ifc, jain irrigation break new ground in corporate water footprinting (october 2010)

8/8/2019 IFC, Jain Irrigation Break New Ground in Corporate Water Footprinting (October 2010)

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Water Footprint Assessments

Jain Irrigation Systems Ltd.

Dehydrated Onion ProductsMicro-Irrigation Systems

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InternAtIonAL FInAnce corporAtIon (IFC), a member of the World Bank Group,

creates opportunity for people to escape poverty and improve their lives. IFC fosters

sustainable economic growth in developing countries by supporting private sector development,

mobilizing private capital, and providing advisory and risk mitigation services to businesses

and governments. New investments totaled almost $18 billion in scal 2010, helping channel

capital into developing countries in the aftermath of the nancial crisis. www.if.g

JAIn IrrIAtIon SySteS LIIted (also known as Jain Irrigation, JISL, or Jains) is an

international organization headquartered at Jalgaon, Maharashtra, India. JISL employs over

5,000 associates and manufactures a number of products, including drip and sprinkler

irrigation systems, PVC & PE piping systems, plastic sheets, greenhouses, bio-fertilizers and

also solar products including water-heating systems, photovoltaic appliances and solar

pumps. JISL processes fruits and vegetables into aseptic concentrates, frozen fruits and

dehydrated vegetables respectively. The Company has a turnover exceeding 30 billion

rupees. JISL also has 21 manufacturing plants spread over 5 continents. The products are

supplied to 110 countries through 3000 dealers and distributors worldwide. www.jais.m

the nAtre conServAncy (TNC) is an international, nonprot organization dedicated to

the conservation of biological diversity. TNCs mission is to preserve the plants, animals and

natural communities that represent the diversity of life on Earth by protecting the lands

and waters they need to survive. On-the-ground conservation work is carried out in all 50 U.S.

states and in more than 30 countries. TNC has protected more than 117 million acres of land

and thousands of river miles around the world, and has more than 100 marine conservation

projects in 21 countries and 22 U.S. states. www.au.g

LInotech is a water science and environmental engineering consulting rm headquartered

in Ann Arbor, Michigan. LimnoTech works with clients across a range of sectors to address

challenging water resource issues. www.lim.m

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providers and content providers. IFC does not represent or endorse the accuracy or reliability

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provider or content provider, or any user of this publication or other person or entity.


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ACKNOWLEDGEMENTS

Tis report is the result of collaboration between the International Finance Corporation (IFC) and

Jain Irrigation Systems Ltd. (Jain), with support from Te Nature Conservancy and Limnoech.We would like to acknowledge the following individuals for their contributions to this assessment:

Jain Irrigation Systems Ltd. In-House Staff: Dr. Santosh K. Deshmukh, Dr. D. N. Kulkarni,Jayant Kumar, Dr. Bal Krishna Yadav, and R.B. Yeole, and S.P. Jadhav

IFC Water Footprinting Team:Bastiaan Mohrmann, Piya Baptista, Sabrina Birner, and BradRoberts (IFC); Brian Richter (Te Nature Conservancy); Wendy Larson and Pranesh Selvendiran(Limnoech)

IFC Financial Support: Te Netherlands Ministry of Foreign Aairs

Primary Authors: Wendy Larson, Brian Richter, Sabrina Birner, and Pranesh Selvendiran

Field Visits: Ashok Sakle, Shahaji Patil, and ukaram Bari

Photo Credits: Jain Irrigation Systems Ltd., Brian Richter, and Wendy Larson

Publication Date: September 2010


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TABLE OF CONTENTS

PREFACE.......................................................................................................................................iii

EXECUTIVE SUMMARY................................................................................................................1

1. INTRODUCTION .......................................................................................................................3

1.1 Purpose and Goals ..............................................................................................................3

1.2 Context .............................................................................................................................. 3

1.3 Scope and Methods ............................................................................................................ 6

2. DESCRIPTION OF PRODUCTION SYSTEMS ............................................................................8

2.1 Dehydrated Onion Production........................................................................................... 8

2.2 Micro-Irrigation Systems .................................................................................................. 11

3. WATER FOOTPRINT OF DEHYDRATED ONIONS ..................................................................15

3.1 Summary of Results ..........................................................................................................15

3.2 Overview of Accounting Method ..................................................................................... 163.3 Supply Chain Water Footprint ......................................................................................... 17

3.4 Operational Water Footprint ............................................................................................23

3.5 Water Footprint of Dehydrated Onions ...........................................................................24

4. WATER FOOTPRINT OF MICRO-IRRIGATION SYSTEMS ...................................................... 25


4.2 Overview of Accounting Method ..................................................................................... 26

4.3 Supply Chain Water Footprint ......................................................................................... 27

4.4 Operational Water Footprint ............................................................................................28

4.5 otal Water Footprint of MIS ........................................................................................... 30

5. SUSTAINABILITY ASSESSMENT ............................................................................................ 31


5.2 Overview of Sustainability Assessment Approach ............................................................. 33

5.3 Sustainability Assessment.................................................................................................. 33

6. RESPONSE STRATEGIES .........................................................................................................41


6.2 Overview of Response Strategies ....................................................................................... 426.3 Proposed Response Strategies ...........................................................................................42

7. REFERENCES ...........................................................................................................................47

TABLE OF CONTENTS


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Water footprint assessments were conducted for two products, dehydrated onions and micro-irrigation systems (MIS), produced by Jain Irrigation Systems Ltd. (JISL) in Maharashtra, India.A water footprint is an indicator of freshwater consumption that looks at both direct and indirectuse, and considers where and when the water was used. It has three components, as dened by the

Water Footprint Network

1

: Te green water footprintrefers to consumption of green water resources

(rainwater stored in the soil as soil moisture);

Te blue water footprintrefers to consumption of blue water resources(surface and ground water);

Te grey water footprintrefers to pollution and is dened as the volume offreshwater that is required to assimilate the load of pollutants based on existingambient water quality standards.

A full water footprint assessment goes beyond accounting of water consumption, in that it alsoaddresses the sustainability of the water use, and allows a business to identify its water-related

impacts and vulnerabilities and identify potential response actions. Of great pertinence to thisassessment is the sustainability of the groundwater resource that supplies irrigation water foronions purchased by JISL. Te company is but one of many users of groundwater, and watertables are declining rapidly due to expansion of the area of irrigated lands, particularly withwater-intensive crops.

Separate water footprints were calculated for the two products. Te accounting results aresummarized below.

Te results indicate that water consumed at the farms accounts for 99% of the total waterfootprint of dehydrated onions. Te water footprint of dehydrated onions accounts for waterconsumed in the supply chain to grow the onions, the production of MIS used on the onionfarms, and in operations for dehydrated onion production.

Onions grown under drip irrigation have a 42% smaller water footprint than onions grownunder ood irrigation. Te largest component of both water footprints is the blue waterfootprint, associated with irrigation.

Te grey water footprint for onions grown under drip irrigation is almost 90% smallerthan the grey water footprint for ood-irrigated onions, reecting the reduced applicationrequirements and lower leaching rate when water and nutrients are applied at the root zoneof the plants using drip irrigation.

Te results for MIS (drip irrigation) indicate that most of the water footprint lies in thesupply chain, associated with production of raw materials (plastics) and accounting for 73%to 96% of the total water footprint.

Te water footprint of MIS (drip irrigation) used on a typical onion eld is a negligiblecomponent of the total water footprint for growing onions.

Te water consumption associated with JISLs production of dehydrated onions and MISaccounts for approximately 1% of total groundwater draft in the Jalgaon District.

1 Water Footprint Manual; State of the Art 2009

EXECUTIVE SUMMARY


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Te sustainability assessment examined the sustainability of the groundwater resource that suppliesirrigation water for onion growing, with a focus on potential social and economic impacts. Toughonion farming constitutes a small percentage of the total area in cultivation, the results suggest thatthe sustainability of JISLs water use is vulnerable in several distinct ways, each of which suggests a

dierent type of response strategy: Te overdraft of groundwater due to cumulative uses in the onion growing regions suggests

that response strategies should help farmers reduce their demand for water, thereby reducingtheir risk of shortages and helping to alleviate the regional declines in groundwater levels.

Given current rates of groundwater overdraft, it may be very dicult or impossible tomaintain or increase crop production. Terefore, the response strategies should also ndways to increase the supply of water.

Finally, the complexity brought about by the presence of many dierent water users suggeststhat a community-based, multi-stakeholder approach to managing the groundwater resourcecould be of value.

Te response strategies formulated for JISL include four dierent and complementary approachesto alleviating water scarcity and improving the sustainability of water use in the onion growingregion:

Trough supporting increased use of drip irrigation by existing onion farmers, JISL canhelp these farmers reduce their water consumption and thereby alleviate local groundwateroverdraft.

