First Prize Dairy

SUMUL DAIRY
(Surat Distt. Co-operative Milk Producers’ Union Ltd.)
Surat (Gujarat)

Unit Profile

Surat District has been a Pioneer in India in channeling trade in Cotton and Milk through co-operatives.
Before SUMUL stepped in, traditional Private Milk Traders were dominant in the area. Dairying on the
other hand, was never popular with tribal (a major rural population in the District) as practically no
infrastructure existed for milk marketing in their talukas, inaccessibility to their villages as well as taboos
regarding keeping of buffaloes prevented the entire population of tribal from considering dairying as a
source of income. To salvage the poor producers from the clutches of these Private Traders, SUMUL
Dairy was established.

Main Objective of Sumul

1. To provide a guaranteed remunerative milk market round the year for all the marketable surplus of
member producers in their villages.
2. To procure milk, process it into good quality milk/milk products and market it most economically and
efficiently to give maximum overall net-returns to the producers and general satisfaction to the
consumers.
3. To provide essential technical inputs and services to the producers’ at their door-steps in an economic
and efficient manner and also in a way most acceptable to them - to increase milk production and to
reduce the cost of production.

SUMUL DAIRY SURAT OTHER UNITS OF SUMUL

Bajipura
Navipardi Uchchal
chilling
Chilling Center Chilling Center
Center

Nizar Chalthan
Lahe, Shahpur
Chilling Cattle Feed
Nasik Plant
Center Plant

`Simul is also ISO – 9002, HACCP and ISO – 14001 certified organization. It is also certified from Export
council of India, which will help in improvement and export of surplus milk and milk product.

165
 Name of Product Packing Type Production
in (kg)
Amul Shakti, standardized 500 ML , 6 Litres 328301659
Milk
Amul Gold, High Fat Milk 500 ML , 6 Litres
Amul Taaza, Toned Milk 250 ML, 500 ML
Skimmed Milk, Cow milk 6 Litres
Butter Milk, Masala chhas 500 ML
Ghee Tin, Pouches 3293942
Paneer Pouches. Tin 232651
Flavored milk Bottle, 446812
Curd Cups (200 & 400 1556623
gm)
Sweets Box 640882
Powder Bag 749400
Butter cartons 732720
Pasteurized chilled water 2429000

Energy Consumption

There is a steady decline of specific energy conservation due to implementation of various energy
conservation measures in last 3 years. The details are as given below:

DESCRIPTION UNIT 2005-06 2006-07 2007-08

Annual milk & milk production Mt 334461 329544 344307

Total electricity consumption/ annum Lakhs kwh 91.90 88.73 90.01

Specific energy consumption Kwh/mt 27.477 26.92 26.14

Total thermal energy consumption / annum Million kcal 13007.41 12856.33 12684.2

Specific energy consumption – thermal Million kcal 0.0389 0.039 0.0368

/mt
Total manufacturing cost Lakhs Rs. 3519.17 4247.97 4780.68

Total energy cost Lakhs Rs. 633.0 596.65 668.78

Energy cost as % of total manufacturing cost % 17.98 14.05 13.98

166
Graphical presentation of Specific Energy Consumption of Sumul Dairy

SPECIFIC ENERGY CONSUMPTION KWH/MT SPECIFIC ENERGY CONSUMPTION MKCAL/MT

0.0389 0.039
27.47
27.6 0.039
27.4
26.92 0.0385
27.2
27 0.038
26.8

MKCAL/MT
K W H /M T

0.0375
26.6 26.14 0.0368
26.4 0.037
26.2
26 0.0365
25.8
0.036
25.6
25.4 0.0355
2005-06 2006-07 2007-08 2005-06 2006-07 2007-08
YEAR YEAR

% Energy Cost To Manufacturing Cost

WATER V/S MILK RATIO 17.98
0.69
18
14.05 13.98
0.69
16

0.685 0.68 % OF 14
ENERGY
COST 12
0.68
10
K L /M T

0.675 0.67 8

6
0.67
4
0.665
2

0.66 0
2005-06 2006-07 2007-08 2005-06 2006-07 2007-08

YEAR

Energy Conservation Commitment, Policy and Set up

Energy Policy

The unit is committed to conserve the energy which is a scarce resource with the requisite consistency in
the efficiency, effectiveness in the cost involved in the operation and ensuring that production quality &
quantity, environment, Safety, health of people are maintained.

