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1

1St Factory of ITCGreen Building

Platinum ratingISO 14001 Certified

Highlights

FAN- BLDC, Backward Curve

Electrocoupling Fan

Energy Saver for AC, VRV, IE4 motor

Energy efficient Burner

Innovative Project

National Energy Conservation Day

World Environment Day

Energy Management

System

Smart link system for Compressor

LP/HP Fan Smart Monitoring

Two fold increase in renewable energy

Portfolio

5 % Reduction in Units/MNC

4 % Reduction in kL/MNC

95 Solar Street Light Under

Greenovation

5Mw Offsite Solar Plant at

Gaya

Engineering

Sustainability

Industry 4.0

Awareness Building

Technical Interventions

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Electrical Supervisor

Branch Engineer

Energy Manager

I/C Electrical

MFG Executive

HR Executive

E.H.S Manager

Commercial Executive

ESP Member

Central Management Committee

The Energy Management Committee consists of Management, non-Management and Service Providers who actively takes part in the meeting

Environment Management organization Chart

TECHNOLOGY

Feasibility

Viability

BUSINESS

Usability, Desirability

HUMAN VALUES

DESIGN &

INTERACTIVITY

ORGANIZATION

BEHAVIOR

MANUFACTURING

Design

Innovation

Resource Conservation Map

Bio GasLight Pipe

Solar Plant

Recycling (PSPD)

ETP

RO

Wind Energy (ISOA)

Condensed water

Light Pipe

Cigarette Packing

AHU

Dust-segregation

Leaf Godown Conditioning Cutting Drying

Dust Recovery Fan

Tobacco Dust

FGCigarette Making

Canteen LPG

Chilling Plant

CTS

Tobacco Reclamation m/c

Cigarette Waste

Paper Waste

To Other

Factory

To Market

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Energy Management Trends

Energy Audits-Expert

Internal Brain Storming

& Learning

Awareness Building

Bench Marking

Innovations

Approach

732

670

636

605

2016-17 2017-18 2018-19 2019-20

kWh/Million No Cigarette

636

861

963

1058

MGR SRE PUN BLR

kWh/MNC

26292729

25852500

2016-17 2017-18 2018-19 2019-20(Target)

Thermal kJ/Kg

TPM pilot project: Energy reduction route for savings in production ancillaries

Improvement in solar 1MW plant performance by 1% through effective solar panel cleaning initiatives

Cost-effective Economizer coil replacement for improved boiler efficiency

Increasing hot condensate recovery for boiler feed-water (from 34% to 45%)

Auto-tube cleaning system for chillers

Replacement of old split/window ACs with VRVs for comfort cooling

Reduction in Excess air in furnace oil-fired boilers to 10-15% (from 50%)

Energy Saving Projects 2016-17

63 Mwh Electrical Energy Reduced

816 GJ Thermal Energy Reduced

Chiller Tube Auto Cleaning System

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Electrocoupling Fan blower system for AHU-2

H.T Heat Recovery System

Extended ATCS system for condenser tube cleaning of chillers

Energy Efficient Air Conditioning System(VRV) for Administrative buildings

LED lights for Process areas, office and compound area

Energy Saving Projects 2017-18

420 Mwh Electrical Energy Reduced

106 GJ Thermal Energy Reduced

Waste Heat recovery system for Hauni Tunnel

Energy Saving Projects 2018-19

349 Mwh Electrical Energy Reduced4.3 GJ Thermal Energy Reduced

No Title of Project YearAnnual Electrical Saving (kWh)

Annual Electrical Cost Saving (Rs

million)

Annual Thermal Saving (In GJ)

1Energy Efficient Process Air Fan with IE4 motor

2018-19128239 0.930

2 Trilobe Blowers with IE4 motors 2018-1912698 0.092

3 Electrocoupling Fan For AHU-1,3&5 2018-1992689 0.672

4 Backward curve fan for Canteen 2018-1922320 0.162

5Occupancy Sensors to control Ac, Light, fan etc

2018-1925600 0.186

6 Energy Efficient Burner (Agnisumukh) 2018-190 0.000 4.3

7 BLDC fan 2018-19 6200 0.045

8 AC energy Saver (Airtron) 2018-19 61380 0.445

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Input voltages of 100~240 VACPower Consumption 24watt only50 nos Fan installed last year6200 unit saved

