11 food processing

8/13/2019 11 Food Processing

1/12

156

Second Prize Food Processing

PERFETTI VAN MELLE INDIA PVT. LTD

Manesar Plant, Gurgaon (Haryana)

Unit Profile

"Perfetti Van Melle India Pvt. Ltd.", a fully owned subsidiary of the global

conglomerate Perfetti Van Melle, headquartered in Lainate, Italy, started its Indian

operations in 1994. The company today enjoys close to 30% market share, thus

making them one of the leading players in the confectionery industry in Indiatoday.

Perfetti Van Melle entered the Indian market in 1994 by offering its first brand

Center Fresh, followed by Big Babol and Alpenliebe in 1995. The other brands like

Chlor.mint, Mentos, Fruittella, Cofitos, Happydent and Marbles followed

subsequently. PVMI enjoys a huge brand recall among its consumers which form a

total estimated market size of Rs.3000 cr.


2/12


3/12

158

Energy Conservation Action & Results (Projects Implemented Duringthe Year 2011-12)

Examples of Energy Conservation Initiatives

1. Relocation Of 170 TR Chiller along with Pumps with modification of

condenser & chilled water piping To Improve Chilled Water System

Efficiency:

Description Of The Energy Conservation Measure:

In process air-conditioning system (Section - II), three chillers (227 TR + 250 TR

+ 150 TR) are installed and located at separate locations (Phase wise installation).

Due to complicated chilled/condenser water piping network, all three chiller running

at 50 % partial loading with full power consumption along with other accessories.

These chillers were running on less efficiency and not getting properly loading

(Short circuit of chilled water was going-on in main header of chilled water line).

Detail study was carried out along with load management, modification in chilledwater piping and positioning at same location (Relocation of chiller & optimum

pipe line sizing and route modification) carried out.


4/12

159

Now only two chillers (227 TR + 250 TR) are running on full/desire load and 01

No. chiller (170 TR) is now as standby and subsequent energy saving.

BEFORE :-Electrical Load = 522.3 Kw , Electricity Consumption = 3,008,448

KWh/Year

After :-Electrical Load = 394.5 Kw , Electricity Consumption = 2,272,320 kWh/

YearElectricity Saving = 736,128 KWh / Year

2. Improvement in steam condensate recovery from 20 % to 40 %.

In process using lots of steam for process heating direct / indirect and condensate

generate. Earlier 20 % condensate recovery was taking place i.e. in boiler 80 %

fresh water used for feed water purpose.

System for condensate recovery installed in cooker area and increased upto 40%.

i.e. now in boiler plant is using 60 % raw/fresh water for feed water purpose.Resulting into higher feed water temperature helping to save furnace oil consumption

in boiler.

BEFORE

Total Furnace Consumption =204,000Ltr/Year

After

Total Furnace Consumption = 153,000 Ltr/Year

Furnace Oil Saving = 51,000Ltr / Year


5/12

160

Energy Management Policy:

At PVMI, it is unit constant endeavor to reduce energy consumption / ton ofproduction so as to be very cost effective in the highly price sensitive market and

also help to control CO2 emission to prevent environment. This is made possible

by:

Internal and external energy audits are being conducted on regular basis.

Creating the awareness of energy conservation among the employees and

encouraging by rewarding the key initiatives taken by them.

Critically monitoring various data on daily basis and taking instant corrective

steps in case of any major deviation.

By setting a standard of reduction in energy consumption by minimum 5%

years over year.

Initiating investment proposals to use renewable resource;

Up-gradation of processes and equipments with latest technology.


6/12

161

Certificate of Merit Food Processing

JAIN IRRIGATION SYSTEMS LIMITED

Food Park, Jalgaon (Maharshtra)

Unit Profile

Jain irrigation systems limited (JISL) is transnational organization headquartered

at Jalgaon (MS), India. It manufactures a range of products in diverse fields which

nevertheless focused on its main stakeholder; the farmer. JISL's entire gamut of

activities is centered on and around farmer, farm & farming. It's mapping of variouscategories of products & services demonstrate this effectively.

1. Hi-Tech Agri Products & Services

2. Agri Processed Products

3. Natural resources Conservation Products

The food division was established in year 1996. The division has two main

businesses namely dehydrated Onion and vegetable and fruits processing. The

dehydrated Onion business account for more than 50 % share of country's export

of dehydrated onion & vegetables and company is number Three onion and

vegetable dehydrator in the World.

Also, company process fruits like Mango, Banana, Guava, Pomegranate, Tomato

and Papaya. For fruit processing the organization account more than 35 % of the

Mangoes processed in India and is number one Mango processor in the World.


7/12

162

The food division constitutes 15 % of the company's revenue, with compounded

annual growth of 25%. The present turnover of the food division is INR 520 Cr. Food

division has six manufacturing plants and employs about 1200 associates across the

World. The Food Park, Jalgaon unit has capacity to handle 350 MT onion & vegetables/

day and 850 fruits/day. The present turnover of unit is INR 350 Cr.

