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WEL COME TO

PRESENTATION BY
WARANA DAIRY

ENERGY CONSERVATION
The Success Story of Warana
Dairy.

„ A movement called Warana was started by a visionary


TATYASAHAB KORE in 1951, with the establishment of a sugar
factory. Initiated for the cause of the economic upliftment of
the poor farmers. Setting a landmark in the field of rural co-
operative industry, today, the movement has gathered a
momentum and has proved to be a precious asset to the
economic progress.
„ The Success story of WARANA was destined to continue
through the young and able hands of Shri. Vinay Kore, the
grandson of Late Shri. Tatyasaheb Kore. Endowed with an
undying, positive approach and great optimism, he
successfully leads the forward march of WARANA GROUP.
„ Shri. C. N. Gulave, Managing Director, has played a massive
role in contributing to WARANA DAIRY’S stupendous success.
The Success Story of Warana
Dairy.

„ WARANA DAIRY Established in 1968 to provide additional


source of income to the farmers.
„ Activity :- To collect the milk and supply to Govt. Dairy

Miraj.
„ 50000 Ltrs. Capacity Processing plant installed in 1974.
„ Activity :- To supply the pasteurized milk by Road Milk

Tanker to Govt. Dairy’s in Mumbai.


„ In 1982 Established its own market in Mumbai & Local area.
„ Since 1994 to 1999 capacity of Dairy increase to handle milk
up to 5 Lac. Liters in same plant.
„ Now Dairy Produces various milk products like Past. Milk, Milk
Powder, Shrikhand, Ghee, Butter, Lassi, Cheese, Paneer Baby
Food, Mix Fruit Jam, Fruit Drinks and Many More.
Need for Energy Saving.

„ To Reduce processing/ production


cost & thereby give maximum
returns to producers / poor
farmers.
„ Need of time to Comparative edge
in market competition.
„ Limitation of fuels sources &
energy.
Task Carried Out.
Self Power Generation
Co-Generation Plant with Waste Heat Recovery.
In operation from July2002.

„ 2002-03 Unit rate Rs 2003-04 Unit rate Rs


„Units generated 43,17,200 64,33,920
„Units supplied 39,05,110 59,36,720
„LDO Ltrs 01,13,050 0.43 00
„Furnace Oil Ltrs 10,54,600 3.70 16,94,000 3.74
„Diesel Ltrs 26,350 0.16 29,000 0.12
„Lube Oil Ltrs 15,290 0.23 25,000 0.25
„Electricity duty 0.33 0.33
„Unit Generation Cost 4.85 4.44
„SAVING by Heat Recovery

„Steam 20,16,450 kg - Rs 25,08,000 34,14,540 kg - Rs 40,80,000


„Chilled Water 91,361 TR - Rs 6,04,000 3,00,101 TR - Rs 23,63,000
„Diesel saving in MSEB

„shut down 2,53,373 Ltr - Rs 58,14,000 3,76,000 Ltr - Rs 91,15,000


„Saving per Unit 2.30 3.05
„Net generation cost 2.55 1.39
UNIT GENERATION COST INCLUDING FIXED COST

2002-03 2003-04
Units generated 43,17,200 64,33,920
Units supplied 39,05,110 59,36,720
Unit generation cost Rs 2.55 Rs 1.39
Intrest Rs 0.50 Rs 1.18
Deprication Rs 1.02 Rs 0.95
Salary Rs 0.31 Rs 0.21
R&M Rs 0.69 Rs 0.48
Total generation cost Rs 5.07 Rs 4.21
MSEB + DG Cost Rs 5.03
Difference Rs 0.82/Unit
Task Carried Out.
„Conversion of F.O. Boiler in to Briquette / Wood fired Boiler.
„In operation from April 2003.

Month Briquttes Equivalent Cost Of Briquttes Saving


in Kg FO FO Cost Cost
Apr-03 50540 14440 209380 103607 105773
May-03 124469 35565 515692 255161 260531
Jun-03 97449 27842 403717 199770 203946
Jul-03 134817 38519 558527 276374 282152
Aug.03 19911/ 26272 380952 164320 216632
Sep.03 112951 28237 409447 169426 240020
Oct.03 66837 16709 242284 100255 142028
Nov.03 123350 30837 447143 185025 262118
Dec.03 136050 34012 493181 204075 289106
Jan.04 133450 33362 483756 200175 283581
Feb.04 118800 32881 476780 211605 265175
Mar.04 81309 23231 336850 146356 190494
Total 1180022 341907 4957709 2216149 2741556
Task Carried Out.

