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Heritage Foods Limited, Uppal, Hyderabad, (Telangana)

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Heritage Foods Limited, Uppal, Hyderabad, (Telangana) Second Prize Dairy HERITAGE FOODS LIMITED Uppal, Hyderabad (Telangana) Unit Profile Heritage Foods Limited founded in the Year 1992 is one of the fastest growing enterprises in Dairy Industry in South India. Uppal Dairy Plant Commissioned in the Year 2006 with a rated capacity of 0.6 LLPD and was subsequently expanded to 0.74 LLPD in 2007, 1.1 LLPD in 2010, 2.0 LLPD (1.5 Milk and 0.5 products) in 2013. Heritage Milk and Milk Products have market Presence in Andhra Pradesh, Telangana, Karnataka, Tamilnadu, Kerala, Maharashtra, Odisha and Delhi with 14 Packing Stations, 106 Chilling Centers/Bulk Coolers/Ice Plants and 39 Franchise Bulk Coolers giving utmost care to preserve the Freshness of the Milk By adopting higher level of operational and QA standards. In the year 2007 the Plant was certified for ISO 22000:2005 towards our commitment to provide fresh and Safe Products. Currently plant is in process of implementing the Energy Management System ISO 50001:2011 towards its Goal to have a Certified Energy Management System. 111 Energy Consumption Energy is the biggest component of the operational costs in the Dairy Industry. Hence plant has taken this as a challenge to reduce our Energy Costs and involved all our total staff to dedicate themselves to avoid any wastage and to save energy at every point. The Energy Conservation Drive taken by the plant in 2012 is in continuous progress. Description Unit 2013-14 2014-15 % Reduction Specific Electrical Energy kWh/Ton 94.25 74.21 20.94 Specific Thermal energy Million Kcal/Ton 0.09922 0.07227 27.17 Solar Power Generation Plant is proud to inform that, 61.76 % of Electrical Energy consumed at Uppal Plant is procured from our 2.34 MW Solar Power Plant situated at Mulugu (Village), 70 KM from Hyderabad for the year 2014-15. 112 Total Electrical Power utilized at Uppal : 51, 46, 511 Units Solar Units adjusted by TS Electrical Board : 31, 78,276 Units % share of Solar Power is : 61.76 % Major Energy Conservation Measures Implemented in 2014-15 1. Recovery of condensate by installation of pneumatic condensate recovery pump Pneumatic condensate Recovery pump has been installed in place of 1.5 kW pump to recover the condensate from utilities in process machinery to boiler feed water tank, in turn boiler feed water temperature is maintained at 75ÚC & 25 KWh per day electrical units were saved. With the installation of recovery pump, thermal saving achieved about 12.4 liters of furnace oil per day. Electrical Units savings/year : 0.091 Lacs KWH F.O saving/year : 4.537 K.L Total cost savings : Rs. 2.64 Lacs 2. De-super heaters were installed to improve the efficiency of condensation De-super heaters (120 TR & 60 TR) were installed for getting better efficiency in condensation of ammonia, thereby efficiency of refrigeration improved. In turn running hours of KC-4 (56 kW) Ammonia Compressor running hours has reduced by 3 hours thereby Electrical energy saved, 152 units per day. As a byproduct plant is getting hot water of 41000 liters/day at 70ÚC, which is used for CIP, Crate Washer and Curd Machines flush out purpose, which leads to Thermal saving of 188 Liters of Furnace oil per day. Electrical Units savings/year : 0.555 Lacs kWh F.O saving /year : 68.6 K.L Total cost savings : Rs. 33.75 Lacs 113 3. Up gradation of old Crate washer with high capacity energy efficient model Unit has replaced the existing low rated Crate washer of 600 crates per hour with high rated energy efficient Crate washer of crates cleaning capacity of 1200 crates /hour. Total Electrical load was reduced to 14.62 kW from 24 kW. Hence, unit saved 203 kWh per day. Electrical Units savings/year : 0.74 Lacs kWh Total cost savings : Rs.5.6 Lacs 4. Ice cream Cold room renovated with Puff panels & EVAPCO for better results Ice cream cold room used at ice cream section was completely renovated with thermal insulated puff Panels to avoid the refrigeration losses along with installation of EVAPCO for better condensation in place of conventional shell & tube condenser. Hence, Unit has saved 373 units of electrical energy per day. Electrical Units savings/year : 1.36 Lacs kWh Total cost savings : Rs.10.28 Lacs 5. Auto temperature control of CIP system to conserve thermal energy The manually controlled hot water system for CIP for processing equipments replaced with auto temperature controlled system (by adding high accuracy PID controllers and pneumatic steam valves). This auto system ensures consistent operating temperature. 114 Hence, Unit has saved thermal energy in terms of Furnace oil i.e 48 Ltrs. per day. F.O saving /year : 17.51 K.L Total cost savings : Rs. 7.55 Lacs Energy Policy We at Heritage Foods Limited are committed to excel in Energy Performance in Process and Manufacture of Milk and Milk products on a continual basis for sustainable growth through, Continual improvement through up gradation of Technology, Systems and Services for improving Energy Efficiency to optimize the Energy Cost. Monitor and Control the Energy Consumption effectively by innovative designing and cost effective methods including procurement of Energy efficient products and services Providing resources to achieve measurable objectives and targets whenever necessary Complying with all applicable legal and other requirements related Energy use, consumption and efficiency. Integrating the energy policy in to our business planning, decision making and reviewing as and when necessary. To establish Bench marking standards in Dairy Industry in Energy Management We commit to communicate this policy to all our employees, persons working for and on our behalf and make it available to the interested parties on request. Date: 01.03.2015 Sd/- GENERAL MANAGER (O) 115.
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