Sustainable Manufacturing ~ Proc. ofthe International Conference on Sustainable Manufacturing: Issues, Trends and Practices (CSM ~ 2011), BITS, Pilani, Indi, November 10-12, 2011 Need of Cleaner Production in Indian Foundries for Sustainable Manufacturing G.S. Patange', M. P. Khond? and A. V. Joshi! ‘Charotar University of science and technology, Changa ~ 388421, Gujarat India *College of Engineering, Pune, Maharashtra — 411005, Corresponding author (e-mail: gajananpatange me@charus Abstract Foundries use a lot of different materials and produce wastes that represent a cost fo the company and can have an impact on the environment if they are not managed effectively. The wider community and governments may also face significant costs for treating and disposing of wastes and for repairing damage tothe environment. These costs can be high and trends show that they are raising a pressure on the environment increases. Traditional environmental protection focuses on what to do with wastes and emissions afer they have been created, Treatment and disposal of waste generally only address the symptoms of an inefficient process. Waste is oflen an indicator that you are losing money unnecessarily All casting opetations have some potentially harmful tothe environment, the health of their employees and to generate nuisance issues in the community, The main objectives of this paper are to disseminate knowledge amongst the Indian Foundries about the best technology available in their respective fields, to molivate them to adopt latest eco friendly technologies and to be globally competitive & prepare for the opportunities for becoming global hub for sourcing cast component, Keywords: Cleaner Production (CP), foundry, waste, Environment. Indian found’ 1. Introduction According to current trends in world population growth and industialization, waste and pollutants are released faster than the earth can absorb them. Natural resources are consumed faster than they can be restored, By 2025 we expect to have an additional three billion people living on this planet. According to some assessments, reductions of over 90% on material throughput, energy use and environmental degradation will be required by the year 2040 to meet the needs of growing population within the planet's carying capacity, If sustainable development isto be achieved, production processes, products and Services have to be redesigned. This requires the development and use of new policy’ and anagement fools in Government and industry. Also we need to develop environmentally sound technologies with focus on cleaner and safer technologies to prevent pollution and make most efficient use of raw materials, (UNEP) {As per India is concerned India's population becomes number one in world and we will have need of automobile and agricultural equipment. Data shows that we need foundry industry as our main \weapons to cope up the demand. 1.1 What is Cleaner Production? Cleaner Production is defined technically as the continuous application of an integrated preventive environmental strategy to processes, products and services to increase efficiency and reduce risks to humans and the environment. For production processes: Cleaner Production includes conserving raw materials and energy, eliminating toxic raw materials, and reducing the quantity and toxicity of all emissions and wastes before they leave @ process, Far products: the strategy facuses on reducing impacts along the entite lie cycle ofthe product, from raw materials extraction tothe ultimate disposal of the products. For services: Cleaner Production reduces the environmental Impact of the service provided over the entie life eyele, from system design and use to the entre consumption of resources Fequited to provide the services. Cleaner Production requires applying know-how, improving technology, and changing altitudes. Many preventive terms - such as cvv-cflicieney, pollution prevention, waste minimization, (UNEP, 1999) 19Sustainable Manufacturing Figurel. Basie concept of cleaner production [Global Environment Centre Foundation (GEC) Japan] 2. Literature review Henry Ford is considered by some to be the father of lean thinking, and was reportedly a master at finding waste. (Mohd Nizam Ab Rahman et al, 2009), Sustainability was defined by the International Union for Conservation of Nature in 2 1969. (Keiner M, 2006) Mobd Nizam Ab Rahman, Hemadewita suggest model which is shown below Figure 2, Model for CP In 1991, Swiss Agency for Development and Cooperation (SDC) established a program to support developing countries in protecting the global environment (P. Pal etal, 2008) Dalquist S and Gutowski 2004) suggested a model for foundry with potential waste streams Dalquist S ‘and Gutow Figure 3, Foundry with potent Ionel waste. (Dalust S and Gutowski T., 2004) Walmart Corporate in 2006 Suggests 7R which stand for Reduce, Recyele, Reuse, Remove, Renews ble,Revenucand Read (WalMart Corporate, 2006) Production system, termed the Toyota Production System recommends ¢ model (US EPA, 2007) S. Ravichandran, N, Alagumurthi (2011), attempted to optimise the casting weight by varying the levels of process parameters namely, moisture, bentonite, coal dust and sand mixing time using Box- Behnken design of experiments (S. Ravichandran, N. Alagumurthi, 2011) ‘Amrinder Singh Chahal and Priyavrat Thareja 2011), suggested use of simulation-assisted casting is seen to offer unprecedented potential, and by using such technigues foundry men can drastically ‘maximize productivity and eco-socio-quality rich castings. 20Sustainable Manufacturing Meena etal. suggests that green ADI grade produced by a novel manufacturing technology is useful 0 save energy and time in foundry ‘A project on "Water modeling of Continuous Casting Tundish for improvement of Yield and Metallurgical performance" was taken up and completed successfully. With the incorporation of the ‘new design, the skull formation is found to be reduced by approx. 50% by Rashisiya Ispat Nigam Lid (Government of India ministry of steel 2011) Ispat industries Indi td and see auority of India td. (SAIL) taking Energy Conservation measures in ifferen project. (Government of India ministry of Steel, 2011) 3. Profile of Indian Foundry Industry ‘The Indian Metal casting (Foundry Industy) is wel established. According to the recent World Census ‘of Castings by Modern Castings, USA India Ranks as 2 largest casting producer producing estimated 7.44 Milion MT of various grades of Castings as pe International standards ‘Share of no. of smal & Meatum foundry Industry in Totabinaia Figure 4, Production Share (Foundry Informatics Centre New Delhi) ‘Share of Small & Medium foundries in Total exports Figure 5. Total Exports (Foundry informatie centre New Delhi 3.1Production Share ‘The Indian Metal Casting (Foundry Industry) is well established, According to the recent World Census of Castings by Modern Castings, USA India Ranks as 2nd largest casting producer producing estimated 7.44 Million MT of various grades of Castings as per Intemational standards, The various types of castings which are produced are ferrous, non ferrous, Aluminum Alloy, graded cast iron, ductile iron, Steel ete for application in Automobiles, Railways, Pumps Compressors & Valves, Diesel Engines, Cement/ElectricalTextile Machinery, Aero & Sanitary pipes & Fittings ete & Castings for special applications, However, Grey iron castings are the major share approx 70 % of total castings, produced. ‘There are approx 4500 units out of which 80% can be classified as Small Scale units & 10% cach as Medium & Large Seale units. Approx 500 units are having Intemational Quality Accreditation. The large foundries are modern & globally competitive & are working at nearly full capacity. Most foundries use cupolas using LAM Coke. There is growing awareness about environment & many foundries are switching over to induction fumaces & some units in Agra are changing over to cokeless ‘cupolas (Foundry Informatics Centre, New Delhi) 3.2 Exports trends ‘The Exports are showing healthy trends approx 25-30% Year over Year [YOY] as ean be seen from the charts below. The current exports for FY 2005-06 ate approx USD 800 Million 2