Looking more broadly at agriculture in the Jalgaon growing region, JISL can also supportthe governments push for new, less water-intensive cropping strategies, which will reduceoverall groundwater consumption.

On the supply side, JISL can increase the amount of groundwater available by encouragingrainwater harvesting and aquifer recharge projects.

JISL is considering supporting or establishing a api River Basin Water Users Dialogue,through which representatives of local water stakeholders could work together towardsustainable water resource management.

Tese approaches address both water demand and water supply. Tey address very local applications(for local onion suppliers in Jalgaon) as well as applications that can make an impact on a regionaland national level. Drip irrigation was highlighted in as a key vector to addressing the projecteddecit between supply and water requirements in India in the recent report, Charting Our WaterFuture(2030 Water Resources Group, 2009). JISLs water footprint response strategies also providea strong foundation for resilience in the face of climate change, and for sustainably meeting thegrowing global demand for food. As such, these approaches are of global importance as examplesof a signicant corporate response to agricultural water scarcity.


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1 INTRODUCTION

Jain Irrigation Systems Limited (JISL) is the worlds largest manufacturer of micro-irrigation systems(MIS) and plastic sheets and pipes. JISL also produces several other products including vegetableand fruit-based food products. Te company is the worlds largest producer of mango pulp, puree,and concentrate, and the second largest producer of dehydrated onions, which are used in dry soup

mixes, pizza toppings, sauces and other products. JISLs headquarters are located in Jalgaon in thewestern state of Maharashtra in India.

Tis report describes water footprint assessments for JISLs MIS (drip irrigation) and dehydratedonion products. A water footprint is the total volume of freshwater consumed in the production ofa product, summed over the various steps of the production chain. Both direct (operational) wateruse and indirect (supply chain) water use are addressed, and the volumes are spatially and temporallyexplicit. A water footprint assessment goes beyond accounting of water consumption, in that it alsoaddresses the sustainability of the water use, and allows a business to identify its water-relatedvulnerabilities and identify potential response actions (Hoekstra, et al., 2009).

Tis study was a collaborative eort between the International Finance Corporation (IFC) and JISL,with support from Te Nature Conservancy and Limnoech. IFC is interested in helping advance

the development of water footprinting, because it is seen as a tool that can help its clients reduce theirwater consumption and associated social and environmental impacts, and reduce the companys ex-posure to water-related risks. JISL is interested in using water footprinting to evaluate its own waterconsumption, and to quantify savings associated with its micro-irrigation products as compared totraditional ood irrigation.

1.1 PURPOSE AND GOALS

Te purpose of this water footprint assessment is to provide JISL with a framework to measure andreport on the water footprints of its products, assess the potential inuence of those footprints onlocal hydrologic systems, assess potential social and ecological impacts, and identify possible responsestrategies. Most importantly, this assessment addresses the sustainability of water use throughoutJISLs supply chain for dehydrated onion products in the context of physical water scarcity concernsin the local (api River) watershed.

Te goals of the water footprint assessment are to:

1. Measure the volumes of water consumed in JISLs operations and supply chains for MIS anddehydrated onions in the api River watershed;

2. Assess the sustainability of this water use, particularly at the farm level;

3. Identify appropriate response actions to address the outcomes of the sustainabilityassessment; and

4. Document and share publicly through the Water Footprint Network the water footprint

assessment results and lessons.

1.2 CONTEXT

A map of the region with key features is presented in Figure 1-1. MIS is manufactured at JISLsPlastic Park, Jain Fields, Jalgaon. MIS includes drip and sprinkler irrigation equipment and thisstudy addresses drip irrigation only. Dehydrated onions are processed at JISLs Agri Food Park inJain Valley, Jalgaon.



Approximately two-thirds of the onion farms that supply JISL are located in the Jalgaon Districtand adjacent Dhule and Nashik Districts, an area referred to in this report as the Jalgaon growing

region. Most of the remaining onions are grown in the state of Gujarat. e Jalgaon growingregion was the focus of this study; other growing regions were not assessed due to time andresource constraints.

Climate

e climate in the Jalgaon region is generally dry except during the monsoon, which occurs fromJune to September. October and November form the post-monsoon season. is is followed aprolonged dry season with minimal rainfall. e average annual rainfall is 822 mm, with about87% of the rain falling between June and September. Average daily temperatures in Jalgaon rangefrom 20o to 34o C (68o to 93o F). May is the hottest month, with mean daily maximum temperaturesof 42.5 C (108.5 F). Evaporation rates in the region, with a mean daily maximum of 13 mm/day,are among the highest in the world.

Surface waters

e Jalgaon onion growing region is located almost entirely within the Tapi River basin. e TapiRiver ows from east to west through Madhya Pradesh, Maharashtra, and Gujarat states for a totalof 724 km and discharges into the Arabian Sea near Surat. A portion of the growing region is inthe sub-watershed of the Girna River, the second largest of the Tapis 14 tributaries in terms ofwatershed area. e waters of the Girna River are used for irrigation in the Nashik and JalgaonDistricts. Surface runo is signicant during monsoon rains in river systems that are generally dryduring the rest of the year.

Figure 1-1. Map of Study Area with Key Features


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Hydrogeology

Figure 1-2 depicts key hydrogeological features for the region. e major part of the district is coveredby Deccan Trap Basalt ows of the upper Cretaceous to Palaeogene age (68 to 62 million yearsago). Deccan Trap Basalt formation is characterized by simple and compound lava ows, which are

shown as variation in green shades in Figure 1-2. Ground water in the Deccan Trap Basalt occursmostly in the upper weathered and fractured parts down to about 20-25 meters depth. ere is athick alluvium deposit at the Tapi River and along its bank, shown in light yellow on Figure 1-2.e upper 70-80 meters of younger alluvium (sand and gravel) form the potential aquifer (Ministryof Water Resources, 2009). e depth to ground water typically varies from 1 to 15 meters belowground level (bgl) in the Basalt region and 10 to 50 meters bgl in the Tapi Alluvial plain.

Figure 1-2. Hydrogeological Features: Jalgaon District

Regional land use

In 2005-2006, more than 80% of the land area in the Jalgaon District was under cultivation, andapproximately 22% of cultivated lands were irrigated (Ministry of Water Resources, 2009). eprincipal crops are cotton, cereals, and pulses (beans) (Ministry of Water Resources, 2009).Bananas are also a signicant crop in terms of land area and water use. Irrigated banana plantationshave increased signicantly in the Jalgaon District over the past two decades, increasing from18,700 hectares (ha) in 1990 to 46,000 ha in 2004 (ATMA, 2007). e cropping area of majorcommodities increased from 867,000 ha in 1980 to 1,254,600 ha in 2004 in the Jalgaon District(ATMA, 2007).



Irrigation practices

Groundwater is the primary source o irrigation water in the Jalgaon growing region, and oodirrigation is the predominant irrigation practice. Te area under irrigation has increased signifcantlyin the Jalgaon District, increasing rom a total o 43,000 ha in 1960 to 295,000 ha in 2005

(Ministry o Water Resources, 2009). Between the 1962-63 and 2002-03 seasons, the groundwaterirrigated area in the State o Maharashtra increased rom 613,000 ha to 1,922,000 ha(Narayanamoorthy, 2010a), an increase o more than 200%.

Te positive benefts o this groundwater use including increased crop productivity and armincomes are well documented (Narayanamoorthy, 2010a). However, adverse impacts rom over-exploitation o groundwater are also recognized. Measurements by the Central Groundwater Board(CGWB) o the Ministry o Water Resources indicate that the Jalgaon District has experienced adecline in groundwater levels o more than our meters during the pre and post-monsoon periodbetween 1981 and 2000 (Narayanamoorthy, 2010a). According to a recent report by the Ministryo Water Resources (2008), our talukas (counties) in the Jalgaon District are consideredsemi-critical and two (Raver and Yawal), are considered over-exploited. Tese categories are

defned by the ratio o the volume o water withdrawal to water availability. Wider use o drip andmicrospray irrigation during the dry season is recognized as one measure to reduce non-benefcialevaporation in the Deccan raps Basalt region o Maharashtra during the dry season (Foster,et al., 2007).

1.3 SCOPE AND METHODS

Tis water ootprint assessment addresses the water ootprint o dehydrated onions producedat the Food Park rom onions grown in the Jalgaon growing region and MIS produced at JISLsPlastic Park. MIS includes drip and sprinkler irrigation equipment and this study addresses dripirrigation only. A water ootprint assessment typically involves our steps:

1. Setting goals and scope;2. Water ootprint accounting;

3. Water ootprint sustainability assessment; and

4. Water ootprint response ormulation.

Water ootprint accounting was conducted according to the approach outlined in the WaterFootprint Manual prepared by the Water Footprint Network (Hoekstra, et al., 2009). Tis studyextends the current methods by incorporating methods under development by the Water Foot-print Sustainability Assessment Working Group o the Water Footprint Network. As such, theJISL water ootprint assessment is an early test case or the proposed ramework.