„ Energy saving by reducing Milk


Past. Temp. 80 to 750C

Month Milk Handled Lit. Rs. Save (in Lac.)


1st Half Year 03-04 424.206 2.33 On Steam
1st Half Year 03-04 424.206 2.73 On Refri.
2nd Half Year 03-04 600.847 2.67 On Steam
2nd Half Year 03-04 600.847 3.41 On Refri.
Task Carried Out.

„ Water saving by Planning & Training.

Month Milk Water Water req. Water Saving


Handled Used as per Last saving Rs.Lakh
Year Ratio Lakh Ltrs.
1stHalf Year 03-04 424.206 932.378 1281.75 349.37 3.49
(1 : 2.20) (1 : 3.00)
2ndHalf Year 03-04 600.847 916.422 1802.54 886.12 8.90
(1 : 1.5) (1 : 3.00)

Total 1025.05 1848.8 3084.29 1235.49 12.39


Task Carried Out.
„ Power saving by Efficient working
in Milk Packing Section.
„ Action taken : - machine set to higher
speed.

Month Hours off Total Unit Saving Rs.


Save In Lakh
1stHalf Year 03-04 860 32043.6 1.37

2ndHalf Year 03-04 915 34092.9 1.47

Total 1775 66136.5 2.84


Task Carried Out.

„ Workers training on regular basis to create awareness


about energy and resource Saving.
„ Provision of improved system/ Equipments.
„ Steam, Water, Milk leakage's strictly monitored and
controlled.
„ Hot water, (Condensate) from NPP, AARP Used for can
washer, crate Washer’, tanker cleaning.
„ Excess of hot water (Condensate Water) is Utilized as wash
point for effective cleaning.
„ Various energy audits performed to use as guide line for
energy / resource saving.
„ Utilization of Solar water heating system 20000 LPD.
Benefits
„ Water utilization is reduced to 1.5 Lit./ Lit.of
Milk handled. (3 Liter. To 1.5 Liter.)
„ Keeping quality of milk is increased by 2
hours. (11 hrs. to 13 hrs.)
„ Dispatch temp. for tanker is 38-40 0F and for
milk pouch dispatch temp. is below 400F.
(600F to 400F)
„ Improvement in quality of products.
„ Improvement in energy saving.
Planning
„ Installation of Multi-fuel Boiler for 30 TPD
powder Plant.-Approx. Saving 1Coror / Year.
„ Installation of multi-fuel 40 T boiler With Co-
Generation And Turbine of 1MW.
„ Modification of Existing ETP-
„ Existing System- Aerobic System.
„ Modification- Anaerobic Digester Followed by Present
Aerobic System.
„ Cost economics of Project-Total Cost Rs.40 Lakhs.
„ Working Cost –Rs.25 Lakh / Year.
„ Savings-1) Electrical – Rs.10 Lakh. 2)Bio Gas –Rs. 20 Lakh
3)Water Floor Washing –Rs. 14 Lakh Total= 44 Lakh.
„ Net Saving- 44 – 25 = Rs. 19 Lakh/ Year
Planning
„ Replacement of refrigeration Condensers.
„ Approx. Cost – Rs.45 Lakh.
„ Existing – Atmospheric
„ Replace – P.H.E.
„ Benefits –1) Plant efficiency will increase by 10 to 15%
2)Qty. of Ammonia in circulation will be
Reduced Considerably. 3)Reduction in fittings hence
reduction in Ammonia Leakages considerably .
„ Provision of Large Cap. Road Milk Tankers .
„ Existing - 9500 lit. Provision – 18000 lit
„ Saving –429 lit Diesel /Day X 350 days =150150 ltrs.
= 150150 Ltrs.X Rs. 30.00= Rs. 4504500.
Thanking You.