more than 3 decades ago, nilkamal had a vision… · more than 3 decades ago, nilkamal had a...
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More than 3 decades ago, Nilkamal had a vision…
• Plastic – a new material, a new opportunity
• Wood & metal conventionally used
Unsustainable
Heavy, damaged easily
Higher carbon footprint
• 3 Core pillars that formed our Philosophy:
• Focus on Quality
• Focus on Customer (Service, Accessibility & Affordability)
• Focus on a Sustainable Future
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Focus on a Sustainable Future means
• Taking measures to minimise environmental impact
• Taking measures to maximise organisational impact
• Detailing each process to make enhancements actionable & results measurable
• Making sustainability a part of the company culture
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Steps ensuring we are the best in the industry…
Excellence in Manufacturing AwardsFrost & Sullivan :: 2013, 2014, 2015, 2016,2018
National Energy Management Award CII :: 2016, 2017, 2018
National Energy Conservation AwardGovt of India :: 2014, 2015, 2016,2018
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…not just once, but consistently
• Audit all processes in plants to identify areas of inefficiency, power
loss and waste generation
• Today, most of our plants are zero waste discharge plants
• Nilkamal plants have been repeatedly recertified ISO 14001 &
50001 for best practices in manufacturing with a focus on energy
efficiency
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A glimpse of some of our initiatives…
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#1 – Zero Discharge Plants
• Waste & sewage water treatment plant installed at
factories
• Freshwater used for human consumption and cooling
towers
• RO Plant rejected water is re-used for Toilets
• Wastewater used for plants & gardening
• Total Water Saving: 5000 Ltr per day
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#2 – Any excess material created is reused
• Six Sigma processes to reduce plastic waste from defects to less than 1%
• Dedicated grinding units at all plants. Material is reused within the factory
• Woven sack bags are scrapped and sold for secondary uses
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#3 – Design for energy conservation
• Factory designs have been engineered tomaximise natural daylight and ventilation
• Fitted with energy saving LED lights
• Machines have been redesigned:
• Insulation on injection barrel
• Retrofitting of servo motors from induction
• VFD installed for power conservation
• Sustainable and Profitable
Before After
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#4 – Usage of Renewable Energy
• Installed capacity of solar power – 4,000 kW across 4 plants
• Use of Wind energy at Hosur – 7,00,000 kWh / month
• Saving of 60,00,000 Kwh / Year resulting in reduction of 4,970 MT CO2 emissions
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#5 – Hydraulic Oil motors to Electric motors
• Indirect Hydraulic drive System Converted into Direct Electrical drive system to reduce energy conversion Losses
• Spent oil is disposed through govt. approved waste collection companies for recycling
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#6 – Breaking the myth of “persistent plastic”
• All moulded products made with single type plastics – no multilayers
• All products are RoHS compliant
• All products carry international recycling code
• All products are multi-use
• All products designed to have significant salvage value
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#7 – Packaging of products
• Shift to more sustainable packaging methods
• Plastic packaging material is 100+ microns
• Eliminate paper carton packaging by designing returnable solutions – metal stacking frame. Reduction in freight costs
• Ongoing initiatives to reduce and eliminate excess packing
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Reflects in our Product approach
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Products that promote sustainability
• Low cost toilet developed costing 50% of ceramic pan
• Flushes using only 200 ml water - promoting water conservation
• Waste Bins to promote segregation
• Industrial packaging product series introduced focusing on reusability
• PalletGUARD - Returnable packaging engineered for freight reduction, cost reduction and 1000+ cycles
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Collaboration with institutional customers to recycle ::Extended Producer Responsibility
• Crate buyback program with bottlers for dairy and beverages
• Recent project to convert half-depth crates to full-depth; Replacement crates produced contain recycled material
• 0 wastage of material
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Initiatives underway
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Educate the consumer
• Initiatives taken to educate the distributor, dealers and consumers about plastic
• Create awareness about correct disposal of any plastic waste
• Plastic can be recycled!
• Spread the message about the importance of waste segregation
• Understand the facts about plastic vs. wood, paper, metal and glass
VS
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Developing a Circular Economy with partners
• EPR Programmes to bring back products from the retail channel to ensure correct disposal and recycling of materials
• Work with institutional partners to collect products after product lifecycle to grind and repurpose
• Design products that minimise waste and maximise useful life
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Piloting series of upcycled products
• Global examples - Adidas, P&G, Fair Harbour, Norton Point, Bisleri and more
• Create product lines with more than 50% recycled material
• Waste plastic sourced from sustainable and fair trade collection centres
• Sales proceeds to be used for greater social impact, awareness and NGO campaigns
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We believe we must create processes that first begin within the company, rather than outside.
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Give back to nature, first by not giving back to nature.