The Mission is to be lowest specific energy consumer in the industry we operate.

This we plan to achieve by the following:-

• Manage efficiently the utilization of energy resources upgrade hardware & employ cleaner & more
efficient Technology.
• Carryout regular internal & external audits to identify area for improvement.
• Bench-mark continuously our performance against best practices.
• Enrich our experience on energy conservation by exchange of ideas with other organization.
• Promote awareness among all members of the Sumul large family.

167
Energy Conservation Plans and Targets

S. Energy Conservation Anticipated savings Approx. Project

No. Measures (Planned) 2008-09 investment Commencement
(Rs. Lakhs) & Completion
year
Energy Value Rs. Status as on
( specify units ) Lakhs 5th Oct-08
A Electrical Project

1. Replacement of 125 HP Star 81457 4.48 5.0 Commissioned

Delta starters with 190 amp Soft
starter for powder plant delivery
fan.

2. Replacement of less efficient 217261 11.95 10 Commissioned

butter milk pasteurizer with high
regeneration new butter milk
Pasteurizer. (As per suggestion
of PCRA audit recommendation.)

3. Replacement of old 3.5 hp motor 7292 0.40 1.8 Commissioned

with new 3.0 hp motor.

4. Replacement of Tank room milk 84715 4.74 5 Commissioned

tank manual agitator system with
PLC automation system.

5. Replacement with new double 26280 1.44 4.81 Commissioned

headed mechanical Ghee
packing machine in place of
pneumatic machine.

6. Installation of PUF Panel in 35770 2.0 5 Commissioned

incubation room of curd section.

168
S. Energy Conservation Anticipated savings Approx. Project
No. Measures (Planned) 2008-09 investment Commencement
(Rs. Lakhs) & Completion
year
Energy Value Rs. Status as on
( units ) Lakhs 5th Oct-08
7. Installation of Soft starter for 10 43444 2.39 3.0 Commissioned
small motors.

8. Milk heating for UHT from 6-35 C 18105 1.01 0.46 Commissioned
by hot water recovered from
ammonia PHE. With electrical
saving in condenser load.
(Electrical saving).

9. Installation of Paneer whey 26280 1.44 0.5 Commissioned

cooling system by incoming milk
from 75 to 30 C & simultaneous
heating of milk from 6-35 C by
improving regeneration.
(Electrical saving).

10. Installation of natural ventilation 6424 0.359 3.6 Commissioned

system.

11. Substation automation in Sumul. - - 1.5 Commissioned

12. Replacement of old IBT agitator 325828 17.92 20 Commissioning

with Grundfos make IBT agitator
for power saving.

13. Replacement of new boiler feed 35841 1.97 5 Under

water pump. Commissioning

14. Installation of common 250 KVA 60590 3.39 5.0 Under installation
automatic voltage stabilizers for & commissioning
lighting load (AS PER ENERGY
AUDIT REPORT).

169
 S. Energy Conservation Anticipated savings Approx. Project
No. Measures (Planned) 2008-09 investment Commencement
(Rs. Lakhs) & Completion
year
Energy Value Rs. Status as on
( units ) Lakhs 5th Oct-08
15. Installation of PLC in Ghee Tin - - 2 Order placed
filling machine.

16. Replacement of 30 kl pasteurizer 79409 4.37 15 Under Inquiry

with high energy efficient milk
pasteurizer.

17. Replacement of crate washer old 21722 1.19 10 Under Inquiry

pumps with new pump.

18. Replacement of old thermocol 43800 2.45 15 Under Inquiry

insulation with PUF Panel in
butter clod store.

