by maint3500 TDS.
ABD SYSTEM
INSTALLATION
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Pump Optimization – Rs 15 Lakhs Annualized savings started from Mar 2017
Sonic Soot Blower & Steam Fuel ratio improvement projects in Boiler – Rs 15 Lakhs Annualized savings started from Mar 2018
HAG Flue Gas Heat recovery system to preheat Spray drier Supply Air – Rs 8 Lakhs Annualized savings started from Mar 2018
Energy Savings Projects
© Confederation of Indian Industry
Energy Savings Projects
Induced Cooling tower for Process Evaporation system which will improve plant Efficiency through Better Heat Transfer. Annualized savings 10Lakhs started from April 2018
Automatic Tube Brushing system for Chiller - Rs 6 Lakhs Annualized savings started from Mar 2018
Servo based air & fuel control HSD burner for Spray Drier – Rs 7 Lakhs Annualized savings started from Mar 2018
© Confederation of Indian Industry
Energy Savings Projects
Solar street lights. 7lights are installed across the plant.
Temperature Based steam control valve for Soft water Preheating in Extraction Process. 10L Annualized Savings started from Mar 2018
Temperature Based steam control valve for Leaf Heater (3Nos) operation in Extraction Process. 6L Annualized Savings started from Mar 2018
© Confederation of Indian Industry
Innovative Projects implemented
Name of
the
Project
Brief description on
why innovative
Trigger for
implementing
the project
Re
plic
abil
ity
Year
of
Imple
menta
tion
Annual
Savings
( Rs. In
lakhs)
Invest
ment
( Rs. In
lakhs
Flue Gas Heat recovery from Indirect Fired HAG
Indirect Fired HAG flue gas was venting to atmosphere which was have with 300 deg C and flow of 750m3/hour. we have taken a call to utilize that heat to preheat the supply air to spray drier before heating diesel fired burner
To reduce HSD consumption in Diesel burner and utilize the flue gas heat which was venting to atmosphere
YES 2018 10 35
© Confederation of Indian Industry
Innovative Projects implemented
Name of
the
Project
Brief description on
why innovative
Trigger for
implementing
the project
Re
plic
abil
ity
Year
of
Imple
menta
tion
Annual
Savings
( Rs. In
lakhs)
Invest
ment
( Rs. In
lakhs
Combined Cooling tower
It was a practice to use two different cooling tower for process. and we were consuming energy for fans as well pumps in both the cooling tower. we have taken a call to go for single cooling tower to use for entire process and made with double fan which can be stopped any one during winter season
Huge power consumption by running both the cooling tower for process requirement
YES 2018 11 21
© Confederation of Indian Industry
Innovative Projects implemented
Name of
the
Project
Brief description on
why innovative
Trigger for
implementing
the project
Re
plic
abil
ity
Year
of
Imple
menta
tion
Annual
Savings
( Rs. In
lakhs)
Invest
ment
( Rs. In
lakhs
ATB system in Chiller
Auto Tube brushing system in Chiller for descaling the tubes in fixed intervals which will increase the heat transfer and give better chilling at low power generation
We observed that huge scaling in the tubes during annual cleaning periods. we found that it was impacting the heat transfer and consuming huge power. we have taken a call to install auto tube cleaning system
YES 2018 8 12
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Innovative Projects
40KL HSD savings Equal to 10 Lakhs
savings/annum
© Confederation of Indian Industry
Innovative Projects
Induced Cooling tower for Process Evaporation system which will improve plant Efficiency through Better Heat Transfer. Annualized savings 11Lakhs started from April 2018
Automatic Tube Brushing system for Chiller - Rs 8 Lakhs Annualized savings started from Mar 2018
© Confederation of Indian Industry
Utilisation of Renewable energy sources & Future Plan
81% of overall Energy is generating from Renewable Energy Biomass Boiler – Fuel is Mixture of Rice Husk & Tea Waste
Proposed Savings
Sl.No
Year Project
Annual Electrical savings (KWH)
Annual Thermal Energy Savings
(HSD in KL)
1 2018-19 Roof Top Solar panel installation 1800002 2019-20 Biofuel in place of Fossil fuel (Diesel) 240
3 2018-19Usage of BMB Steam to Eliminate Electrical heater 66000
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Utilisation of waste material as fuel
3090
2040
2761
0
1000
2000
3000
4000
2015-16 2016-17 2017-18
TEA WASTE in MT (Biomass Fuel)
35% of Tea Waste used in Boiler as Biomass fuel which is generated from the Instant Tea Process. We are installing In-House Tea spent drier to maximize the Tea waste usage upto
55%
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GHG disclosure
3483
32773362
2500
2700
2900
3100
3300
3500
3700
2015-16 2016-17 2017-18
Tons of CO2 from Power & HSD
CO2 generation from Electricity and HSD. And 184kgs of R134 refrigerant in the site.
