pepsico, palakaad

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1 PepsiCo - Palakkad Water Conservation PepsiCo - Palakkad Water Conservation CII National Award for Excellence in Water Management Hy derabad December 16, 2008 With in the Fence Plant Overview Plant located in Industrial Development Area, Kanjikode in Kerala. Three filling lines Glass line for CSD PET line for CSD Aqua Fina line Plot Area - 50.48 Acres Employment - 250

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This is a presentation from PepsiCo, one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry. This presentation was in the "Within the Fence" category.We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.

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Page 1: PepsiCo, Palakaad

1

PepsiCo - PalakkadWater Conservation

PepsiCo - PalakkadWater Conservation

CII National Award for Excellence in Water Management Hy derabad

December 16, 2008With in the Fence

Plant Overview

• Plant located in Industrial Development Area, Kanjikode

in Kerala.

• Three filling lines– Glass line for CSD

– PET line for CSD

– Aqua Fina line

• Plot Area - 50.48 Acres

• Employment - 250

Page 2: PepsiCo, Palakaad

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PRIMARYPURIFICATION

PRIMARYDISINFECTION

PARTICLEFILTRATION

FINALDISINFECTION

COAGULATIONREVERSE OSMOSIS

ION-EXCHANGE

SANDCARBON

MICRONFILTRATION

OZONECHLORINE

ULTRAVIOLET

THERMALTREATMENT

SUGARDISSOLUTION

CARBONPURIFICATION

PARTICLEFILTRATION

Tre ate dCO2

Tre ate dLiquid S ugar

Sugar CO2

Tre ate d Water

Blendi ngConcentrate

Sugar Purification

Filling

VAPORIZATION MULTI- MEDIAFILTRATION

SILICAALUMINACARBON

MICRON

Water Purification

• Technol ogy-intensiv e

• High precisi on equi pme nt

• Stringe nt proce sscontrols to e nsure adhere nce to qualitystandards.

CO2 Purification

Manufacturing Process

Water

Water Recharge a t Plant lev el

+Water Initiativ es atCommunity lev el

+Promoting water

Conserv ation measuresin agriculture

> Water used in manufacturing plants

CREDITS DEBITS>As a result of this focus, water was revalued

PepsiCo’s Vision

Positive water balance Positive water balance —— going beyond zerogoing beyond zero

Page 3: PepsiCo, Palakaad

3

What we’ve accomplished on “debit” side of the equation

SCORECARD 2008

• 60% water u sage reduction in 2008 over 2004 (4.41 to 1.77 L/L)

• 77% reduction in effluent over 2001(3.41 to 0.77 L/L)

• The journey continues…

2008 vs. 2004: > 250 Million L saved2008: We could save another 16 Million liters

2008 vs. 2004: > 250 Million L saved2008 vs. 2004: > 250 Million L saved2008: We could save another 16 Million liters2008: We could save another 16 Million liters

NowNow……what about the credits?what about the credits?

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

2004-05

2005-06

2006-07

2007-08

We continue to achieve water “credits” through recharge of water resources

• Roof water harve sting at our facilities

• Surface water st ructure--pilots– Palakkad plant

These results reinforced that our goal of positive water balance is possible!

Rain water su rface infiltration pond

Surface water desilting chambers Water balance• Total Cons:153

– million L/yr• Total recharge:

– 108 million L/yr

• The results:– 71%

recharge of the aquifer at Palakkad

Page 4: PepsiCo, Palakaad

4

Palakkad Water Strategy

Conserve Source

(Recharge)

InProcess

AtDischarge

In TheCommunity

Water Strategy

4R

RWH

ZER

O

CSR

Rain Water Harvesting

De silting chamber for pond De silting chamber for pond

Surf ace Water Harv esting – Palakkad Plant

Page 5: PepsiCo, Palakaad

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Roof Water Harv esting – Palakkad Plant

Page 6: PepsiCo, Palakaad

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22.5

1.6

6.1

5.24.7

1.7

0

1

2

3

4

5

6

7

CSD CSD w/Ref illable

Containers

Spring Water Beer - SmallBrewery

Beer - MediumBrewery

Beer - LargeBrewery

Dairy

Water

Use

Rati

oGlobal Best in Class WUR in Beveragesfrom Benchmarking Survey

Palakkad

0.8 L/L Better

Source: WBCSD Report

Zero based targeting

Roadmap for reduction• Define specifications of water to be used at each step

in the process

• Determine quantity and quality of discharge at each stage

• Identify opportunities for recycling, treatment and technology to be deployed

• Discard as effluent after establishing that it is unfit for recycling

Page 7: PepsiCo, Palakaad

7

Consu mption Redu ction

ETP load Redu ction

Recover

Imp act on Energy

Water

Water use

optimization

Water sustainability

Rain water harvesting

Ground W ater Table

4R

Recycle

“When the well is dry, we learn the worth of water.”