19. Replacement of pneumatic milk 163520 9.15 5 Under Inquiry

filling cylinder by magnetic type.

20. Hydro flow system for ETP plant. 28928 1.62 0.83 Under Inquiry

21. Installation of vfd for milk transfer 39099 2.19 5.0 Under Inquiry
to pouch packing machine in
packing section.

22. Generation of power at ETP 182500 9.12 35.0 Under Inquiry

through Bio-methanization.
Capacity 100 KVA
TOTAL 1528265 83.579 156.5

Environment and Safety

A) Water Effluent

The major effluent in dairy is the flushing of milk pipelines with Caustic & Acid which comes to the Effluent
Treatment Plant. Our plant comprised anaerobic treatment followed by aerobic system, while making use
of all the existing units. With the addition of UASB system, there will be a potential for reusing a valuable
byproduct of the plant i.e. Biogas. Due to the conservation of process water at various stages of milk
processing, the effluent generation came down from 700 to 500 M3 / Day.

170
For that, unit has upgraded our Effluent Treatment Plant with recycling plant to reduce pollution load as
well as to reduce water consumption by using ETP reused water.

GPCB Analysis data ( BOD) GPCB Analysis data ( COD) GPCB Analysis data ( SS)
premicible limit 30 permicible limit 100 permicible limit 100
30 96 100
23 23 100 88 82 80
25 20 84

V alue
18 80 75 69 60 42
20 17 32 36 32 SS

COD
BOD COD 26
V alue

14 13 52 40 22 18
15 11 60 43
20 8
10 40 0
5 20

08
7

8
07

07

07

7
.07
0

.0

r. 0
c. 0

b.
ri l .

ly.

g.
ne
ay

Ap
7
.0 7

8
7

07

Fe
Au

De
07

Ju
Ap
y .0

b .0
0

c .0

Ju
r .0

M
ly .

g.
r i l.

ne
7

08
07

07

07

Ma

Fe

Ap
De
7

Au
Ju
.0

Ap
.0

Ju
.0

r .0
b.
ly .

g.

c.
ne
ay
ril

Month
Fe

Ap
De
Au
Ju
Ap

Ju
M

Month Month

B) Air Emission Analysis

The major source of air emission in Sumul is through Boiler, DG set, Hot air generator stacks. The unit
is constantly using natural gas a source of fuel which is eco friendly.

Stack Analysis (SO2) data of 07-08 Stack Analysis (NOx) data of 07-08 Details of SPM of 07-08 SPM
20 50
permicible limit 100 permicible limit 50
200
40 permicible limit 200
162.5 162
S O 2 v alu e

N O x v a lu e

146.3 148.15
9.2
30 150 137.9
132 133 137.3 134.55
128.36
135.5

Value
10 8.5 8 7.75 122
7 6.6 6.5 20
4.35 4.31 4.51 11.65 12.7 11.85 10.7 9.85 11.15 12.6 11.75 10.95 10.8 10.15 11.25 100
3.45 3.4
SO2 10 Nox
50
0 0
Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec. Jan. Feb. Mar. Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec. Jan. Feb. Mar.
0
Month Month Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec. Jan. Feb. Mar.
Month

Plantation

Sumul Dairy has planted Rs. 2.825 Lakhs of plant in 369 villages of Surat District as part of forestation.

Celebration of Energy Conservation Day

Sumul has celebrated Energy Conservation Day on

14th Dec-2007. Employees from top to bottom level
have participated. Banners, posters are placed
at various places in plants.

Training program was conducted at floor level.

171
Second Prize Dairy

HERITAGE FOODS (INDIA) LIMITED

Chittoor Distt. (Andhra Pradesh)

Unit Profile

Heritage Foods (India) Limited is one of the fastest growing enterprises in Dairy Industry in South India.
The Main Dairy Plant, Gokul was commissioned in 1996 with a rated capacity of 1.5 LLPD and was
subsequently expanded to 2.5 LLPD in 2007.

Presently, Heritage Milk and Milk products have prominent market presence in Andhra Pradesh,
Karnataka, Kerala, Tamilnadu and Maharashtra.