Energy Consumption

The Main sources of energy in plant are fuels and electricity from grid. Following

are sources of electrical as well as thermal energy in plant.

Electricity from Gird

Captive 1.7 MW Biogas power plants

Coal - input in boiler for steam generationLPG- onion frying Purpose

Diesel- used in DG sets for electricity generation & forklift etc.

The total consumption of energy of applying unit is 20763 MTOE. The electricity is

supplied from MSCDCL. Fuels are major sources of energy in plant i.e. almost 85

% energy requirement met by fuels. Main fuels used in plant are coal, diesel, LPG

out of which coal is dominant fuel.

The following is the energy consumption & Specific energy consumption Scenario

of applying unit.

Energy conservation measures implemented during FY 11-12

Project 1. Installation of 7 TPH Biomass fired Boiler

This 7 TPH biomass fired boiler used other non digestible waste generated during

processing such as mango stone etc. and purchased briquettes. Almost 15 % of

input biomass is purchased remaining 85% is from mango stone i.e. waste

generated in mango processing operation in plant. From this project almost 20 %reduction in coal consumption was achieved.


8/12

163

Total Investment, INR 55 lakh.

Total amount saved/year INR 211 lakh.

Project 2. Conversion of Dehumidifier condenser from air cooling to water

cooled

Earlier dehumidifier in onion division is air cooled. The unit has converted air

cooled condenser to water cooled. It has resulted into uniform cooling and also

reduction in compressor pressure.



Dehumidifier condenser

Picture after modification

Picture before modification


9/12

164

Project 3. Energy Efficient lighting project

Unit has replaced HPMV lights of 290 watt by CFL light of 144 watt resulting into

saving of 30660 kWh /annum.

Total Investment, INR 1.65 lakh.

Total amount saved/year INR 2.3 lakh.

Energy efficient lighting.

Project 4. Installation of Turbo Ventilators on roof.

Earlier total 5 exhaust fan of 5.5kW rating are used. Now 40 turbo ventilators of

are used for ventilation.


Total amount saved/year INR 7.8 lakh

Turbo Ventilators on roof


10/12

165

Project 5. Waste Heat recovery from 1.68 MW biogas power project

In 1.68 MW Biogas power project, unit has installed WHRB for steam generation

and 350 TR vapor absorption chiller operating on steam & 150 TR vapor absorption

chiller is on hot water. Amount of energy saved is 10.69 lakh kWh/annum.



Project 6. Installed Flash steam Recovery system

In dryer section of onion dehydration unit, organization has recovered the flash

steam by installing the heat exchanger. Through this project implementation, unit

is able to recovered 450 kg/hr flash steam. This recovered flash steam is used toheat the air through which unit is able to reduce its steam consumption. Also due

to condensate recovery unit is able to save DM water which is used in boiler.



Project 7. Installation light pipe for available day light utilization

This project initiates to reduce 33% lighting load in DHO plant by utilizing naturally

available daylight. The transparent silicon sheet with aluminum reflectors numbers

is installed.

Total Investment, INR 7.5 lakh.

Total amount saved/year INR 1.98 lakh.

Picture before modification Picture after modification


11/12

166

Light pipe installation

Project 8. Modification for increasing production capacity of drying line 3

In existing dryer of capacity 7 MT unit has done some design modification and

increased the dryer capacity to 10 MT. This improves dryer productivity and resulted

into energy saving.



Ongoing ENCON projects

Improving performance of various refrigeration compressors

Improving performance of vapour absorption machine

Improving performance various cooling & chilled water/brine pumps

Improving performance various refrigeration systems for the cold storage

Optimize heat recovery from flash steam of onion dryer

Optimizing performance of onion dryer by partial recirculation of exhaust air

Installation of 2 MW solar PV power project on roof top of manufacturing

plant. Capacity enhancement biogas project

8.5 MW solar power project

Energy Management Policy

Jain Irrigation systems Ltd, the associates and management are committed to

utilize the Energy as a vital resource rationally and efficiently. Company will do

every attempt in its daily endeavor to enhance innovative and creative ideas for

driving & aiming at energy conservation.

Company plan to achieve the above dogma within the framework of

sustainable business and environment by :

Promoting awareness on the significance of energy conservation among all

associates of the Jain Group & its stakeholders at large.

Optimizing energy utilization through adoption of best available technology,

effective operation, understanding for timely maintenance and periodic review

of company practices.

Supporting scientific research & technological development to deliver eco-

friendly and cost effective sources of renewable energy.


12/12

167

Integrating energy management vis-a-vis business management by establishing

performance driven goals.

Carrying out regular audits and periodic refresher training of employees topromote sustainable drive for energy conservation as a work culture across

the entire business functions.

Continuously benchmarking with superior norms of company energy efficiency

and energy productivity.

... ...... . Company believe in "Energy Saved is Energy Generated"

11 food processing

Documents