Te total water ootprint o a product is equal to the sum o the supply chain water ootprint and

the operational water ootprint.

TOTAL WF = SUPPLY CHAIN WF + OPERATIONAL WF [1.1]

A water ootprint has three components:

Te green water footprintreers to consumption o green water resources (rainwater storedin the soil as soil moisture);


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OVERHEAD

(COLOR OF WATER)

(Blue) Water used for buildingmaterials, energy, fuel,transportation

(Blue) Water used for handwashing, toilet flushing,drinking, landscaping

(Grey) Water from

domestic use

(Blue) water used for buildingmaterials, energy, fuel,transportation

(Blue) water used for domesticpurposes such as hand washing,toilet flushing, drinking,landscaping

Wastewater discharged (grey)

PROCESS STEP

Growing onions

Processing onionsinto food products

Producing plastics(raw materials)

Manufacturing MIS

DIRECT WATER USES

(COLOR OF WATER)

Rain (green) water andirrigation (blue) water togrow onions.

Pollutants in runoff orinfiltration togroundwater (grey)

Process water used at theprocessing plant to washthe onions and to produceproduct (blue)

Water used for cleaningequipment (blue)

Wastewater discharged(grey)

(Blue) water consumed inthe production of plasticsfrom crude oil and otherraw materials


(Blue) water consumed inthe production of MIScomponents


COMPONENT

Supply Chain

Operational

Supply Chain

Operational

DEHYDRATED ONIONS

MICRO-IRRIGATION SYSTEMS

Table 1-1. Water Uses Considered in the Water Footprint Calculations

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Te blue water footprintreers to consumption o blue water resources (surace andground water);

Te grey water footprintreers to pollution and is defned as the volume o reshwater thatis required to assimilate the load o pollutants based on existing ambient water quality

standards.

able 1-1 lists the supply chain and operational water uses that were considered in the waterootprint calculations.



2 DESCRIPTION OF PRODUCTION SYSTEMS

An understanding o the production processes or dehydrated onion products and MIS is anessential rst step in water ootprint calculations, to determine the materials fow and identiy keyinormation needs. Te two production systems are described in this section.

2.1 DEHYDRATED ONION PRODUCTION

Dehydrated onions are processed at the Agri Food Park in Jain Valley, Jalgaon. JISLs dehydratedonion products are produced rom white onions. Te raw onions are dehydrated and processed atthe Food Park into sliced, diced, chopped, granulated, powdered, roasted, and ried products.

Farm production

JISL purchases approximately two-thirds o its onions rom contract armers and on the openmarket rom the regions shown in Figure 2-1. Contract armers grow onions in six districtsincluding Jalgaon, Dhule, Badwani, Buldhana, Khandwa, and Nandurbar. Approximately 85% othe contract onion arms are located in Jalgaon and Dhule Districts. Open market onion arms are

located in Jalgaon, Dhule and Nashik Districts. JISL also purchases onions on the open markets oGujarat and Madhya Pradesh.

Figure 2-1. Locations of Onion Farms Supplying JISL


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able 2-1 presents the distribution o onions by region and irrigation type. Te water ootprintcalculations described in Section 3 are ocused on onions grown in the Jalgaon growing regionshown in Figure 2-1. Approximately 18% o the onions sourced rom the Jalgaon region are grownunder drip irrigation, and 22% are grown under sprinkler irrigation. JISL is targeting a conversion

to MIS or the remaining 60% o food-irrigated crops under contract arming at a rate o 15 20%per year.

62%

35%

3%

18%

3%

14%

22%

7%

2%

60%

90%

84%

PERCENT SOURCED

BY REGIONDRIP SPRINKLER

PERCENT IRRIGATION TYPE

FLOOD

SOURCING REGION

Jalgaon Growing Region1

(Maharashtra State)

Gujarat State

Madhya Pradesh State

MONTH JULY AUG SEPT OCT NOV DEC JAN FEB MAR APR MAY JUNE

Season

Kharif Onions

Rabi Onions

Irrigation

Storage

Processing

Hot Wet (Kharif) Cool Dry (Rabi)

Planting Growing Harvesting

Planting

Protective Irrigation1

Growing Harvesting

Hot Dry (Jayaad)

Table 2-1. Onions Purchased by JISL by Region and Irrigation Type

Table 2-2. Schedule for Growing and Processing of Onions Grown in Jalgaon

Te typical schedule or growing, irrigating, storing, and processing onions is shown in able 2-2.

1Dened as onion growing regions in districts o Jalgaon, Nashik, and Dhule as shown in Figure 2-1.

1Monsoon rain typically occurs rom June - September. Khari onions are mostly rained. However, irrigationwater is applied at times when rainall amounts are not sucient to meet crop demands.

Onions are grown during the cool dry (Rabi) and hot dry (Jayaad) seasons. Tese are periods withlittle to no rain, and high temperatures that peak during the later part o the growing season andduring harvest, as shown in Figure 2-2. Te gure shows the variations in monthly average rainalland temperature based on data collected by JISL rom 2002-2010. Maximum temperatures occurduring the dry harvest months o April and May. Irrigation is a requirement throughout theplanting, growing, and harvest periods.



0

5

10

15

20

25

30

35

40

45

0

50

100

150

200

250

300

350

400

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

AverageExtremeTemperatures,

oC

AverageMonthlyPrecipitation,mm

a gaon - a n

Precipitation

Maximum Temperature

Minimum Temperature

Figure 2-2. Monthly Average Rainfall and Maximum and Minimum

Temperatures for Jalgaon: 2002 2010.

Food processingAll onions are processed at the Food Park in Jalgaon. Onions are transported rom arms to theFood Park via trucks, with an average transport distance o 100 km.

Te process steps are outlined below:

1. Reception: Raw onions are cleaned, graded, and sorted.2. Preparation: Washing, peeling, inspection, and cutting.

3. Drying: Cut pieces are ed to continuous belt dryers.

4. Drying: Hot air evaporates water, which is exhausted.

5. Milling: Dehydrated fakes are milled.

6. Storage: Finished products are stored in cold storages.

Ater the onions are dried, the weight o dehydrated onions is approximately 14.8 percent o theweight o the raw onions. Te remainder o the raw onion is composted on the grounds o theAgri Park and used on-site as ertilizer. Te dehydrated onions are processed into seven products,as shown in Figure 2-3.


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85.2%

14.8%

Moisture Content(Removed in Kilns)

+Peels (Composted)

Dehydrated Onions

Diced

Fried

Sliced

Chopped

Granulated

Powdered

Roasted

Onions

11

Figure 2-3. Percent by Weight: Dehydrated Onion Products

Te source o water used in ood processing is groundwater drawn rom wells on the plantgrounds. Supplemental water is provided occasionally rom the api River when local groundwatersupplies are insucient. Te local aquier is recharged through a large-scale rainwater harvestingsystem known as the Jain Watershed Project. Covering 207 ha (512 acres), the project involvesland and water conservation measures and rainwater harvesting measures by means o dams,barrages and water harvesting structures that capture and store rainwater during the monsoonseason or use during the dry season. During a normal rainall year, approximately 2.5 billion literso water is gained through these measures (JISL, 2003). Te Jain Sagar Dam alone has a capacity

o 1.2 billion liters. Since its construction,

substantial groundwater recharge has occurredin areas downstream o the dam. Approximately500 acres o barren land has been transormedto cultivable land due to construction o JainSagar (see Figure 2-4).

Wastewater rom ood processing is treatedonsite to secondary treatment standards at aneuent treatment plant. Te treated water isused or irrigation at the Agri Park, whereJISL conducts research and development.

2.2 MICRO-IRRIGATION SYSTEMS

JISLs micro-irrigation systems or drip irrigation are made rom more than 1,000 components andover 95% o them are manuactured by the company. In MIS application, water is delivered to thecrop using a network o mainlines, sub-mains and lateral lines with emission points spaced alongtheir lengths, as shown in Figure 2-5. Te waterlines are made o thermoplastic-extruded polymerpipes and tubes with molded emitters suitably spaced at regular intervals on the tubes, eitherembedded internally (drip-tube) or mounted externally (polytube). Te emitters are designed to

Figure 2-4. Aerial Photograph of

Jain Watershed Project


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RAW MATERIAL

Poly Vinyl Chloride (PVC)


Polypropylene (PP)

Linear Low Density Polyethylene (LLDPE)

Linear Low Density Polyethylene (LLDPE)

Metal fabricated parts purchased from vendors

COMPONENT

MIS PVC Pipe

MIS PVC Molded Fittings

MIS Molded Components

MIS Poly Tube

MIS Drip Tube

MIS Filter Equipment

12

release water at preerential fow rates rom the drippers. Te MIS system operates under lowpressure, and according to the precise water requirement o the crop. Each dripper/emitter suppliesa precisely-controlled quantity o water and nutrients directly to the root zone o the plant.Nutrients are added with the help o the ventury (see gure), which is installed beore the ltration

unit in the MIS assembly. Water and nutrients taken up by the plants are replenished almostimmediately, ensuring that the plant rarely suers rom water stress. Te crops grown under dripirrigation achieve optimum growth and high yields.