GOKUL PLANT

172
Energy Consumption

There has been a steady increase in the milk handled and decrease in the energy consumption since the
establishment of Energy Management policy implementation in 2005.

Last 3 years Specific energy consumption figures are shown below, which depicts continual reduction in
energy consumption over last 2 years due to our sustained efforts to conserve with the implementation of
various energy conservation measures and ideas to increase efficiency of all its our operations.

Description Unit 2005-06 2006-07 2007-08

Electrical energy KWh / Tonne 52.93 52.32 44.75

M Kcal /
Thermal Energy 0.0984 0.0890 0.0730
Tonne
Total Manufacturing Cost Rs. Lakhs 367.71 440.12 570.63

Total Energy cost Rs. Lakhs 160.62 177.85 248.18

Energy as % of Total cost of
% 43.68 40.41 43.49
production

SPECIFIC THERMAL ENERGY

SPECIFIC POWER CONSUMPTION
CONSUMPTION

54
0.12
52
0.1
50
M KCal / Tonne
KWh / Tonne

0.08
48
0.06
46
0.04
44

42 0.02

40 0
2005-06 2006-07 2007-08 2005-06 2006-07 2007-08

YEAR YEAR

Energy Conservation Commitment, Policy and Set up

Heritage Foods (India) Limited, Main Dairy Plant, Gokul visualized the importance of Energy Conservation
and taken measures accordingly in forming the core team and conducted several brain storming sessions
section wise by creating awareness and to identify the areas to concentrate.

173
 Energy Conservation Team Structure

General Manager (O)

Plant Manager / Energy Manager

Energy Conservation Core Team consists of

Maintenance Engineer
Electrical Engineer
Utilities Incharge
Quality Representative

The above team activities

- Brain storming
- Identify the area / Investment & ROI

Implementation Monitoring team

team Executive
Executive Supervisor
Supervisor Fitter
Executing the Monitoring and
designed activity as analyzing the output and
per plan feedback to core team

174
Energy Conservation Achievements

During the period 2007-2008, The Unit implemented 13 major Energy saving Ideas through Brain
Storming Sessions conducted in Energy cell and in Energy Conservation awareness classes. Annual
Savings of Rs. 18.99 lakhs was achieved with an investment of Rs. 8.06 lakhs only. It has resulted in
Percentage Reduction of 14.469% in Electrical Energy and 17.98% in Thermal Energy.

Achievement of energy savings per year

basis
Investment
Electricity Fuels*
Total incurred on
Project description
Total savings the project
(Lakhs F.Oil in (Rs. Lakhs)
(fuel) in
(kWh) (KL) (Rs. Lakhs)
Mkcal)
Replaced raw effluent pump of 0.20 0.69 0.30
5HP capacity with Energy Efficient
2HP pumps
Replaced CBMM rotopump 5HP 0.26 0.93 1.50
capacity with Energy efficient VFD
driven 1HP rotopump
Instead of Cooling tower for 0.06 0.19 0.00
Cream Pasteurizer water
connection taken from ATM sump.
Condensate recovery tanks 12.0 119.70 2.86 0.25
provided. One tank for the
pasteurizers condensate and one
tank for the condensate of Khoa
pan and Paneer vats
Replaced 10KL and 3KL 0.16 0.58 0.81
pasteurizers Hot water pumps of
3.5HP with Energy Efficient pumps
2.0HP
Multi purpose vat jacket Chilled 0.55 4.0 39.90 2.88 1.50
water taken back to IBT and chiller
arranged to reduce temp. from 85
degrees 50 degrees with soft
water. The heated soft water used
for bottle cleaning
Installed Condensed milk chiller, 0.56 8.0 79.64 3.88 1.67
there by reducing the temperature
of condensed milk from 55
degrees to 10 degrees and
preheating the skim milk going to
powder plant.
IBT make up water with the 0.04 0.13 0.00
Chilled water getting from Cream
silo during heating cream from 8
degrees to 13 degrees