Energy Management - Electrical

BLDC FAN Electronically commuted Motors for AHU

Direct Coupling, FRP bladesPower Consumption reduction by 45 % of AHUInstalled at Ahu-1,3&5

92.68 Mwh power reduced

Backward Curved Centrifugal Fan with IE4 motor

• Highest static efficiency• Non Overloading characteristics• Blade design efficiency >82%• Reduces Motor size• PMD DRF, Lamina Air lift, Canteen

Supply & Exhaust Fan replaced by Backward curve fan150.60 Mwh Reduced

Energy Management - Electrical

Low Approach Cooling Tower

Sl.No Description Unit Formula Value

Water saving

1 Water flow M3/hr A 90

2 Water Loss for 2 coling tower operation @ 2% M3/hr B=A x 2% 1.8

3 Water loss for single efficient cooling tower M3/hr C=A x 1% 0.9

4 Annual operating hrs Hrs D 7000

5 Fresh water saving by new effcient cooling tower M3/Year E=( A-B) x D 6300

6 Water cost for pumping & treatment Rs/M3 F 20

7 Annual Water cost saving Rs/year G=E x F 126000

Electrical saving for CT fan

8 Power consumtion for 2 operating cooling towers kW H 9.3

9 Power consumtion for ingle efficient cooling tower kW I 5.8

10 Annual power saving Rs/Year J=(H-J) x D 24500

11 Power cost at ITC Munger Rs/kwh K 6

12 Annual power cost saving Rs/year L=K x J 147000

Power saving due to improvement in cooling

13 Present specific power consumption of chillers kwh/TR M 0.700

14 Expected specific power consumption of chillers with new cooling towerkwh/TR N 0.665

15 Averge chiller load TR O 125

16 Annual power saving kWh/year P=Ox (M-N)x D 30625

17 Annual power cost saving Rs/year Q=P x K 183750

18 TOTAL SAVINGS AFTER REPLACEMENT Rs/year R=G + L + Q 456750

Energy Efficient MAC Purging Valve

ENERGY SAVINGS (TOOL : Compressed Air Monitoring System)

DRF combination : CDRF B+APre valve : 41 cfmPost valve : 34 cfmNet impact on SMD air consumption : 0.8 - 1%

HVAC pumps With IE4 motor

Water balancing of the system

Upgradation of the both Chilled water & Condenser pumps with IE4 motors

Potential Savings 10Mwh

Potential Savings 30Mwh

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Recovering 100% Flash steam and

Condensate energy

Optimizing Consumption:Compact TD Trap for Steam line

Boiler Performance

Bulk Tank Heating System

Energy Management: Thermal

Demand Side

Use of Condensate at Process:Direct Condensate usage for high temp application

13.213.4 13.5

13.7

2016-17 2017-18 2018-19 2019-20(Target)

EVR

Temperature based Control Valve to Control the steam to heat up FO bulk Tank

Recovering 100% Flash steam and Condensate energyPotential savings 2Gj per day

Uniform heat Across the Heat pot

Higher Thermal efficiency

Low gas consumption (15% reduction)

Energy Efficient Burner

The Agnisumukh devices are built on low gas pressure platform. Each device is fitted with a step down regulator

No emission Carbon Soot

15.68

14.10

12.56

11.3

LPG (Tons)

LPG Consumption Trend

15-16 16-17 17-18 18-19

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Waste to Energy

First tobacco sand (process waste) to biogas conversion plant installed

Composite Pit

Tobacco dust in feeding tank

Digest the dust using anaerobic digester

Send the effluent to ETP for treatment

Output

Anaerobic

Digester

Collection of bio gas

Output

Catalyst : pH>7 • Achieved by less tobacco mixed with large

amount of water (1kg :20L)• Neutralizing tobacco’s acidic nature

48575790

8870

2016-17 2017-18 2018-19

Bio Gas Consumption Trend(M3)

53%

Sustainability: Solar & ISOA

Key Challenges

•No precedence for Captive in Bihar

•Huge Loss of Revenue to State Utility

•Infrastructure changes as per Regulations and shutdown required of Railways

•Number of agencies are involved – SLDC, DISCOM, ERLDC

Interventions

• Extensively engaged with regulatory authorities pre & post approval

• Worked with PSPD and Railways

• Representation to SLDC, DISCOM for captive consumption

• New ABT meters(3 nos) installation

23% 22%

46%

90% 87%

16-17 17-18 18-19 19-20(Target)

