Training need assessment for capacity development of DCCI staffs in technical, financial and general

management

Presented BySumit Kedia

Sita Ram Gokul MilkKathmandu, Nepal

Contents

•Background

•MOU of Sitaram Gokul Milks Ktm. Limited (SGML) with Environment Sector Program Support(ESPS)1. Findings2. Solutions

•MOU of SGML with Energy Efficiency Center(EEC)1. Findings2. Findings implemented and under process

•Significance of Energy Audit in Industrial Sector•Conservation of Energy for future generation•Conclusion

Established on Asadh 4, 2052 BS by Late Shankar Lal Kedia

Located at Dudhpokhari, Kirtipur occupying around 27 Ropani of land

Employment to around 300 people

Around 1.5 lakh farmers directly and indirectly benefited by the industry

Annually, crores of rupees being flown from factory to rural sector

Plant Capacity more than 1 Lakh LPD and produces milk and milk products

MOU of SGML with ESPS Study conducted on SGML was from 24th August 2003 to 31st

December 2003

Major Focus of ESPS was Cleaner Production(CP)

Objective of CP• Minimize waste generated in the life cycle of all the products or

services

Tools of ESPS to implement CP• Participatory approach for capacity building, organized approach

and involvement of employees at all levels of organizations

Findings

Waste management aspect

1. Introduce Trigger Nozzle to the end of floor washing hoses2. Introduce timer in water pumping house3. Introduce high pressure jet cleaner for cleaning purpose4. Make the facility to recycle and reuse the homogenizer

(piston) cooling water5. Modification of CIP facility6. Platform and conveyer installation for immediate storage and

closed feeding during reconstitution of SMP7. Reuse of buttermilk by installation of cream pasteurizer

Energy Aspect

1. Insulation of Boiler Head and proper boiler tuning

2. Conversion of pneumatic filling machine to mechanical filling machine

3. Installation of capacitor banks to improve power factor from 0.81 to 0.98

4. Use of flat belts instead of v-belts in ammonia compressor drives

5. Installation of TOD( Time Of Day) energy meter

Solutions All the findings were implemented

and we are very thankful to ESPS for their technical and financial support which they provided for the completion of the findings.

Few Clips after ESPS was implemented in Sitaram

Gokul milks

Crate washing Machine

Packaging machine

CIP System in Dairy industry

Tanker CIP system

SMP Reconstitution System

.

After we had finished with ESPS, due to technical and financial scarcity, despite of we wanting to do many more energy saving related programs we could not move ahead but somehow we came to know about EEC and the MOU between SGML and EEC was signed on 16th September, 2012.

MOU of SGML with Energy Efficiency Center (EEC)

Audit conducted on SGML was from 20-25th September, 2012 Major Focus of EEC was Energy Audit The audits were carried out under the guidance of GIZ/NEEP Experts

and trained Auditors

Objective of IGEA

Brief history of production and energy use measurement and monitoring of plant facilities for energy consumption Assess energy efficiency improvement opportunities in the areas of Power Factor

Management Load Management Sizing of Electrical Motors Lighting Systems Boiler Operation Insulation Waste Heat recovery Diesel generator sets House keeping

Findings The findings were categorized under

immediate, short term and long term and the basis for this was investment and ROI(Return On Investment)

Immediate

Revising the approved electrical demand with NEA from 500KVA to 400KVA

Operating the ETP(Effluent Treatment Plant) during low tariff peak period

Operating ground water pump at night off peak hours

Insulation of chilled milk pipeline

Recovering condensate during diesel boiler operation

Effective use of Ice Bank Tank

Insulation of Ghee Boiling Pan

Condensate Recovery from Cream Pasteurizer and Ghee Boiling Pan

Installation of VFD for chilled water pump

Installation of De-super heater at ammonia compressor discharge

Short Term

Performance of boilers and measures for fuel economy (Replacement of Oil Fired Boilers with Rice husk boiled boiler)

Heat Recovery from DG set flue gas

Milk Chilling and Pasteurization efficiency improvements

Long Term

Installation of a 1KL/Day solar hot water system to generate hot water

Findings Implemented and under processImplemented

Revised the approved demand with NEA from 500 KVA to 400 KVAa) Saving on demand charge

Operated ETP during low tariff perioda) Peak demand reduction and energy cost reduction