175
Splash steam from all the steam 5.0 49.88 1.19 0.25
traps recovered by connecting
them to hot water tub and used as
boiler feed.
By following sequence of 0.57 2.01 0.00
operations, minimized the
Ammonia compressor running
hours. In 2006-07 per hour of
Compressor 7534lts milk handled
and in 2007-08 8063 lts handled.
391hours of KC6 compressor
reduced
By elevating the Silo avoided 2HP 0.09 0.31 0.50
pump for the FCBT of Curd
Pasteurizer
Arranged Electro Magnetic Water 10.0 99.75 2.38 0.48
Flow meters in CIP section and
monitored efficiently the qty. of
water per object CIP (achieved
5000Lts/ Day hot water saving)
Replaced the IBT agitators 0.27 0.96 0.80
motors 10HP 2 numbers with
Energy Efficient 7.5HP motors
Sub Total 2.76 38.98 388.87 18.99 8.06

Energy Conservation Plans and Targets

Anticipated savings
in Approx. Project
Energy Conservation
investment Commencement &
Measures (Planned)
Energy Value Rs. Lakhs (Rs.lakhs) Completion year
(specify units)
6 tons Multi Fuel Fluidized
bed boiler planned (Coal) in 27141.5
place of Furnace Oil fired --- 248.0 62.0 March'2009
M Kcal
boilers
Prechiller for returned chilled 1.095 --- 3.9
water Lakh 10.0 Dec'2008
Kwh
Pasteurizers Hot water 1000 2.3
source to be changed from Mkcal 5 2009
Steam Battery system to
PHE system

176
Environment and Safety

1. A Safety committee is constituted with employees working at Different levels which meet
periodically to analyse all aspects of Employees health & safety during work. The safety
committee’s recommendations are being implemented to improve the working conditions & safety
of all.

2. A good ETP system consisting of USAB reactor and Aerator tanks treat our plant water very
efficiently and this water is being used for the development of green belt around the plant

177
Certificate of Merit Dairy

KOLAR MILK UNION LIMITED

Kolar (Karnataka)

Unit Profile

Kolar District Co-operative Milk Producers Union is registered under Co-operative Societies act after
bifurcation from Bangalore District Co-operative Milk Producers Union on 23/03/1987. The area of
operation is restricted to Kolar and Chikkaballapur Districts having 2919 villages of 11 revenue Taluks.

Energy Consumption

With the implementation of various energy conservation measures in the dairy unit, there is significant
reduction in energy consumption and also considerable decline of specific energy consumption. Due
to the sustained efforts to conserve energy and with the implementation of various energy conservation
measures and novel ideas to increase efficiency of equipments, the declining trend of specific energy
consumption in last three years is shown below.

Description Unit 2005-06 2006-07 2007-08

Specific Electrical energy Kwh/Tonne 43.71 38.52 36.10
Specific Thermal energy Mkcal/Tonne 0.0648 0.0548 0.0486
Total turn over Lakhs 30583.6 29837.42 35780.65
Total Manufacturing cost Lakhs 3035 2410 3131
Total Energy bill Lakhs 333.95 361.54 360.14
Energy as % of Total cost
% 11 15 11.5
of production

178
* Though there is a remarkable decline in specific thermal & electrical energy the total energy bill is at
higher side due to the increase in the prices of furnace oil, diesel and also power tariff rates.

Specific Electrical Energy Consumption 2007-08

50
45
40
43.71

35

38.52

36.1
30
25
20
15
10
5
0
2005-06 2006-07 2007-08

Kwh/Tonne

Specific Thermal Energy Consumption 2007-08

0.07
0.06
0.0648

0.05
0.0548

0.0486

0.04
0.03
0.02
0.01
0
2005-06 2006-07 2007-08
MKCal/Tonne

179
 Energy Policy

Kolar District Co-operative Milk Producer’s Societies Union Ltd.,

ENERGY POLICY

We continuously strive to effectively improve the overall operations and

management systems by adopting cost effective advanced technologies and by
educating and motivating the workforce to achieve maximized qualitative production
with least energy consumption and safeguarding environment and natural
resources.

