Second Price Food Processing

TATA COFFEE LIMITED INSTANT COFFEE DIVISION Toopran Unit, ()

Unit Profile

Tata Coffee Limited (TCL) is the largest integrated coffee plantation company in the world. Tata Coffee has a hand in every aspect of the coffee making process, with business activities ranging from growing and curing of coffee and tea to the manufacture and marketing of value-added coffee products. Tata Coffee grows coffee on its own estates, processes the beans, exports green coffee, manufactures and exports Instant Coffee and retails coffee with its own branding in the domestic market.

Tata Coffee owns 19 Coffee estates located in ideal coffee growing highlands of Southern , with fertile soils and invigorating climate. Spread over 8037 hectares in Coorg, Chickmaglur and Hassan districts of Karnataka and in Valparai district of Tamil Nadu, Tata Coffee produces 10,000 metric tonnes of natural shade grown Arabica and Robusta coffees, in both washed and unwashed forms. The company also owns 7 tea estates which spans 4755 hectares in Coorg and Chickmagalur districts of Karnataka and Annamalais district of TN and produce 7.5 million kilograms of tea.

The Instant Coffee Division consists of two units that are 100% EOU units at Toopran in Hyderabad and Theni in Madurai with an installed capacity of 8500 TPA. TCL is focused on value addition in all its products.TCL has entered Japanese and Korean Markets and has now plans to enter other regions such as South Africa and Europe. Instant Coffee is produced from a blend of fine varieties of Arabica and Robusta Coffees. The strength and the cup quality of Instant Coffee produced by TCL are due to high degree of quality control at each stage of manufacturing operations and expertise that has been developed over the years. The powder meets BIS, European and GOST Standards.

179 Energy Consumption Details

The Main sources of energy in plant are bio mass fuels and electricity from grid. Following are sources of electrical as well as thermal energy in plant. - Electricity from Gird as well as Captive source - Biomass like rice husk and coffee waste – input in boiler for steam generation - Diesel- used in DG sets for electricity generation, Roaster & Spray drier. The total consumption of energy of applying unit is 3766.26 MTOE. The electricity is supplied from TSSPDCL. Fuels are major sources of energy in plant i.e. almost 62 % energy requirement met by fuels. Main fuels used in plant are Rice husk, diesel, Coffee waste out of which coffee waste is dominant fuel.

The following is the energy consumption & Specific energy consumption Scenario of applying unit.

180 Energy Conservation Measures

Project 1:

Company has installed Condensate recovery system, As company explore a lot of energy saving potential through installation of condensate recovery system, routing the same to boiler feed water and decreasing the load on boiler which will possess the savings in boiler fuel consumption (i.e husk and coal fuel specific consumption quantities reduction)

Total Investment : Rs.5 Lacs. Total Savings/Year : Rs.46 Lacs

Project 2:

Installation of Energy efficient 12.5 HP motors (4 No’s) in place of 20 HP Motors in AC plant.

Through 3rd party energy audit by Armstrong international pvt limited, company explored the potential of energy saving, it installed Energy efficient 12.5 HP Motors (4 No’s) in the place of 20 HP(4 No’s) in AC plant.

Before: After

Total Investment : Rs.2.38 Lacs Total Savings/Year : Rs.8.7 Lacs.

181 Project 3:

50HP, 40HP VFD’s Installation in Boiler For boiler ID, FD fans, company has installed 50HP, 40HP VFD’S to reduce the power consumption and increase the motor efficiency.

Before After

Total Investment : Rs.2.35 Lacs. Total Savings/Year : Rs.9.87 Lacs.

Project 4:

Installation of 2 No’s -50HP & 40HP energy efficient motors in place of old one’s

Replaced old motors with Energy efficient motors in spray dryer

Total Investment : Rs.1.5 Lacs Total Savings/Year : Rs.0.83 Lacs

Project 5:

Installation of solar street lights and LED

Project is having a focus on complete replacement with LED lights. Total 3455 Watts LED lights installed inside the Plant (30%).

Total Investment : Rs.1.5 Lacs Total Savings/Year : Rs.0.83 Lacs.

Our Policy

“TCL policy is to ensure the prevention of pollution specific to instant coffee plant by implementing environmental management programs, complying with legal and other requirements, and continually improve the established environmental management system by conservation of water and energy resources and effective utilization of renewable energy resources.”

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