--Benjamin Franklin

Page 8: PepsiCo, Palakaad

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• Assess current situation• Estimate Losses• Take Loss Reduction Target• Identify Losses• Identify Projects• Formation of Task force / Teams• Deploy 4R Tool• Implement Solutions• Check Results• Plan further actions

TPM WAY

PLAN

DO

CHECK

ACT

Approach

Estimate Losses

• Best in Pepsi 1.6 lits/lit

• Palakkad plant @ 4.4 lits/lit (25 lit/8oz case) in 2004

• Potential for reduction = 2.8 lits/lit ( 15.9 lit/8oz case)– This translate s to 350 kL of water sa ving potential per day.

• Zero based calculation– 8 oz case contents = 5.664 lits

– Evaporation losse s = 1.0 lits

– This equals to 1.2 lits/lit of water consumed – this is the ab solute

minimum if the effluent discharge from ETP is to be ZERO

Page 9: PepsiCo, Palakaad

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Target

1.4

1.9

2.4

2.9

3.4

3.9

4.4

4.9

2004 2005 2006 2007 2008 2009

Target lit/lit Achieved

Case Study

GOOD

Av g for 2004-05

4.4 lit / li t

Present 1.69

Ltr/Ltr

Reduction in Chemical Usage Over 2006

Chemical consumption Trend

05000

1000015000200002500030000350004000045000

Jan 06

Mar 06

May 06

July 06

Sep 06

Nov 06

Jan 07

Mar 07

May 07

July 07

Sep.07

Nov 07

Jan 08

Mar 08

May 08

July 08

Sep.08

Month

In K

gs

Caustic Salt HCL

Page 10: PepsiCo, Palakaad

10

Solid waste Management – ETP Sludge

Sludge Generation Avg/Month

3000

588

1970

0

500

1000

1500

2000

2500

3000

3500

2006 - 07 2007 - 08 2008 - 09 2009 - 10

year

Solid

was

te in

Kgs

ETP Sludge

Target

RECOVER

REUSE

RECYCLE

REDUCE

B ACKW ASH W ATER

BOTTLE W ASHER

TREATED EFFLUENT

CIP WATER

PET RINSE W ATER

AF-RO REJECT

STEAM CONDENSATE

SF AIR SCORING

FLOOR CLEANING

Page 11: PepsiCo, Palakaad

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Case StudyCase Study

Water Conservation

REDUCTION OF WATER USE BY COMPLETE USAGE OF ETP

TREATED EFFLUENT

AFRO Reject – Opportunity to Improve

Opportunity: Currently AFRO reject being used in ETP Tertiary Treatment & permeate used for Utilities & TDS balancing.

ETP Treated Effluent is having all the required parameters to treat through ETP UF RO, but due to AFRO reject availability Plant is using effluent for own land discharge to develop green field.

Effective use of Treated Effluent through ETP UF RO could save another 17KL/Hr.

Page 12: PepsiCo, Palakaad

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PDCA

Reuse Pot ent ial

Pay BackEffect ivenessSust ainabilit y

Compile & DiscussFindings

M odificat ions &Addit ions

Estimat e CostRaise C APEXDefine U sage

PI Guidelines for Usage

PLAN

ACT

CHEC K

DO

Why-WhyAnalysis

done

Analysis for Reuse Potential

• AFRO Reject is having more or less same Qualities of Raw Water

due to permeate re-circulation.

• Additional Generation of permeate through new CSD RO could save

another 12 KL/Hr out of 17KL which is now being pumped to ETP

UF RO.

• Proposed CSD RO can be able to treat this Reject.

• This phenomenon prompted team to work on e stimated reduction of

TDS through New RO.

Page 13: PepsiCo, Palakaad

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Estimated Savings

• AFRO Run Hours/Day: 20• Total Reject Generation @ 17KL= 17*20 = 340 KL• Permeate Generation through proposed CSD RO @

12KL/Hr for 20 Hrs = 12*20 = 240 KL• Balance 100KL will be pumped to ETP UF RO.• There will be direct reduction of 240KL/Day in Gross

Water Usage of Plant.

Approximate 70 Mill ion L annualized Water Sav ings

TASK PLANNING – 5W-1H

Propose f or New RO in CSD WTP to recycle AFRO reject.