ENERGY CONSERVATION CELL

Energy Committee Chairman

(General Manager)

Energy Manager
(Manager Engineering)

Energy Team
Coordinator

DM’s (Eng) DM’s (Prod)

AM’s (Eng) AM’s (Prod)

Technical Officers Technical Officers

Energy Conservation Cell

180
Energy Conservation Plans and Targets

In this regard few energy conservation projects were planned, discussed in detail to be taken up in the
year 2008-09.

1. 225 TR De-Super Heater

The unit is replacing the existing 75 TR De-Super Heater with 225 TR De Super Heater, to conserve more
thermal energy and to run the refrigeration plant efficiently. Unit has estimated savings to an extent of Rs.
25 Lakhs/Year, with an investment of Rs 24 Lakhs.

2. Installation of energy saver for lighting system.

The lighting load of Kolar dairy is 70 KWH. The energy savings by installing energy savers is Rs 2.00
Lakhs with an investment of Rs 2.75 Lakhs.

3. Improvement of Power factor from 0.93 to 0.99

By providing additional power capacitors unit is able to increase power factor from 0.93 to 0.99, there by
decreasing the electrical load on the system. The total cost of providing additional capacitors is Rs 60,000
only and expected savings is Rs 1.2 Lakhs per annum.

4. Replacement of Slip ring induction motors

At present 100 HP capacity of type slip ring induction motors are connected to 4 No's KC-3 ammonia
compressors. Unit has planned to replace higher capacity slip ring induction motor with lesser capacity
(75 HP) high torque squirrel cage induction motor, which consumes less electrical energy. The cost of 75
HP induction motor is Rs 6.0 Lakhs and expected savings is Rs.5Lakhs/annum

5. Replacement of 7.5 HP reciprocating type boiler feed water pump.

The boiler is fed through 7.5 HP capacity reciprocating type boiler feed water pump. Unit has planned to
replace it with 5 HP capacity vertical type boiler feed water pump at a cost of Rs 85,000; the estimated
savings is Rs 62,000 per annum. The proposal is under process.

181
Certificate of Merit Dairy

MOTHER DAIRY
Gandhi Nagar, (Gujarat)

Unit Profile

Mother Dairy, Gandhinagar (MDG) is a unit of Gujarat Cooperative Milk Marketing Federation (GCMMF)
Ltd., which markets its products under the brand name of AMUL & SAGAR. The earlier milk processing
facility in Gujarat was totaling around 37 lac liters per day (LLPD) as against the expected procurement
totaling 45 LLPD in 1994-95. Thus it was decided to put up the most modern, PLC based automated dairy
processing plant with in-built capability to produce milk products matching to the best quality standards
and handle the surplus 10 LLPD of milk. MDG was commissioned in September 1994 by L & T with
assistance of APV, Westfalia & Niro. The dairy processes fresh milk to the tune of 10 LLPD. The dairy
initially had Liquid Milk, Pouch Filling, Butter Oil plant & Milk Powder Plant. To keep pace with changing
time Pouch filling Expansion Project, Mozzarella Cheese plant, UHT plant & Ice Cream plant were
installed subsequently. Recently unit has increased it’s Milk Processing Capacity from 10 LLPD to 25
LLPD. It is estimated that in the year 2010, MDG would receive 35 LLPD of milk. To meet these
requirements, unit has expanded it’s milk handling capacity by installing 100 MTPD milk powder plant. The
plant is a state-of-art in terms of civil structural engineering and most modern process technology and
automation. In the 2nd phase of expansion, there would be another 100 MTPD milk powder plant. As flow
of milk became intermittently incessant, it was decided to convert milk into other milk products such as
Ghee, Butter oil, Milk powders, Ice Cream, UHT milk, Cheese, UHT Softy Mix, UHT Chocolate milk. The
other product portfolios apart from milk and milk products are Pizza and Parathas. The plant is
professionally managed and has adopted world-class quality management systems and similar initiatives
like ISO 9001:2000, ISO 22000:2005, HACCP, ISO 14001:2004, Total Productivity Maintenance, Six
Sigma, Total Energy Management, etc. Mother Dairy, Gandhinagar is conscious about Energy
Conservation, since its inception. It is the first dairy in India to install VAM (Vapour Absorption Machine) &
WHRB (Waste Heat Recovery Boiler), as energy conservation measure.