19-20Q1

Renewable Energy substitution

1206 1219835 842

1224

847

17-18 18-19 17-18 18-19

Units Consumed in Mwh GHG Reduction in Tonnes

Green Energy

Green Energy Solar Green Energy ISOA

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Off-Site Solar Power Plant

25 Acre Land at Gaya

5 MWp Seasonal Tilt

68 Lacs unit per year Electric Boiler

Project Status Plan 19-20

• Regulatory approvals underway• Detailed design under process

• C0ordinate with government authorities for necessary approvals

• Solar plant commissioning • Intra state open access for captive

consumption

Capacity: 200 Kg/hr Pressure: 7 Kg/hr

• Space effective: To be installed at point of use

• Cost effective considering off site solar

0.470.44

0.29

2016-17 2017-18 2018-19

0.049

0.101

0.12

16-17 17-18 18-19

GHG Inventorisation

0.17

0.24 0.25

16-17 17-18 18-19

Scope-1Scope-2

Scope-3

0.689

0.781

0.671

16-17 17-18 18-19

Total

Production Volume for other Cigarette Manufacturer increased

14% Reduction

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Water Management

• ERS upgradation to increase reuse of water (40KLD)

• In house Rain Water Storage & Treatment System• AHU Condensed water(4-5KL Avg) reuses at

Cooling Tower• Installed Decanter System to minimize suspended

solid from the water

Major Interventions

4.22

3.50 3.353.00

16-17 17-18 18-19 19-20

KL/MNC

82%

7%11%

Water Source Utilisation2018-19

Ground Water Rain water ERS water

87%

2%11%

Water Source Utilisation2017-18

Ground Water Rain water ERS water

Rain Water

ERS water

Ground Water78%

13%

9%

2019-20 Target

Rain Water Storage

Industry 4.0 Smart Utility- Compressed Air

• Maintenance Alerts by Compressor

• Run Hours & machine health ( Smartlink)

• Compressed Air Demand Measurement

• Loss Measurement

• Performance Dashboard• Benchmarking among same M/C• Email Alert on

Deviations/reports

• Reduction in Machine Demand• Efficient Compressor Run

Key Features

Benefit Achieved

Standarised the Different Machine ConsumptionTime to time Leakage identification and Rectification the sameSwitching the Compressors as per the demand

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Innovative Project- Industry 4.0Energy Management System

To provide a complete Energy Monitoring systems integrated with 72 Energy Meter

Power, Current & Voltage graph at any instance as well as historical trend of every feeder

Hourly consumption trend to help in analyzing open access requirement

System can be integrated with steam and water monitoring in the future

• Monitoring real time Energy consumption of HP/LP motors in makers

• Specific Alerts to concerned stakeholders

• Online monitoring through specific dashboards

• Real time parameter tracking through smart sense software

• Energy reduction through predictive maintenance

• Augment equipment reliability

Key Features

Industry 4.0 Initiatives

LP/HP Fan Smart Monitoring-PowerGenome

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Wireless licensed multi user connectivity of Compressors through smart link module

Specific Alerts to concerned stakeholders

Online monitoring through specific dashboards

Enables remote performance monitoring with alarms

Predictive maintenance scheduling

Augmentation of equipment reliability

Key Features

Industry 4.0 Initiatives

Smart Link System - Compressors

Innovative Project- Optimisation Water Supply & Energy Conservation

PRESSURE SWITCH

PRESSURE SWITCH

PRESSURE SWITCH

• 3 Bore well pumps are installed in the plant premises to supply waterto the plant

• Bore wells were operated manually on continuous basis till thewater level in the collection tank is maintained on daily basis

• Yield of water from each bore wells differ substantially and yield isnot uniform throughout the operating hours on and it is high in theinitial hours and reduced when it is operated for long continuoushours

• Installed Microprocessor based bore well controller to optimise theoverall water supply and energy consumption

• Microprocessor will operate bore wells on sequential basis with on/off timer and pressure switch

• High yielding bore wells will operate on longer duration and willswitch off bore wells if yield reduces

• If the pressure in the supply water lines reduces due to low yield , bore well will be switched off

• If still there is water requirement next bore well will be selected automatically

Key Features

• Reduced manual intervention for bore well operation• Eliminating operation of dry run of pumps• High yielding bore well pumps operating more

• Reduction of total operating hours of bore wells• Reduction in overall energy consumption• High water level bore operated more• Operating cost reduction by 30%

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Green Supply Chain

All ITC Units continue to pursue efficient use of raw materials through focused efforts on waste elimination/reduction. Moreover, as most of ITC’s Businesses are vertically integrated, this provides the Company unique opportunities for exercising greater control over optimum utilisation of raw materials, recycling/reuse of wastes as well as efficient logistics.

