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RESPONSE TO CLIMATE CHANGERESPONSE TO CLIMATE CHANGERESPONSE TO CLIMATE CHANGERESPONSE TO CLIMATE CHANGE

TATA MOTORS LTD. PANTNAGAR

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• Established in 1945, Tata Motors' presence cuts across the length and breadth of India.

• Over 7.5 million Tata vehicles ply on Indian roads, since the first rolled out in 1954

• India's largest automobile company, with consolidated revenues USD 32.5 bn in 2011-12.

• Leader in commercial vehicles in each segment, and among the top in passenger

vehicles

• The world's fourth largest truck and bus manufacturer.

• Presence in Europe, Africa, the Middle East, SE Asia, South Asia, South America and Russia

• Over 55,000 employees are guided by the mission

• Working on four thrust areas - employability, education, health and environment

COMPANY PROFILE

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Uttarakhand

Pantnagar - 2007

� In Uttarakhand State

(Northern part of India)

� 250 kms North–East of Delhi

� 7419 Employees

Karnataka

Dharwad - 2011

Maharashtra

Pune - 1966

Gujarat

Sanand- 2009

Geographical Plant Location of TATA Motors

Uttar Pradesh

Lucknow - 1992

Jharkhand

Jamshedpur - 1945

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Present Models

ACE 0.75 Ton

ACE CNG

Magic

Magic CNGACE -Fuel Efficient

Super ACE

Magic IRIS Ace ZIP

Venture

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Concern for the

Environment

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• Bhumi Poojan - March 30, 2006

• Construction started - April 2006

•Construction completed - Feb 2007

•Trial production started - April 2007

•Export Started - May 16, 2008

• 1,00,000th Vehicle- Feb 2009

• 2,00,000th Vehicle - Oct 2009

• 5,00,000th Vehicle - Apr 2011

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2

3

4

5

7

6

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9• 8,00,000th Vehicle - Mar 2012

10• 10,00,000th Vehicle – 27th Oct 2012

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Environment Policy Climate Change Policy

Env Procurement Policy Energy Policy

EMS / ISO 14001 OHSAS : 18001

Water Policy

Audit done &

Recommended for

ISO 50001 - EnMS

by BVC

ISO 500017

Facilitating and

Maximizing Reduction

in Carbon Footprint

through Value Chain

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Actions :

� To reduce 30% Steel for building structure

� Modular concept

� To reduce heat load on ventilation by installing Double

insulated side and roof walls .

� To reduce illumination load by installing Sky light sheets

� To install energy efficient motors for blowers, conveyors

� To install Screw chillers for AC system

� VFD for Compressor and all High powered motors

� Servo controller for Compressed Air Supply .

� Fan less cooling towers for compressor

� Propane for process heating, instead of

conventional fuel e.g. HSD/LDO/FO

� Use of natural resource Artisan wells

� CFL Lamps, Solar Lamps, Wind Ventilators

� Lakes & Rain water harvesting

Infrastructure Manufacturing

Actions :

� Efficient Washing Machines

� Inter Shop Conveyor

� Friction roller conveyor

� “Wet on Wet” Painting process

� Process Optimization

� Power & Free Conveyor

� Electrified Monorail System

� CNC Machines

� Reuse, Recycle, Reduce process waste

Strategy - To Reduce Environmental Footprint

New Product Introduction

Actions :

� CNG Vehicle

� Fuel Efficient Vehicle – with Start-Stop arrangement

� Adherence to emission norms

Logistics

Actions :

� Vendor park near the mother plant to reduce inbound

transportation

� Out bound Transportation

� Transportation internal & employee transport 9

�

STRATEGY Reducing

Environmental

Foot printInfrastructure

�Integrated

Manufacturing

� Modular concept

� Innovative construction

� Less Cement & Steel

� Efficient Facilities

� Water conservation

Logistics� Vendor Park Near Mother

Plant

� Transportation

� Recyclable bins , pallets

Manufacturing

� System

� Process

� Ramp up plan

� Continuous Improvement

New Products

� CNG vehicles

� BS III & IV

…. towards green plant10

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TML Plant Area - 616 Acres Vendor Park area - 337 Acres

Roads length ~ 15 km

Effluent Treatment Plant (Largest ETP in SIDCUL Industrial Estate, Udham Singh Nagar, Uttarakhand).