182
Energy Consumption

Mother Dairy, Gandhinagar has witnessed a steady decline in specific energy consumption as a result of
implementation of various energy conservation measures as ongoing practice. Figure showing the usage
of Total Energy in comparison to Total Cost of Manufacturing, clearly reveals continual improvement due
to our strong and consistent efforts during the last two years. Also the annual energy savings achieved as
a ratio of annual sales turnover is highly remarkable, as shown in the figure.

DESCRIPTION UNIT 2005-06 2006-07 2007-08

Total Manufacturing Cost Rs. Lakhs 123124.79 88703.72 76103.40
Total Energy Cost Rs. Lakhs 2088.07 1553.02 1957.57
Energy Cost as % of Total % 2.74 1.75 1.59
Manufacturing Cost

DESCRIPTION UNIT 2005-06 2006-07 2007-08

Actual Energy Savings achieved Rs. Lakhs 93.92 155.88 335.97
Annual Sales Turnover Rs. Lakhs 834 896 1124
Energy Savings Achieved % 0.1062 0.1740 0.2989

183
Energy Conservation Commitment, Policy and Set up

Mother Dairy, Gandhinagar has visualized importance of energy conservation and had made sincere
efforts in achieving the same. Mother Dairy is committed to make continual improvements in energy
conservation. For this Total Energy Management (TEM) team is established at Mother Dairy. The team is
led by General Manager and it is delineated below. The team works in close co-ordination to achieve our
Energy Policy objectives. The energy conservation initiatives are reviewed periodically and new projects
are identified.

Energy Conservation Achievements

During the period 2005-2006 to 2007-2008, the unit implemented, 48 energy saving ideas generated.
Annual savings of Rs. 616.74 lakhs was achieved as against the investment of Rs. 438.85 lakhs.

Major projects implemented for Energy Conservation during the period 2007-2008

1. Installation of Vapour Absorption Machine (VAM) and Waste Heat Recovery Boiler (Trend-setter
Project)

02 Nos. of Vapor Absorption M/C are

installed those are utilized to produce the
Chilling Effect from the Hot Water of all 04
Gas Engines. This concept of using VAM
for chilling of hot water (a major
requirement in dairy) is first done by MDG

02 Nos. of Waste Heat Recovery Boilers

are installed those are utilized to produce
Steam from Exhaust Gas from all Engines.
Plant is getting 1.5TPH steam from each
WHRB.

Investment: Rs. 345.46 lakh

Saving: Rs. 300.04 lakh

184
2. Installed new burner for air heater in old powder plant

Replaced burner of air heater of powder

plant to achieve best O2 level of 2.8% -
3.0% to save gas consumption of around
10%.

Investment: Rs. 11 lakh

Gas Saving: 1.1 lakh SCM

Saving: Rs. 14.02 lakh

3. Replaced conventional Chock with electronics ballast in Tube light fittings

Replaced Conventional Chock in tube light

fittings by new Electronics ballast.

Investment: Rs. 1.77 lakh

Electricity Saving: 0.24 lakh KWH

Saving: Rs. 1.08 lakh

Environment and Safety

Basically the unit being a food processing industry, considerable thrust has been given to implementation
of HACCP which is currently in place and is being upgraded for the purpose of obtaining, ISO 22000:2005.
Since the internal operations are being covered by HACCP, the waste residues are considerably brought
down and the leftover waste discharges are sufficiently treated as per the requirements of water-air
pollution control Act. There is a plan to use the effluent for industrial cleaning purpose after secondary
treatment.

185