Certificate of Merit Soap & Detergent ORAI DETERGENTS FACTORY, HINDUSTAN UNILEVER LIMITED, JALAUN Orai (Uttar Pradesh) Unit Profile Orai Detergents factory of Hindustan Unilever Limited was setup in 1989 in the town of Orai, Uttar Pradesh (around 100 km from Kanpur). It is the only toilet soap manufacturing unit for HUL in central India. The plot area for the factory is 52 acres out of which 22 acres is the built up area (42%). The factory is the toilet soap manufacturing unit for Lux, Lifebuoy and Breeze brands. The grammage of the soap manufactured varies from 35 to 100 grams. The unit has a process plant for producing Distilled Fatty Acid (DFA) from oils. DFA acts as a raw material to the soap manufacturing process. Adjacent to the DFA Plant is the sweet water evaporation plant, which processes sweet water to produce crude glycerine. The manufacturing setup includes 3 PSMs and one Mazzoni to produce soap noodles. The soap noodles are then fed into the packing lines where the finished goods are made. Plant has 4 cascades in the packing hall that cater to various brands. 348 With an installed capacity to produce 50000 tons per year, the plant is strategically located to serve the region of central India. The manpower strength of the factory consists of 5 managers, 20 executives and 330 employees. The NPS of the factory is 463.62 Cr for 2014 Energy Consumption of HUL Orai Factory Orai Factory is using Non Renewable Energy, basically Fossil fuels & Electricity to fulfil its Process Utility requirements. 2.1 Electricity Factory has 33KV Express Feeder from UP Electricity Board with 2800KVA Sanctioned Load. Factories per day average consumption are 32000 kWh Out of the total electricity, 80-85% is consumed by induction motors of process equipments, Pumps & Utility Equipments. Around 8-10% of total Electricity is consumed by factory lighting and Office equipments. These are basically single phase loads and are feed through a separate Isolation transformer. Factory has some heating loads also which is very less and is about 2-5% only. Annual Electricity cost is one of the major contributors of Factory’s total Energy Bill. It is around 35.5% of total Energy Bill. 2.2 Coal Coal is used as fuel of FBC Boiler to produce MP Steam. Factory has two nos of MP Boilers of Capacity 18Ton per Hour at 17.5Kg/cm2. One is running at a time. Indian steam coal of 4800GCV is the main fuel of FBC Boiler. Per day average consumption of coal is 38 ton in the year 2013-2014 which has come down to 32.6 Ton in the year 2014-15. There are some factors for which coal consumption varies throughout the year. Basically process steam requirements, weather condition, coal quality etc. Coal is also taking a major part in Factory’s Energy Bill. It is around 33% of total Energy Bill. 2.3 FO Furnace Oils of GCV 10200 is used as the main fuel of HP Steam Boilers. Factory has two nos of HP Boilers of capacity 3 Ton/Hour at 75Kg/cm2 which generates steam at a pressure of 65Kg/cm2. One is running at a time the other remains as standby. HP Steam is mainly used in the DFA Plant to split the PFA. Average FO consumption rate for the year 2014-2015 is 5.1 KL/day. Total Cost of FO contributes 31% of Factory’s total Energy bill annually. 349 2.4 HSD This is the common fossil fuel used by HUL Orai Factory in DG sets. Factory has four nos of DG Sets of capacity 1000KVA, 415V, 50Hz each as power back up. 1000KVA DG sets generating Powers at a specific Power to fuel ratio of 3.4. DG power is very costly almost 2.5 times of the cost of EB Power. The UP Electricity Board Power situation is not so good that they can provide uninterrupted power through the year. Power Cuts happens and factory has to take the burden of high captive generation cost. Energy Conservation As per plant energy conservation policy, it has undertaken various projects to improve the efficiency of its equipments and processes. Plant has focussed on reduction in all three stages of the energy usage: 1. Generation 2. Distribution 3. Usage 3.1 Generation Under generation, Plant has undertaken various projects like MP Boiler automation and rigorous monitoring of coal quality to improve the efficiency of MP Boiler and hence reduce coal. From the electricity front, plant monitor the power factor of the electricity usage. Along with this, it has also undertaken proper maintenance of the HT Yard to ensure minimal losses due to breakdowns in the system. 3.2 Distribution In distribution, plant has started recovering back the condensate from the tank farm and the drip legs along the distribution header and started using it in the MP Boiler to improve the efficiency. Along with this, it has optimized the pressure setting at various places to improve the usage. Unwanted steam pipelines have been removed to reduce the losses. 3.3 Usage In the usage front, projects like CSFA Dryer in the DFA Plant have reduced the usage of Furnace oil in the HP Boiler by increasing the production while using the same utilities. Energy efficient super chillers, energy efficient motors + pumps and VFDs on heavy motors not running on full load have helped same good amounts of electricity. The reductions have been as follows: 1. Coal – Reduction of 1860 tons (from 11629 to 9769 tons) 2. Furnace Oil – Reduction of 420 tons (from 1714 to 1294) 3. Electricity – 4.6 lac units (from 121.47 lac kWh to 116.87 lac kWh) 350.