Figure 2-5. Model Design of JISLs Drip Irrigation System

Production of raw materials

Te components o JISLs drip irrigation equipment are made rom various raw materials, mostlythermoplastic polymers, as shown in able 2-3. JISL purchases the raw materials rom over a dozenmajor and minor suppliers located in India, Japan, United Arab Emirates, Saudi Arabia, USA,China, and other countries. Materials are transported by sea, road, and rail routes rom theselocations around the world.

Table 2-3. Raw Materials for MIS Components


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Te category o MIS Filter Equipment in able 2-3 includes abricated and powder-coated ltertanks purchased by JISL. Some process water is used at JISLs Plastic Park to assemble the tanks.

MIS manufacturing

Most o the MIS components are manuactured with thermoplastic polymer materials. Pipes andtubes components are made by extrusion process, and molded components by injection moldingprocess as indicated in able 2.4 below.

MANUFACTURING PROCESS

Extrusion of PVC Resin

Injection Molding PVC Resin

Injection Molding Polypropylene (PP)

Extrusion of Polyethylene (LLDPE)

Extrusion of Polyethylene (LLDPE)

Assembly & testing of fabricated metal parts sourced from vendors

COMPONENT

MIS PVC Pipe



MIS Poly Tube

MIS Drip Tube

MIS Filter Equipment

Table 2-4. Manufacturing Process of MIS Components

Raw Material.Receipt PVC

[Step 1]

Blending &Mixing

[Step 2]

Pipe Extrusion

[Step 3]

Socket Forming

[Step 4]

FinishMIS PVC

Pipe

Extrusion of MIS PVC Pipe

Extrusion of MIS Polytube /Drip-tube

Injection Molding of MIS (PP) Components & MIS PVC Components

Raw Material

Receipt

LLDPE

[Step 1]

Mixing

[Step 2]

Tube Extrusion

[Step 3]

Coiling &

Packing

[Step 4]

Finish MIS

Poly Tube/

Drip Tube

Raw Material

Receipt

PP /PVC

[Step 1]

Mixing

[Step 2]

Injection

Molding

[Step 3]

Finish &/

Assembly

[Step 4]

Finish MIS

Molded

Component

General process fow diagrams are depicted in Figure 2-6 below or extruded pipe, tube andinjection molded MIS components.

Figure 2-6. Process Diagrams for MIS Components



In the extrusion process, the thermoplastic polymer materials are blended and mixed with certainadditives and chemicals beore being ed to the extruder machine. Te thermoplastic polymerblend is then thermally treated to achieve the desired shape, and cooled or hardening or normalizing.Te extruded pipe or tube is then cut to the desired length. Te MIS PVC Pipe socket orming

operation is done ater extrusion o the PVC Pipes. Te socket is ormed at one end to enable thejoining o pipes in eld application. Poly-tubes and drip-tubes are then packed as coils o speciedlength.

Te injection molding process involves melting the blended thermoplastic materials in theplasticating unit o the injection molding machine. Te injected thermoplastic is cooled down tore-solidiy in mold cavities, and shaped in the orm o the desired article dimensions. Te moldedarticle is ejected out o the mold ater cooling.

Both the processes o polymer extrusion and polymer injection molding require water or cooling theequipment, polymer extrudate, or molded material ater ormation o the desired prole. Recyclingo process material waste also requires water as a process chilling media. Water used or processcooling is recycled in a closed loop system. Te loss in the volume o water in the circulation

system is due to evaporation and spillage. Water is added daily to compensate or losses in theclosed loop system o water circulation.

Te water source or operations at the Plastic Park is groundwater pumped rom bore wells andopen wells on the plant property. otal water withdrawal in the Plastic Park is approximately1.24 million liters per day, o which approximately 0.3 million liters per day is used or MISmanuacturing. Water is consumed in plant operations through evaporation during cooling andwashing, and through runo and spillage. Water is also used in the plant or domestic purposesincluding drinking water, toilets, washing, and gardening.

JISL has implemented and is currently testing a rainwater harvesting and aquier recharge systemat the Plastic Park. wo methods are being used: rootop collection; and a percolation pond.Approximately 28 acres or 40% o the rootop area o the Plastic Park is currently being utilized

or rainwater harvesting. Rainwater that alls on the rootops is collected, ltered, and directed toopen wells on the property. Te polylined percolation pond drains 40 acres, and another pond isplanned to drain an additional 30 40 acres o land area. A total o 42.5 million liters is collectedannually through these methods (10.5% o annual water withdrawal), with an ultimate target o88 million liters (23% o annual water withdrawal).

Grey water is generated in small amount rom the process, which is only a raction o total waterusage in the plant. Te resulting grey water is routed to a central euent treatment plant which islocated on site. Approximately 25% o the treated water is utilized or irrigating onsite lawns andgardens. Te remainder is discharged into the local stream. Eorts are underway to reuse all o thetreated water.


21/5615

1600

1400

1200

1000

800

600

400

200

0

Nov-0

8De

c-08

Jan-09

Feb-09

Mar-09

Apr-09

May-0

9

Jun-09

Jul-09

50

45

40

35

30

25

20

15

10

5

0

DHO(metrictons)

WaterUse(millionliters)

DHO Production Water Use

3 WATER FOOTPRINT OF DEHYDRATED ONIONS

Water ootprints were calculated or dehydrated onions produced by JISL at the Agri Food Parkrom onions sourced rom the Jalgaon growing region. Te supply chain water ootprint accountsprimarily or water consumed in the growing o onions, and the operational water ootprintaccounts or water consumed in the processing o onions at the Food Park.

Onions are grown and processed mainly during the dry season (November-June), as shownpreviously in able 2-2. Monthly production rates or dehydrated onions and monthly water userates or the actory in 2009 are shown in Figure 3-1. Te annual water withdrawal or operationalwater use in 2009 was 35 liters per kg dehydrated onion product.

Figure 3-1. Monthly Dehydrated Onion (DHO) Production Rates and

Factory Water Use

JISL has made signicant eorts to reduce water consumption at the ood processing plant. Tesewater conservation activities are refected in measures o water consumption in recent years. Tevolume o water withdrawn rom wells or use in the plant declined substantially during the our-year period rom 2007-2010. Notable eciency measures include improved recovery o the fashsteam and maximum recovery o steam condensate. In addition, signicant improvements to theltration unit in the process line have considerably reduced the requency and the quantity owater consumption in the plant. JISL continues to implement water conservation eorts at theplant. For example, approximately 100,000 liters o water/day rom fash steam are currentlywasted, and plans are underway to recover and reuse this water.

3.1 SUMMARY OF RESULTS

Te water savings when onions are grown under drip irrigation compared to food irrigation isestimated to be 129 liters/kg raw onions, calculated as the dierence between the consumptive(green plus blue) water ootprints or drip and food-irrigated onions. I 100% o JISLs dehydratedonions were produced rom onions grown under drip irrigation (instead o the current 30%), thenthe annual water savings would be approximately 7 billion liters.

Te water ootprint results or dehydrated onions expressed as the sum o the supply chain andoperational water ootprints are presented in able 3-1.



Table 3-1. Water Footprint Results for Dehydrated Onions

Approximately 99% o the total water ootprint is associated with supply chain water use, and theremaining 1% is associated with operational water use in the processing plant.

Te accounting method provides the water ootprints or raw onions grown under both irrigationstypes, and a weighted average water ootprint or raw onions purchased by JISL. More detail onthe steps involved in the supply chain and operational water ootprint calculations are provides inSections 3.2 through 3.4.

3.2 OVERVIEW OF ACCOUNTING METHOD

Te water ootprint o dehydrated onions (DHO) is equal to the sum o the process water ootprintsor all processes in the production chain. Tere are two process steps in the production o DHO:1) onion growing; and 2) onion processing. Tereore, the water ootprint is calculated as ollows:

WFprod[DHO] = WFproc[DHO] + WFprod[onions] / p [3.1]

WFprod[DHO] = water ootprint o output product (DHO), liters/kg DHO

WFproc[DHO] = process water ootprint o processing steps that transorm the inputproduct (raw onions) into output product (DHO), liters/kg DHO

WFprod[onions] = water ootprint o input product (raw onions), liters/kg onion

p = product raction = quantity o output product obtained per quantity o inputproduct, kg DHO/kg onions

Te value raction, dened as the market value o the product to the aggregated market value o allthe outputs products, is not shown in Equation 3.1. Tere are no byproducts in the production odehydrated onions, so the value raction is unity.

