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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