Munger Printing Factory Supplies Major Raw Material (HLP) implemented following energy conservation project

No Title of Project Year

1 Replacement of window AC by central AC (with FCU) 2017-18

2 Turbo ventilator fixing in go downs 2017-18

3 Advance cool portable chiller installation 2017-18

4Steam shut up valve connected with m/c power for auto cut in m/c stoppage

2017-18

5200 nos LED lights 40 w fitting replacing 80w light

2018-19

6VSD installation for Fan of SR plant

2018-19

7Occupancy sensor fitting in officers toilet, meeting room and lab

2018-19

8 50 Nos old Fans Replacement 2018-19

24

Employee Engagement

• Training Session • Celebration of Key Events • Events Extensive Communication

Organise Quiz contest, Skitcompetition, Slogan & SuggestionContest conducted along withrecognition

Participated by Employee’s and ESP’s.

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Industry 4.O demo sessionsAllen Bradley Product knowledge session

Communication Technology Knowledge- OEMs

Demo & training on wheels on smart pneumatics by Festo

Leveraged TU for bearing and pneumatics

Capability Building

100 % fitters covered in technical Training in ancillary areas

Robotic ApplicationPMD DELIVERY LINE AUTOMATION

Robotic Case Packing

SMD UPGRADATION

Units are going to upgrade from 9k to 12K automated Cigarette Manufacturing Machine which will reduce the run hours of the operation

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Sustainable SocietyLED street Lamp with Solar system

95 no’s Solar LED lights provided for communitySolar Street Lights : Around 22000 people are getting benefitted

Retail Outlet Solar Lights : 45 Shops covered in 2018-19 as Pilot &

700 more will be done in 2019-20.

Sustainable Society

Solid waste recycling- Extended to 30 wards/8500 HH

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Q U E R Y M G TFor Bills & Purchase Orders

V A R I A N C E A N A L Y S I STool for Analysis of Costs

P R O C U R E M E N T I N I T I A T I V E SAutomation in Value Chain

D A T A A N A L Y T I C SAnalytics tool for strengthening Controls

T R A V E L P O R T A LEnd to End Travel Management System

T D S P R O C E S S I N GSystem for automated working of TDS

provisions

Process Excellence

S U R P R I S E C H E C K S Y S T E M

Workflow based system

H O S P I T A L T R A C K E R

Tracking of Hospital Payments

Digital Munger

Efficiencies

Co

ntr

ols Service

Delivery

30

1.Energy ManagementUnits/MNC-605 (2019-20)Units/MNC-575(2020-21)

8.Environ friendly MaterialsExploring Environment friendly Materials-

Biodegradable plastics, filters , led free pain etc.

7.Greening the supply chainStandarisation of vendor selection

criteria based on green parameters and provide support

6.Regulatory FrameworkScan regulatory framework

continuously and frame suitable strategies

5.Green RecognitionsIGBC platinum Certification renewed-2021

Exploring and applying various national and international Green award.

Greenovation– Roadmap of Green Journey 2018-21

1

2

3

4

5

6

7

8

Greenovation

4.Waste ManagementUpgradation of Bio gas to 100m3 -2020

3.Water Management

KL/MNC-2019-20 3.00Kl/MNC-2019-21: 2.86

2.Renewable Energy5Mw Offsite Solar plant-2019

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1st Prize Winner for Energy Conservation

Initiative & Sustenance

Excellent Energy Efficient Unit for Energy Conservation Initiatives

Platinum Rating for Green Building Design

& Systems

Suraksha Puraskar(Bronze ) Award for Excellent Safety System

1st Runner Up for Energy, Water & Solid Waste Management

Awards & Accolades-2018

ICC Environment Excellence Award

CII Energy Conservation Award-

Eastern

CII Energy Conservation Award-National

Green Building Recertification

National Safety Council

Environment Energy Energy Environment Safety

National Energy Leader-2018 for Energy Conservation Initiatives