Te rst calculation step accounts or water consumed in the growing o onions, or the supplychain water ootprint. Te output o this calculation step is the water ootprint o raw onions,WFprod[onions]. Te water ootprint o raw onions accounts or:

Benecial consumption by crops (evapotranspiration)

Grey water component

Water consumed in the production o MIS used on onion elds

Crop yields

Overhead

18

58

76

0

76

500

1796

2296

33

2329

13

286

299

0

299

531

2140

2671

33

2704

BLUEGREEN GREY

WATER FOOTPRINT (LITERS/KG, OF DHO)

TOTAL

COMPONENT

a. Supply Chain Water Footprint

Drip

Flood

Total Supply Chain Water Footprint

b. Operational Water Footprint

c. Total Water Footprint


23/5617

Tese calculations are described in Section 3.3.

Te second calculation step addresses operational water use, and accounts for water consumed inthe processing of raw onions into dehydrated onions at the Food Park. Tis includes water used towash the onions and clean equipment, as well as domestic water use (overhead). Te output of this

calculation step is the process water footprint, WFproc[DHO]. Tese calculations are described inSection 3.4.

Te nal step is the calculation of the water footprint of DHO according to Equation 3.1. Tesecalculations are described in Section 3.5.

3.3 SUPPLY CHAIN WATER FOOTPRINT

Sixty-two percent of the onions purchased by JISL are grown in the Jalgaon growing region.Approximately 18% of the onions from this region are grown using drip irrigation, 60% are grownusing ood irrigation, and sprinkler irrigation is employed for the remaining 22% (see able 2-1).o estimate the water footprint of onions purchased by JISL, water footprints were calculated for

drip and ood-irrigated onions, and then weighted according to the percent grown under eachirrigation type. Water footprints were not calculated for onions grown using sprinkler irrigation.It was assumed for this purpose that the onions grown under sprinkler irrigation are split evenlybetween drip and ood irrigation. Under this conservative assumption, 70% of JISLs onions aregrown under ood irrigation, and 30% are grown under drip irrigation.

Te method for computing the supply chain water footprint for dehydrated onions also accountsfor water consumed in the production of materials and energy used at the Food Park, which isconsidered supply chain overhead water footprint. Te loss of mass in the production process isalso accounted for in these calculations. Tese calculations are discussed in the following sections.

Benefcial crop consumption and grey water ootprint

Te water footprint of the process of growing onions is the sum of the blue, green, and greycomponents:

WFtotal = WFgreen + WFblue + WFgrey [3.2]

Te blue and green water footprints are related to evapotranspiration loss and therefore reectbenecial crop consumption.

reen and blue water footprint

o calculate blue and green water footprints, crop water use (CWU, m3/ha) is rst calculated forboth components. CWU represents water consumed in evapotranspiration. Crop water use isdivided by the mass of crop produced per unit area, or yield (Y, metric tons/ha) to compute the

water footprint: [3.3]

Te green and blue components of CWU are calculated separately. Green crop water (CWUgreen)use refers to the evapotranspiration loss of rain water stored in soil as soil moisture. Blue cropwater use (CWUblue) refers to the evapotranspiration loss of surface and groundwater. CWUgreenis independent of irrigation water supply and depends upon total rainfall and soil characteristics,whereas CWUbluedepends upon green water availability and irrigation water required to meetcrop evapotranspiration demand.

WF =CWU

Y



JALGAON DISTRICT

20.3

33.8

51.1

18.6

12.3

8.5

822.0

PARAMETER

Min Temp (o

C)

Max Temp (oC)

Humidity %

Radiation (MJ/m2/day)

Wind (km/day)

Sunshine (hrs/day)

Rainfall (mm/yr)

Crop water use is derived from the crop water requirement (CWR, mm/growing season). TeCROPWA model of the Food and Agriculture Organization (FAO, 2009) was used to estimateCWR under non-optimal conditions, as recommended in the Water Footprint Manual. Te modelwas run using the irrigation schedule option of the CROPWA model. Te timing o irrigationwas set to irrigate at critical depletion and the irrigation water application was set to rell soil toeld capacity. In this option the model computes a daily soil water balance and keeps track ofthe soil moisture over time using a daily time step. CWR is calculated as the sum of total cropevapotranspiration (EC, mm/day), accumulated over the entire growing period.

Dierent values for the crop coecients (Kc) used in the CROPWA model were selected forood and drip irrigations. Local values for crop coecients for onions were not available, so theestimates of Kc were based on literature sources. Kc values for ood irrigation were obtained froma study of onions grown in a similar semi-arid region (Lopez-Urrer et al., 2009). For drip irrigation,the Kc values are based on crop coecients for dierent irrigation techniques as reported by Allenet al. (1998). Te authors report a lower value for Kc for cotton grown under drip irrigationcompared to cotton grown under ood and sprinkler irrigations. For this study, it was assumedthat the same relative dierence in Kc values applies to onions grown in the Jalgaon growing region.

Te Kc values used in the CROPWA model for ood and drip irrigation are shown in able 3-2.

Direct solar radiation, wind speed, ambient temperature, and humidity are some of the mostimportant factors that inuence crop evapotranspiration at a given location. As evapotranspiration

proceeds, the surrounding air becomes saturated. Wind speed aects evapotranspiration by bringingheat energy and replacing the saturated air mass. Terefore, dierences in climate parameters caninuence the rate of evapotranspiration between dierent growing regions.

Climate parameters for the Jalgaon District are shown in able 3-3. Due to proximity, it was assumedthat these climate data are representative of the entire Jalgaon onion growing region. Te variabilityin rainfall and temperature in the Jalgaon District is high, as discussed in Section 1.2.

IRRIGATION TYPE

Flood irrigation

Drip irrigation

KcINITIAL

0.65

0.50

KcMID

1.20

1.05

KcFINAL

0.75

0.60

Table 3-3. Long-Term Annual Average Climate Parameters or theJalgaon Growing District

Table 3-2. Crop Coefcient Values Used in CROPWAT or Flood and Drip Irrigation


25/5619

Te estimates of CWR (mm/growing season) based on CROPWA modeling are expressed ascrop water use (CWU) in terms of volume per hectare by multiplying by a factor of 10. Te waterfootprint is then calculated by dividing CWU by average yields. Te green and blue waterfootprint of onions is estimated from the CWUs and yields as follows:

[3.4]

[3.5]

Te yields used in the analysis, and estimated green and blue components of CWR, CWU, andresulting water footprints are provided in able 3-4.

Table 3-4. Benefcial Crop Consumption or Raw Onions

Onions grown under drip irrigation have smaller green and blue water footprints compared toood-irrigated onions. Te consumptive water saved with drip irrigation is 129 liters/kg rawonions. Much of the dierence is due to the higher crop yields obtained for drip-irrigated onions,which are 35% larger than crop yields from ood-irrigated onions. Tese calculations have relevanceto eorts to reduce the green water footprint of rainfed crops, in that they highlight how the greenwater footprint may be reduced through the use of drip irrigation, which increases crop yields.

rey water footprint

Te grey water footprint (WFgrey) relates to the volume of water that is required to assimilate loadsof pollutants (fertilizers, chemicals and pesticide) from agriculture lands such that it meets theestablished water quality standard. Te grey water footprint for growing onions was calculated fromestimated nutrient loads reaching groundwater supplies or surface water adjacent to onion elds.According to the Water Footprint Manual, it is sucient to account for the most critical pollutantthat is associated with the largest pollutant-specic grey water footprint (Hoekstra et al., 2009). Inthis study nitrogen is considered as the most critical pollutant because of documented nitrateproblems in groundwater in the Jalgaon District (Ministry of Water Resources, 2009).

31

843

309

8,425

36.1

9

233

31

959

309

9,589

26.7

12

359

DRIP

JALGAON REGION

FLOODPARAMETERS

Crop Water Requirement (mm/growing season)

Green

Blue

Crop Water Use (m3/ha)

Green

Blue

Average Crop Yield (tons/ha)

Total Water Footprint (liters/kg)

Green

Blue

WFgreen =CWUgreen

Y

WFblue =CWUblue

Y



Te three color components of the water footprints for raw onions grown under ood and dripirrigation are shown in Figure 3-2.

WFgrey=

Y

( xAR)/(Cmax Cnat)

Te grey water footprint is estimated as follows:

[3.6]

AR = the application rate of fertilizer (kg/ha);= the leaching fraction pollutant entering the water system;

Cmax= ambient water quality for the pollutant (mg/liter);Cnat= natural concentration of pollutant in the receiving water body (mg/liter); andY = the annual crop yield (ton/ha)

Te natural concentration of pollutant in the receiving water body (Cnat) is assumed to be zero.In the absence of local water quality standards, the USEPA-recommended maximum contaminantlevel or concentration (Cmax) of nitrate in drinking water of 10 mg/L was assumed.