Recovered condensate during the diesel boiler operationa) Thermal energy saving

Under Process

Effective use of IBT Installation of VFD for chilled water pump Installation of de-super heater Insulation of Ghee Boiling Pan Condensate Recovery from Cream Pasteurizer and Ghee Boiling Pan Pasteurization efficiency improvements Heat Recovery from DG set flue gas Installation of De-super heater at ammonia compressor discharge

Left Out Things

Replacement of Oil Fired Boilers with Rice husk boiled boiler/Multi Fueled Boiler

Installation of a 1KL/Day solar hot water system to generate hot water

Problems Encountered to implement left out things

The reason why we could not implement left out things was because of initial heavy investment for the purchase and commissioning. Therefore, we are looking forward for technical and financial support from EEC and GIZ.

Significance of Energy Audit in Industrial Sector

In this competitive world , it is very necessary to cut your costs in order to survive and utility section contributes to a significant amount of the total cost. Therefore, energy audit is an excellent factor for financial gain as well as the good feeling that comes from doing something that benefits the planet.Successful Energy Management sustains savings and integrates projects with

Understanding energy use Operation and management Behavioral changes Tracking and bench marking energy use Communicating to the employees

Tools for energy saving

Make energy a priority Assign responsibility Set a goal Look beyond first Cost Get with the program

This audit relates to other industries also in terms of environment friendly and energy saving the final outcome which is reduction in production cost of any industry and conservation of energy for our future generations. For example:

ETP (Effluent Treatment Plant) Boiler Refrigeration system Air Compressor Electricity Solar power

Effluent Treatment Plant (ETP)

Findings

Almost all the industries are using water in some or the other form & the used water is thrown in nearby streams and localities without any treatment and the results is pollution.

Results

SGML is very proud to say that our processed water is being treated through our state of the art ETP plant and this is how we are conserving the nature and we are reusing the treated water.

Global warming has become a major concern in the National and international community therefore in the farm level and industry level it needs to be controlled

Boiler

Findings:

The cost of production becomes very high on using diesel /furnish oil.

Results:

To reduce cost of production multi fuel boiler has become the need of the hour.

Refrigeration System

Findings:

As most of the food industries use Refrigeration system. In our case installation of de super heater at ammonia compressor discharge was lacking, IBT system was not converted to PHE system.

Results:

We are under process for implementing these thing & if other industries also can follow the same , it will be very beneficial.

Air Compressor

Findings:

we was running compressor on high pressure & facing pipe line leakage problem.

Results:

We reduced working pressure & which in turned to solve leakage problem & reduce running hours.

Electricity

Findings:

The demand with NEA was higher than needed also power factor was low

Results:

Reduces the KVA demand and installed the capacitor as per requirement to increase power factor

Solar PowerFinding:

Though the solar is clean and renewable source of energy applicable for many application such as heating, lighting, water pumping etc, we are not using it.

Results:

We are planning to install solar lighting system and solar hot water system

Conservation of energy for future generation

We have become so mean that we try to prove ourselves in the society by exploiting the nature and we also try to pamper our children by giving them better education, shelter and food it is there right but what if all forms of non renewable energy is exhausted.

We do not mind if our children misuse electricity, water and fuel but friends we need to save non renewable energy and promote the use of renewable energy(solar energy, harvest raindrop,

Therefore the need of the hour is as in Kyoto protocol summit the whole world came together to reduce the emission of green house gas and carbon footprint

in similar way the whole world has to come together to save non renewable energy(fossil fuel, natural gas oil and coal) and to promote the use of renewable energy (sun,wind,rain and tides)

Few initiatives by Sitaram Gokul milks in conserving nature

1) has implemented the use of effluent treatment plant

2)has promoted the use of cotton bag instead of plastic bag with consumers in market.

under process initiations to save energy 1) to generate electricity by solar for light purpose

as well as production purpose

Phrases

“our elder generation spent dark nights but we see bright lights let us conserve energy to keep away future generations in dark frights”

“natural resources are not our property we have borrowed it from our future generations energy is life use it wisely”

Effluent Treatment Plant

Sitaram Dairy is promoting cotton Bags instead of plastic Bag in Market Level

Short-term Strategy

Conclusion

In the end we are thankful to EEC (an autonomous center functioning under FNCCI) and we are looking forward for TECHNICAL AND FINANCIAL SUPPORT from EEC AND GIZ for implementing the desired energy audit results conducted in Sitaram Gokul Milks.