Total area - 953 Acres

TML

Background

Vendor Park

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UtilityAir, Water, Power, Fuel

ETP,STP

Ready Paint Shop

Utility

WIP

Plant layout Training

TC

F 1

C

TC

F 1

B

TC

F 1

A

BIW

1C

BIW

1B

BIW

1AEngine

&

Gear Box

Inter shop Conveyor

Weld shops to Paint toAssy Lines

1.5 Km long

Engine

&

Gear BoxTC

F 1

D

BIW

1D

TC

F 1

E

BIW

1E

We

ld S

ho

p 2

A

Ve

hic

le A

ssy

2A

,

2B

Service

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Employee Buses run up to

1. 40 Km from Plant

2. On 9 Routes

3. 70 Buses

Transportation Facilities

Inter shop Conveyor for Fast, Safe & Efficient Body

movement

Floor Conveyor - FRC

Floor Conveyor with Dolly

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Carbon Footprint - tCO2 / Eq Ace Veh

Indirect Emissions - UPCL Power

0.25

0.15

0.15

0.15

0.00 0.05 0.10 0.15 0.20 0.25 0.30

2008-09

2009-10

2010-11

2011-12

Year

T CO2 / Eq Ace Vehicle

UPCL Electrical

Direct Emissions - Fuel

0.07

0.08

0.08

0.06

0.00 0.02 0.04 0.06 0.08 0.10

2008-09

2009-10

2010-11

2011-12

Year

T CO2/ Eq Ace Vehicle

Fuel (HSD + Propane)

Specific emissions (Scope I + Scope II)

Scope I (Fuel) emissions Scope II (Electricity) emissions

0.32

0.24 0.23

0.21

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

tCO2 / Eq Ace Vehicle

2008-09 2009-10 2010-11 2011-12

Specific GHG Emisisons (Electricity + Fuel)

45

%

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Use of Environmentally

Sustainable Technologies

Minimize Waste

Generation and Enhance

Recycling and Recovery

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With help of Robots and Efficient

Painting guns, the wastage is reduced by

20-25%

Use of Eco – Friendly (Water Based)

Paints

Reducing Waste Generation

Incineration Recycling

Recycling of Paint sludge into Industrial Reusable Primer

Total Paint Sludge Recycled : 100 MT (i.e. 200 KL Fresh Paint Saved) 16

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Modular Concept

ETP : 1300 + 1300 KLD

STP : 600 + 600 KLD

Effluent & Sewage Treatment Plant

Total ETP Sludge Reused : 400 MT (i.e. 4 Lakhs Bricks Manufactured)

Re- Utilization of ETP Sludge as a raw material into Paver Blocks

ETP Sludge utilization for Pavement Tiles

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120

218

410

0

70

140

210

280

350

420

490

FY 08 -09 FY 09 -10 FY 10 -11 FY 11 -12

CUMSUM Utilization of ETP Sludge

MT

Approved by

CBRI

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Objective : Use of Zero Ozone depletion potential

refrigerant in HVAC system - R 410A

Eco - friendly activities

Objective : Use of Recycled materials such as AAC

bricks, made of Ash content.

Objectives :

• Low VOC Paints, Adhesives, Sealants

• No TOBACCO / NO SMOKING premises

• Reserved car parking for car pooling users

• Electric charging station for electric vehicles

Objective : Recycling of E – Waste

Total E – waste Recycled : 15 MT

Proactively initiated along with draft proposal in March 2011

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250 tCO2

Reduction

per Year

Offset Carbon Footprint

Total 40, 000 Trees Planted till date

Tree Transplantation

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Select, Purchase and Use

Appropriate Energy

Efficient Equipments,

Services and Eco-

Friendly Technologies

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Screw Compressor

With VFD Savings 250 MWH/Yr

Fan less cooling tower

Servo Control Valve

Efficient Facilities

22% Energy saved

Picture/ sketch/ drawing before modification

Picture/ sketch/ drawing after modification

Patent

CFLs

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Wind Ventilators

Renewable Energy

More than 1280 no’s installed and saved 2.9

Million Units.