Pollutant load information was estimated based on the rate of fertilizer application for onionsgrown under ood and drip irrigation in the Jalgaon growing region. In the absence of site-specicinformation for leaching rates and pollutant loads in runo, a 10% leaching rate was assumed forall locations where ood irrigation is used, as recommended by Hoekstra et al. (2009). A leaching

rate of 2% was assumed for drip irrigation, based on the relative quantities of fertilizer requiredunder each irrigation technique and the method of application (JISL, personnel communication).

Te estimated grey water footprints for raw onions associated with fertilizer application are:

Drip irrigation: 6 liters/kg

Flood irrigation: 57 liters/kg

Grey water footprints from other pollutants in fertilizer and pesticide applications were notcalculated because data were unavailable. Tey are assumed to be smaller than the grey waterfootprint related to the critical pollutant, but further study would be needed to conrm this.

Tese grey water footprints are approximations based on the assumptions related to leaching ratesand other inputs described above. Further study using site-specic data would be needed to renethese calculations.

summary of reult

Figure 3-2. Water Footprints or Onions Grown in Jalgaon Region

450

400

350

300

250

200

150

100

50

0

liters/kg Grey WF

Blue WF

Green WF

Drip

248

Flood

428


27/5621

Te results show that onions grown under drip irrigation have a 42% smaller water ootprint thanonions grown under food irrigation. Te largest component o the water ootprints is the bluewater ootprint, associated with irrigation water. Te grey water ootprint or onions grown underdrip irrigation is almost 90% smaller than the grey water ootprint or food-irrigated onions,

refecting the lower leaching rate when water and nutrients are applied at the roots o the plants.

Water consumed in MIS manufacturing

Te water ootprints calculated or each o the primary MIS components (see Section 4) were usedto estimate the water ootprint o MIS equipment used on a typical onion eld. Te mass o eachcomponent on a typical 5 hectare eld was then estimated, and multiplied by the water ootprint(liters/kg) to calculate the liters required to produce the mass o each component used on a 5hectare eld. Tis value was then divided by yield to calculate the water ootprint or each MIScomponent. Te results are shown in able 3-5.

Table 3-5. Calculation of Water Footprint of MIS components on a Typical Field

ITEMMIS PVC Pipe



MIS Poly tube

MIS Drip tube

MIS Filter Equipments

TOTAL

TOTAL WATER

FOOTPRINT

(LITERS/KG MIS)

10.9

15.0

18.5

14.9

14.8

3.0

77

WATER FOOTPRINT

OF MIS

COMPONENTS

ON A TYPICAL 5 HA

FIELD (LITERS/HA)

491

44

31

812

11

8

1398

CROP YIELD

(KG/HA)

36,100

36,100

36,100

36,100

36,100

36,100

---

WATER

FOOTPRINT

(LITERS/KG OF

ONIONS)

0.0136

0.0012

0.0009

0.0225

0.0003

0.0002

0.04

Te water ootprint o MIS calculated using this approach (0.04 liters/kg onions) was oundto be less than 0.02% o the total water ootprint o raw onions grown under drip irrigation(248 liters/kg onion).

Supply chain overhead

Water consumed in the production o materials and energy used at the onion processing plant(not directly related to production) is considered supply chain overhead. Tis was considered to bean insignicant source o water consumption. For urther discussion o supply chain overhead, seeSection 4.3.



Supply chain water footprint results

Te supply chain water ootprint was calculated according to the ollowing steps.

STEP 1.

Calculate water footprint of raw onions grown under drip and ood irrigation

Te supply chain water ootprint o raw onions (liters/kg) is calculated or onions grown underdrip irrigation (WF [onions]drip) and food irrigation (WF [onions]ood) as ollows:

WF [onions] = (WFblue+ WFgreen+ WFgrey) + WFMIS + WFoverhead [3.7]

WFblue+ WFgreen + WFgrey= benecial consumption, liters/kg

WFMIS = WF o MIS equipment used to irrigate onion elds, liters/kg

WFoverhead = Overhead WF, liters/kg

STEP 2.

Weight the results

Te results rom Step 1 refect onions grown under each irrigation method. Te water ootprint oall onions purchased by JISL was estimated by weighting the results based on the relative percentsgrown under each irrigation method (70/30 split) as explained previously:

WF [onions]JISL = (0.30 * WFdrip) + (0.70 * WFfood) [3.8]

STEP 3.

Account for product fraction

Te nal step in the calculation o the supply chain water ootprint is an accounting or the masso input material (onions) that enters the plant and is not incorporated into the nished product.Tis loss is accounted or in the calculations through the product raction (p), which is the quantityo output product obtained per quantity o input product. Te water ootprint o the input rawmaterial, WFprod[onions], is divided by the product raction so that the water ootprint iscalculated per unit o output product.

Supply chain WF (liters/kg output) = WFprod[onions] / p [3.9]

Te product raction or JISLs dehydrated onion product is 0.14. Tis was estimated based on rawmaterial eed and DHO production data collected by JISL in 2009.


29/5623

Te water ootprint results or raw onions and intermediate calculations are presented in able 3-6.

Table 3-6. Water Footprints Results for Raw Onions Grown in Jalgaon District

Te results indicate that blue water associated with irrigation is the largest component o the totalwater ootprint or raw onions, comprising 86% o the total supply chain water ootprint. Asexpected, the water ootprint o MIS on a typical eld is a negligible component o the totalsupply chain water ootprint.

Te results show that onions grown under drip irrigation have a 42% smaller water ootprint thanonions grown under food irrigation. Te largest component o the water ootprints is the bluewater ootprint, associated with irrigation water. Te grey water ootprint or onions grown underdrip irrigation is almost 90% smaller than the grey water ootprint or food-irrigated onions,refecting the lower leaching rate when water and nutrients are applied at the roots o the plants.

Tese gures refect the volumes o water consumed in the growing o onions. Te relativepercentages are consistent with data on water withdrawals under drip and food irrigation. Availabledata indicate that approximately 40% less water is withdrawn and applied to food-irrigated eldscompared to drip-irrigated elds (JISL, personnel communication).

3.4 OPERATIONAL WATER FOOTPRINT

Tis section describes the accounting method and results or process steps that transorm the rawonions into dehydrated onions. Water is consumed in the cleaning and processing o onions inthe processing plant. Water is also consumed at the plant or domestic uses not directly related toproduction, such as toilets and gardening.

GREEN BLUE GREY TOTAL

WATER FOOTPRINT (LITERS/KG)

PRODUCT

Onions grown under drip irrigation:

Beneficial crop consumption and greycomponent

WF of MIS on typical field1

Total Water Footprint

Onions grown under flood irrigation:

Beneficial crop consumption and grey

component (total water footprint )

Water footprint of raw onions (liters/kg raw onions)

Supply chain water footprint (liters/kg DHO)2

Weighted Average for all Onions Purchased by JISL

9

0

9

12

10.7

76.3

233

0.039

233

359

321

2296

6

0.0004

6

57

42

299

248

0.04

248

428

374

2671

1Calculations or water ootprint on a typical eld are shown in Section 3.3.2Accounts or product raction o 0.14 kg DHO/kg raw onions



Wastewater rom the processing plant is treated to standards and applied through drip irrigationin the Agri Park. Te rate o leaching related to this application and the associated nutrient loadis unknown but assumed to be negligible, so the grey water ootprint is estimated to be zero. Teoperational water ootprint results are shown in able 3-7.

Table 3-7. Operational Water Footprint Results

1Overhead includes domestic water use plus water consumed in the plant during non-processing season.

3.5 WATER FOOTPRINT OF DEHYDRATED ONIONS

Te water ootprint or dehydrated onions is the sum o the supply chain and operational waterootprints, as shown in able 3-8.

Table 3-8. Water Footprint Results for Dehydrated Onions

24.6

8.0

32.6

BLUE

0.0

0.0

0.0

GREY

24.6

8.0

32.6

TOTAL

WATER FOOTPRINT (LITERS/KG)COMPONENT

Water Associated with Production

Overhead1

Total Operational WF

Te results indicate that water consumed inthe supply chain accounts or approximately99% o the total water ootprint o dehydratedonions, and water consumed in operationsaccounts or approximately 1% o the totalwater ootprint (see Figure 3-3). Te greenwater ootprint is small (3% o the total waterootprint), refecting the limited rainall during

the growing season. Te blue water ootprintaccounts irrigation water, making up 87% othe total water ootprint. Te entire grey waterootprint is associated with the growing oonions in the supply chain, and the operationalgrey water ootprint is zero.