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Green Supply Chain – Green Purchase Policy
100% RA Certified Raw Material used for Instant Tea Process
Unilever Responsible Sourcing Policy – Business should be conducted in a manner which embraces Sustainability and reduces Environmental Impact
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Green Supply Chain – Projects & Benefits
Title of the project
Annual Electric
al Savings (KWH)
Annual ele cost savings (Rs Mn)
Annual Thermal savings
with units
Annual thermal cost
savings (Rs Mn)
Total Annual savings
Investment made
Payback in
Months
Boiler Evaporation ratio improvement
0 0 7000 Kcal 1.45 1.45 1.85 15
SABD Project - 2015 135479 1.35 0 0 1.35 3 26
11KVA Express Feeder 0 0255 Klof HSD
10.2 10.2 9.4 11
Energy Efficient Motor in Plant
88228 0.84 0 0 0.84 1.1 16
Energy Efficient Pumps in plant
85657 0.8 0 0 0.8 1.2 18
SABD Projects - 2016 0 01952 tons of steam
5.3 5.3 7.6 16
3D Element controller in Boiler
0 0172 tons of fuel
0.5 0.5 0.8 19
© Confederation of Indian Industry
Green Supply Chain – Projects and Benefits
Title of the project
Annual Electric
al Savings (KWH)
Annual ele cost savings (Rs Mn)
Annual Thermal savings
with units
Annual thermal cost
savings (Rs Mn)
Total Annual savings
Investment made
Payback in
Months
Yield Improvement 67500 0.7164 tons of Steam
2.23 2.93 3.7 15
Pump Optimization to reduce Power
72000 0.72 0 0 0.72 1.5 25
Boiler Efficiency Improvement
0 0666 tons of fuel
1.7 1.7 2.6 18
Combined Cooling tower 110000 1.1 0 1.1 1.1 2.5 25
SABD projects - 2017 72400 0.721200 tons of steam
2.1 2.82 4 16
HAG Flue Gas heat recovery system
0 01550 tons of steam
2.6 2.6 3.5 16
Diffused Aerator in ETP 61344 0.67 0 0 0.67 1.85 26
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Green Supply Chain – Evaluation Process
Evaluation on Energy reduction, Savings & IRR verification and Approval through capex
portal by Central team
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Daily performance Monitoring
Environment performance Monitoring and reporting system
Daily monitoring system for Energy and Efficiency. Daily performance is getting reviewed by Factory Head
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Capex allocation for Energy saving projects
Dedicated Capex is available for Energy and Sustainable projects and it is being allocated centrally from Unilever HO. No limit on Energy savings capex
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Team work & Employee Involvement
Energy Savings projects are identified through Kaizens and Implemented by Factory Team. Factory team members are trained for Energy reduction activities
© Confederation of Indian Industry
Encon projects investment %
618.4
16.50
200
400
600
800
Turnover of the company INR Mn Invested in Encon Projects INR Mn
Encon Projects Investment - Year 2017-18
Investment – 3% on overall Turnover
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Sustainability Award at NFEST
34
Sustainability Award at NFEST 2018 at its 1st International conference at New Delhi
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Thank you