Solar Water Heating System

Main Features: Main Features: Main Features: Main Features:

� Used for Hot water requirement

� Total system capacity – 5000 Litre / Day

� Max water Temperature – 900 C

� 1, 25, 000 KWH saved per year

� 1.05 Lakh tCO2 per year

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Main FeaturesMain FeaturesMain FeaturesMain Features

� Energy efficient building

� Use of eco friendly and recycled building

materials such as AAC Blocks

� Zero VOC paint and materials

� Automatic control of lighting

� Zero ODP HFC refrigerant

LEED INDIA – GOLD RATING

Green Building 220 KV Switch Yard & Open Access

220 KV Switch Yard Hence Pow er Quality

Improvements

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5 430 0

0

5

10

15

20

P owe r Fa i lur e Ov er / Unde r Vol t a ge Fluc t ua t ion

2011 2012

500

0 tCO

2

50 % Reduction in Direct Emissions 23

-

Use of DALI (Digital addressable light interface) Ballast 75%

reduction in energy consumption

Maximize comfort and reducing strain / glare.

Objective : Energy Conservation in ventilation

Energy conservation activities

Objective : Energy saving in lighting load

Use of Low U Value (thermal transmittance) Glass.

Double jacket glass to reduce thermal loss.

Tinted Glass to save reduce energy consumption in Air

conditioning

Objective : Energy saving on air conditioningDay Light Sensor / LDR for Street Lights

Total Annual Saving = 1 Lakh KWH24

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Insulated the

Washing machine

Insulation of Washing Machine Timer Based Switch (On/Off)

Benefits:

Energy Saving of 0.135 Lakhs KWH PA

Benefits:

Energy Saving of 0.91Lakhs KWH PA

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BASE PRIMERTOP COAT

(RUBY RED)

BAKING OVEN

2C-1B SYSTEM

Reduction in baking time & Fuel Savings Waste Heat Recovery

BAKING OVEN BASE PRIMER

SANDING

TOP COAT

(RUBY RED)

BAKING OVEN

2C-2B SYSTEM

Benefits:

Saving of 1403 Million Kcal PA

The waste heat of exhaust

flue gases from ED oven RTO

is recovered to raise the water

temperature of Hot Water

Generator system used in

paint Shop.

• 168 MT fuel saved PA

• 1 Cr INR saved PA

• 505 tCO2 saved PA 26

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Green Drive at DealersGreen Drive at Suppliers

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32

%

Specific Energy Consumption

32

%

Power Consumption

KWH / Vehicle

Fuel Consumption

M KCal / Vehicle

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Select, Purchase and Use

of Appropriate Water

Efficient Processes,

Equipments, Services and

Technologies for

Treatment, Reduction and

Recycling

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Efficient Facilities

Water conservation

Efficient Facilities

Water conservation

Eco Friendly Lake – water harvesting

Daily 500 KL/Daytreated water is used for gardening purpose

It saves 150 KWH per day

One of artesian well

is Supplying Raw water

to WTP with out power

Reduce the energy consumption for water pumps for WTP

Total Rain Water Harvested

78, 000 KL

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Recycling of Treated Industrial Effluent by Reverse Osmosis (RO) Technique and Reusing in Paint Shop Process

Main Features: Main Features: Main Features: Main Features:

� Recovery Capacity - 95% and unique system in recovery point of view.

� All the equipments are placed above the tank, hence looks compact & less space required

� Good quality of inlet water for paint shop and huge reduction in Ground water extraction.

� Stand by options with existing process water supply system.

� Reduction in 40% Ground Water withdrawal.

R.O. Recovery

started.

One

Lakh

KL

Reduction in Ground

Water

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-

Objective : Water efficiency in Gardening

•Water reuse- 100% STP water for landscaping

•Use of Shrubs and trees which needs less water.

•Gardening design so that minimum water should

flow out of the spaces.

Water conservation activities

Objective :

Prevent loss of soil and storm water during

construction due to rain

Objective : Reduce consumption of water

•Use of water efficient fixtures

• Saves approx 30% water

Objective : To harvest and recharge

•Total we have 5 no. of water bodies

•Total Rain Water Harvested 78, 000 KL

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PLC

PH Meter

Power Supply

GSM Modem

RS 232 PLC Input

PH & DO VALUE MONITORING SYSTEM LAYOUT

SMS Format

pH: High (> 9) / Low (<5)

DO : High (>4) / Low (<2)

DO Data Logger

Annunciator Panel

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Specific Water Consumption

47

%

Water Consumption

KL / Vehicle

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Suggestion Scheme Launched on Climate change & Environment Theme

…. towards green plant…. towards green plant…. towards green plant…. towards green plant

Reducing environmental foot print….Reducing environmental foot print….Reducing environmental foot print….Reducing environmental foot print….

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To generate awareness

STICKERS are developedAwareness

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National Energy Conservation Awards 2009 & 2010 CII Awards

State Energy Conservation Awards 2010 & 2011

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