76

076

GREEN

2296

33 2329

BLUE

299

0 299

GREY

2671

332704

TOTAL

WATER FOOTPRINT (LITERS/KG)WATER FOOTPRINT TYPE

Supply Chain Water Footprint

Operational Water FootprintTotal Water Footprint

Figure 3-3. Supply Chain and Operational

Water Footprints for Dehydrated Onions

Operational

33 liters/kg(1%)

2671 liters/kg(99%)

Supply Chain

DEHYDRATED ONIONS


31/5625

4 WATER FOOTPRINT OF MICRO-IRRIGATION SYSTEMS

JISLs micro-irrigation systems or drip irrigation are made up o multiple components manuactured

rom various raw materials, as described in Section 2. Te water ootprint o each component wascalculated separately, accounting or water consumption in the supply chain to produce the raw

materials, and operational water use in the MIS manuacturing process.

A complete drip irrigation system on a typical onion eld is primarily made up o six components,which are manuactured individually within JISLs Plastic Park (Figure 4-1). Te operational waterootprint or each o the six components can be divided into the input and overhead water ootprint.

Te input operational water ootprint reers to process water that is directly related to theproduction o a product. Operational overhead reers to water consumption not directly related to

the production o the product, such as domestic waters use and water use in the actory duringnon-production months.

With regard to the supply chain, themajor raw material fows to the Plastic

Park are polyethylene (PE), polypropylene(PP), and poly vinyl chloride (PVC).

Other raw materials include steel ltercomponents purchased rom vendors and

assembled to make lter equipments. Inaddition to raw materials, the supply

chain water ootprint also includeselectricity consumed in each o the six

manuacturing units.

A simplied schematic o the fow o raw

materials and electricity and the dierentcomponents manuactured at JISLs

Plastic Park is shown in Figure 4-2.

PVC Pipe

Molded Fittings

Molded Components

Poly Tube

Drip Tube

Filter Equipments

PVC

PE

PP

Filter Components

Electricity

Supply Chain WF Operational WF

Jain

Plastic Park

Figure 4-2. Primary Supply Chain and Operational

Water Footprint (WF) Components

Figure 4-1. Aerial Photo of Plastic Park



4.2 OVERVIEW OF ACCOUNTING METHOD

Te water ootprint o MIS components is equal to the sum o the process water ootprints or allprocesses in the supply and operation chain. Tere are two processes in the production o MIS: 1)production o raw plastics materials; and 2) production o MIS components at the Plastic Park.Tereore, the water ootprint is calculated as ollows:

WFprod[MIS] = WFproc[MIS] + WFprod[Raw Materials] / p [4.1]

WFprod[MIS] = water ootprint o output product (MIS), liters/kg MIS

WFproc[MIS] = process water ootprint o processing steps that transorm the input product(raw materials) into output product (MIS), liters/kg MIS

WFprod[Raw Materials] = water ootprint o input product, liters/kg raw materials

p = product raction = quantity o output product obtained per quantity o input product, kgMIS/kg raw materials

Te rst calculation step accounts or water consumed in the manuacturing o the raw materials, orthe supply chain water ootprint. Te supply chain water ootprint o raw onions accounts or:

Water consumed in the production o raw materials

Product yield

Grey water component Overhead

Te second calculation step addresses operational water use, and accounts or water consumed inthe manuacturing o MIS rom raw materials at the Plastic Park. Tis includes water consumed inthe production o MIS, as well as domestic water use (overhead). Te output o this calculation stepis the process water ootprint, WFproc[MIS]. Since no rain water is used in production stages insupply chain or plant operations or MIS, the green water ootprint is zero.

Te nal step is the calculation o the water ootprint o MIS according to Equation 4.1. Allcalculations and results are described in the ollowing sections.

Table 4-1. Summary of MIS Water Footprint Results

0

0

0

0

0

0

GREEN

10.7

15.0

18.3

14.8

14.6

3.0

BLUE

0.13

0.06

0.19

0.12

0.15

0.04

GREY

10.9

15.0

18.5

14.9

14.8

3.0

TOTAL

WATER FOOTPRINT (LITERS/KG)ITEM

MIS PVC Pipe



MIS Poly Tube

MIS Drip Tube



Te water ootprint results or MIS components expressed as the sum o the supply chain andoperational water ootprints are presented in able 4-1. More detailed steps involved in the supplychain and operational water ootprint calculations are described in Sections 4.2 through 4.4.


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4.3 SUPPLY CHAIN WATER FOOTPRINT

Te supply chain water ootprint is calculated as the sum o the water ootprints o all input(raw) materials produced by suppliers and the water ootprint o supply chain overhead activities.

Water footprint of raw materialsGeographically-explicit data on the water ootprint o raw materials were not provided by suppliersand are not generally available. Tereore, average water ootprint estimates or PE and PP wereobtained rom a recent study published by Borealis Group on water ootprint assessments orthe manuacturing o polyolen across all its production sites (Katsous, 2009). For PVCmanuacturing, water inventory inormation was obtained rom the Environmental ProductDeclaration (EPD) report (ECVM and Plastics Europe, 2008). Te EPD is a standardized method(ISO 14025) o communicating environmental perormance o a product or service based onLCA data. Te calculated water ootprints o raw materials obtained rom these dierent sourcesare presented in able 4-2.

Table 4-2. Water Footprint of Raw Materials for MIS

13.7

13.1

10

BLUE

0

0

NA1

GREY

13.7

13.1

10

TOTAL

WATER FOOTPRINT (LITERS/KG)RAW MATERIAL REFERENCE

Polyethylene (PE)

Polypropylene (PP)


Katsoufis, 2009

Katsoufis, 2009

ECVM and Plastics

Europe, 2008

Supply chain overhead water footprint

Water ootprint accounting includes consideration o water associated with the production obuildings, machinery, trucks, oce equipment and materials, cleaning equipment, workingclothes, and other water use not directly related to production o MIS. Water consumed in theproduction o energy used to power operations at the Plastic Park is also considered to be part othis supply chain overhead.

Recent eorts by others to calculate the water ootprint o overhead have indicated that mostcomponents o the overhead water ootprint add up to a very small percentage o the total waterootprint, and that it is generally not worth the signicant eort to compute it. As an example, thewater ootprints o construction materials, paper, and transportation (vehicles, uel) were calculatedas part o a recent pilot study or a hypothetical carbonated beverage (Ercin, et al., 2009). Teresults demonstrated that supply chain overhead is less than 0.5% o the total water ootprint.

Supply chain overhead was considered as part o this study or the purpose o completeness, anddetermined to be very small. Only the water associated with electricity was considered, assumingthat other components are negligible based on the ndings o Ercin et al. (2009). Coal providesapproximately 73% o energy generation in the state o Maharashtra and approximately 53% othe energy in India (ERI, 2009). Based on this inormation, it was assumed that all o the energyor the Plastic Park is sourced rom coal. A water ootprint or production o coal o 0.59 liters/kWh was used in the calculations, as reported by Gerbens-Leenes, et.al. (2008). Electricity consumedin the Plastic Park (kwh/kg) was multiplied by the water ootprint o coal to obtain the waterootprint in units o liter/kg o output product. Using this approach, the supply chain overheadwater ootprint based on energy use was ound to be only 0.03 to 1.4 liters/kg MIS.

1Not available



Supply chain water footprint results

Te calculation o the supply chain water ootprint accounts or the portion o the raw materialthat enters the manuacturing process and is not incorporated into the nished product. Tis lossis accounted or in the calculations through the product raction, which is the quantity o output

product obtained per quantity o input product. Te water ootprint o the raw material is dividedby the product raction so the supply chain water ootprint is calculated in terms o liters o waterper unit mass o nished output product. Te product raction or all MIS components in thePlastic Park is unity because process material loss is completely recycled in the plant as raw material.

able 4-3 provides a breakdown o the supply chain water ootprint results by component.

10

10

13.1

13.7

13.7

2.4

WF OF

RAW

MATERIALS1

1.0

1.0

1.0

1.0

1.0

1.0

PRODUCT

FRACTION

10

10

13.1

13.7

13.7

2.4

WF OF

MIS

COMPONENTS2

0.18

0.99

1.40

0.29

0.47

0.03

OVERHEAD

WF

10.2

11.0

14.5

14.1

14.2

2.4

TOTAL

WF

NA

NA

NA

NA

NA

NA

GREY

WF

(LITERS/KG)3

WATER FOOTPRINT (LITERS/KG)

MIS COMPONENT

MIS PVC Pipe



MIS Poly Tube

MIS Drip Tube


1Units are liters per kg raw material2Accounts or product raction; units are liters per kg nished product3Not available

Table 4-3. Supply Chain Water Footprint Results

4.4 OPERATIONAL WATER FOOTPRINT

Te operational water ootprint includes:

Blue water consumed in the manuacture o MIS components (water used to cleanequipment and or cooling) and or domestic water use (overhead); and

Grey water ootprint associated with wastewater discharged rom the plant.

Blue water footprint

Te blue water ootprint is the summation o water consumed in the production o MIScomponents and domestic water use or overhead, which includes water consumed or pollutedrelated to toilets, cleaning, kitchens, gardening, and laundry. Te blue water ootprints calculatedor each o the primary MIS components, are shown in able 4-4.