To optimize the water consumption of the Plant

QC Exec/WTP associate

During AFRO Run

WTP & Production processes

Reuse of AFRO Reject f or process

How?

Reuse AFRO Reject in the process only .

Why

This activ ity propmtscomplete recy cle of Treated Eff luent.

Who

QC Exec/ETP associate

When

Daily

Where

ETP UFRO f eed

What

Reduce Usage of AFRO Reject in ETP UFRO

Page 14: PepsiCo, Palakaad

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PROPOSED CSD RO SCHEMATICWITH TDS BALANCING

22 KL @ 550TDS < 10 TDS ,4 KL

Reject 26 KL @ 500 TDS Permeate @<10 TDS

Permeate

Reject @ 800 TDS For Aquafina Production11KL @ 15 ppm TDS

1 KL Miscellaneous *

8 KL for GRB * < 400 TDS

38 KL @ 800 Tds 18 KL for PET*

* Maximum Limits Mentioned For FLOW* Minimum Limits Mentioned For TDS

Bore Well Water

620 TDS

Bore Well WaterBore Well WaterUG Sump

450 KL

PSF 2

RAW WATER

RO

ACF 3

SR.COAG INTERMEDIATE

PSF 1

ACF 1

ACF 2

AQUA SUMP

AF RO

ST-

ST-

Proposed Reuse

New CSD RO

AF Reject Collection Tank

Supplier: GE Water

Capacity : 12KL/Hr

Project Cost: 40 Lac

Time : 6 Weeks

Page 15: PepsiCo, Palakaad

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1.94

1.77

1.65

1.71.751.8

1.851.9

1.952

2007 2008

%

KL/Day

Consumption Target – Total Plant

REDUCTION OF 0.17 L/L TRANSLATES TO REDUCTION OF 120KL/DAY

Actions towards Water reduction

Wk – 5 100Per meate usage opti mizati on based on the r equirement

Connect CSD R O per meate to Stor age Tank.

5

Wk – 1Proper usag e i denti fication for Reject Str eam & D esign consider ation

Wor kout TD S esti mati ons pre & exi t R O and proposed use.

1

Wk – 4 100Enable AFR O storag eRe-dir ect Rej ect line to CSD R O F eed T ank.

4

Wk – 3 450Storag e AFRO rej ect in case any s toppag es i n the new C SD RO.

Provi de 50KL Storag e tanks for both feed & per meate.

3

Wk – 2Esti mati ng Pay Back & Resource Sustai nability

Esti mate N et Benefit to the Plant and esti mated water usage r ati o.

2

DateCostRs’000

BenefitsActionsSr

Page 16: PepsiCo, Palakaad

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Result of New CSD RO Project

220 220 220240 240 240

200180180

160

140

0

100

200

300

NOVDEC

JAN

FEBM

ARAPR M

AYJU

NEJU

LYAUG

SEPT

Month

Savi

ngs

in K

L

GOOD

70% ofTargeted Overall

Savings

Implementation

• 2 Major Projects Implemented in 2007-08 resulting in Annualized Water Savings of 70,000 KL (CSD RO & AF Rinse Water Recovery)

• Redesign, Rethink initiatives Identified & implemented, resulting in a saving of 15,000 KL in the year 2008.

• 18 Core consumption points metered on daily basis.

• Abnormalities paid higher attention by top to bottom.

Page 17: PepsiCo, Palakaad

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Results

1.4

1.9

2.4

2.9

3.4

3.9

4.4

4.9

2004 2005 2006 2007 2008 2009

Target lit/l it Actual l it/ lit

GOOD

Backwash Recovery

B/W Dacausticizer

Recovery

NEW CSD RO

Overall Results

• Total Savings of 240 Million Ltrs over 2004.

• No.2 on YTD Basi s acro ss 43 Pepsi Plants in India with 1.69 Lit/Lit

Water Con sumption.

• Zero Di scharge from the plant

• Controlled Effluent Generation. (0.69 KL/KL of Bev)

Page 18: PepsiCo, Palakaad

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Way Forward

•Identifying further opportunities to save water through proce ss effectiveness.

•Rede sign & Rethink Strategy added to 4R (No other stream available to deploy 4R)

•Reduction of Effluent by adopting latest technologies. (Electro Chlorinator)

•Optimizing total recovery from the existing water recovery system s.

•Con sulting Experts to generate ideas on water con servation.

“The significant problems we face cannot be solved at the same level of thinking we were at when we created them.”

--Albert Einstein

Page 19: PepsiCo, Palakaad

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THANK YOU!