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Grey water footprint

Te grey water ootprint o a process step is an indicator o the degree o resh water pollutionassociated with the process step. Wastewater euent resulting rom the manuacturing o dierentMIS components is collectively processed at an on-site treatment plant. First, chemical characteristics

o the treated euent were evaluated to determine the critical pollutant, which is the pollutantthat is associated with the largest grey water ootprint. Second, the grey water ootprint wasestimated as ollows:

[4.2]

El= euent volume (liter/year);

Cef= concentration o pollutant in the euent (mg/liter);

Cmax= ambient water quality or the pollutant (mg/liter);

Cnat= natural concentration o pollutant in the receiving water body (mg/liter); and

Y = MIS production (kg/yr)

Finally, the total grey water ootprint was allocated to each o the six MIS components based oneuent discharge.

Te critical pollutant considered or the grey water ootprint calculations is total dissolved solids(DS). Te natural concentration in the receiving water body is assumed to be zero (Cnat). Amaximum contaminant level o DS in drinking water o 500 mg/L (BIS, 1991) was assumed orthe calculations. Te grey water ootprints estimated or each o the MIS components range rom0.04 to 0.19 liters/kg.

Summary of results

A summary o the estimated blue and grey water ootprints o dierent MIS components isprovided in able 4-4. Te total blue water ootprints ranged rom 0.4 liters/kg or drip tubes to4 liters/kg or PVC molded ttings. Filter equipments have the smallest grey water ootprints(0.04 liters/kg), and molded components have the largest (0.19 liters/kg).

0.24

1.3

2.3

0.38

0.3

0.5

MIS INPUT

WATER

0.25

2.7

1.4

0.32

0.07

0.09

OVERHEAD

0.5

4.0

3.8

0.7

0.4

0.6

TOTAL

0.13

0.06

0.19

0.12

0.15

0.04

GREY WATER

FOOTPRINT

(LITERS/KG)

0.6

4.1

4

0.8

0.5

0.6

TOTAL WF

(LITERS/KG)

BLUE WATER FOOTPRINT (LITERS/KG)

COMPONENT

MIS PVC Pipe



MIS Poly Tube

MIS Drip Tube


Table 4-4. Operational Water Footprint Results

WFGrey=Efx (Ce- Cnat)

Cmax- Cnat



4.5 TOTAL WATER FOOTPRINT OF MIS

Te total water ootprint is the sum o the supply chain and the operational water ootprints. Teproportion o supply chain and operational WF or each o the six MIS components is shown inFigure 4-3.

Figure 4-3. Supply Chain and Operational Water Footprintsfor MIS Components

0.6 (6%)

MIS PVC PIPE

4.1 (27%)

MIS PVC

MOLDED FITTINGS

4.0 (22%)

MIS MOLDED

COMPONENTS

MIS POLY TUBE MIS DRIP TUBE MIS FILTEREQUIPMENTS

0.8 (5%) 0.5 (4%) 0.6 (21%)

OperationalSupply Chain

10.2 liters/kg(94%) 11.0 liters/kg

(73%)

14.5 liters/kg(78%)

14.1 liters/kg(95%)

14.2 liters/kg(96%)

2.4 liters/kg(79%)

Te water ootprints associated with the manuacturing o MIS equipments are generally verysmall, ranging rom 3 liters/kg or lter equipments, to 18.5 kg/liters or molded components.Most o the water ootprint or the manuacturing o MIS components lies in the supply chain,accounting or 73% to 96% o the total water ootprint. Most o the supply chain and total waterootprint is blue water associated with raw material production. Data to calculate the grey waterootprint associated with production o raw materials (plastics) were not available, so thiscomponent is unknown.

Te supply chain water ootprints or MIS components are large relative to the operational waterootprints because water is used or extraction and rening o oil resources, and petrochemicalplants uses large boilers and heat exchangers that consume signicant amount o water.

Te operational grey water ootprint associated with the manuacturing o MIS components isquite small (see able 4-4). Tis is due to the act that most o the process water is used or cooling.Te evaporative losses in cooling towers have been minimized by gradually replacing water coolingunits with air-cooled chillers. In addition to lowering water consumption, this upgrade has reducedthe sotening process required or cooling water, which in turn has reduced the wastewater load tothe euent treatment plant.


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5 SUSTAINABILITY ASSESSMENT

Sustainability assessment is the third step in a water ootprint assessment. Te purpose o asustainability assessment is to gain an understanding o the infuence o a particular water user,such as armers supplying onions to JISL, on local hydrologic systems, and to assess possibleecological, social and economic impacts o that water use. A sustainability assessment ocuses on

the particular aspects o the water cycle being aected by the water user, such as the water sourcesrom which a companys water supply is being drawn, or the water bodies into which anywastewater or surace runo is fowing.

O great pertinence to this assessment or JISL is the sustainability o the groundwater resourcethat supplies the vast majority o water used in irrigating onions in the api River basin. Tearmers interviewed in Shirsoli Village in the Jalgaon District during June 2010 expressedconsiderable concern about growing groundwater scarcity:

Ground water levels have been steadily declining since the 1970s.

Water levels in the wells are totally rainall dependent.

Wells have gone dry during growing seasons in extreme drought years.

Tese quotes rom local armers provide anecdotal evidence o declining water tables, but theirobservations are consistent with reports in the literature o steadily declining groundwater levels,as discussed in Section 1.2. o supplement and ground-truth this evidence, considerablegroundwater and rainall data were assembled and analyzed to gain deeper insights into trendsin groundwater availability.


A strategic decision was made to ocus the JISL sustainability assessment on the potential socialand economic impacts associated with the companys use o groundwater (its blue water ootprint),with particular emphasis on the possible consequences o groundwater depletion in the api Riverbasin. While other issues such as potential contamination o groundwater with nitrogen ertilizerused in arming (grey water ootprint) or the ecological impacts o surace and groundwater usein the area may be deserving o attention as well, those issues are addressed here only peripherally,due to time and resource constraints and lower priority.

Because the onion arms supplying JISLs production o dehydrated onions are distributedthroughout the Jalgaon, Dhule, and Nashik districts, water level data rom a large number ogroundwater wells located throughout the api River basin were analyzed or this sustainabilityassessment.

JISLs water consumption in the api River basin takes place in a rich and evolving physical, social,and economic context. Te company is but one o many users o water resources in the basin,

and the nature and volume o those uses has been changing rather substantially in recent decades.For instance, the total area o irrigated agriculture is increasing, with water-intensive crops such asbananas and cotton accounting or much o this agricultural expansion, as shown in Figure 5-1.



Figure 5-1. Temporal Trends in Area of Crop Cultivation: Jalgaon District

By comparison, approximately 3,500 ha o land were cultivated or onions in Jalgaon in 2000,

which is roughly 0.5 percent o the total land area cultivated or these ve major crops in thedistrict. Tough onion arming constitutes a small percentage o the total area in cultivation, thesustainability o JISLs water use is vulnerable in several distinct ways, each o which suggests adierent type o response strategy:

Te overdrat o groundwater due to cumulative uses in the onion growing regions makesJISLs dependence on onions rom this area at risk. It also places onion armers themselves atrisk, because any urther loss o crop production or associated revenue could cause armersto shit to other sources o income, including moving to cities. Tis suggests that responsestrategies should help armers reduce their demandor water, thereby reducing their risk oshortages and helping to alleviate the regional declines in groundwater levels.

Given current rates o groundwater overdrat, it may be very dicult or impossible to

maintain or increase crop production. Tereore, the response strategies should also ndways to increase the supplyo water.

Finally, the complexity brought about by the presence o many dierent water users suggeststhat a community-based, multi-stakeholder approach to managing the groundwaterresource could be o value in ensuring the sustainability o water-dependent livelihoods andin preventing uture confict over water resources.

0

1000

2000

3000

4000

5000

6000

7000

8000

1980 1990 1995 2000 2004

Area(hectaresx100)

Area of Crop Cultivation

Jalgaon District

Ground NutsBananas

Cereals

Pulses

Cotton

Total 5 crops


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5.2 OVERVIEW OF SUSTAINABILITY ASSESSMENT APPROACH

A water ootprint sustainability assessment can be carried out at a local, river basin, and/or globalscale, and it can address environmental, social, and/or economic sustainability. Tis assessmentconsiders the social and economic sustainability o JISLs blue water ootprint, at the scale o the

api River basin.

Te JISL sustainability assessment was conducted in accordance with a method developed recentlyby the Water Footprint Networks (WFN) sustainability assessment working group. Te assessmentcan be broken down into the ve steps depicted in Figure 5-2.

Figure 5-2. Steps in a Wat

ifc, jain irrigation break new ground in corporate water footprinting (october 2010)

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