Presented by: N.Vamseedhar:GM op J.Rajasekhar: Manager Op MahenderMahender--Sr.ExeSr.Exe op AERIAL VIEW OF GOKUL PLANT 2 GOKUL PLANT 3 The Heritage Group was founded in 1992 by Sri Nara Chandrababu Naidu garu, with Three-business divisions viz., Dairy, Renewable Energy and NutriVet under its flagship Company Heritage Foods Limited (HFL). 4 HERITAGE PROFILE Smt N.Bhuwaneswari Vice Chairman & Managing DirectoDirectorr Smt N.Brahmani Mrs. N Brahmani Executive Director Heritage Golden Peacock Award for Excellence in Fortune List of 50 Most Powerful Business Woman Corporate Governance' for the year 2016 & 2017 5 VISION Delighting Every Home With Fresh and Healthy Products and Empowering the Farmer. 6 MISSION To be a Nationally recognized brand for healthy and fresh products with a revenue of INR 6000 core by 2024. We anticipate, understand and respond to our customers needs by creating high quality products and making them available through innovative and convenient channels. We embrace the right technology to delight our customers. We are a strong supporter of balancing Economic, Social and Environmental aspects to create a better tomorrow. We are devoted to empowering the farming community through our unique "Relationship Farming model. We aim to be employer of choice by nurturing entrepreneurship, Promoting empowerment alongside transparent and open Communication. 7 HERITAGE INTRODUCTION At Present Heritage Foods Limited is with 18-Packing Stations & 199199--Chilling Centers & Bulk Coolers 3,00,000 Farmers - Supply Fresh, Pure Milk Twice a Day 199 Bulk Coolers, Mini Chilling &Chilling Centers - Procure Milk Daily 12663 Milk procurement villages 2.10 million liters per day - Chilling Capacity 2.6 million liters per day - Processing Capacity 1.7 million liters per day - Packaging Capacity 1400 Heritage Parlours - Operated by Our Franchisees 1,18,500 Retail Outlets - Sell Heritage Products From Their Stores 1.5 Million Families - Buy Heritage Milk Daily Direct employment – 2,400 Indirect employment – 10,000 The annual turn over of Heritage Foods crossed Rs.2699.22 Crores in financial year 2019 – 20. 8 GOKUL : THE CROWN OF HERITAGE Was Commissioned in the Year 1996 The Biggest Plant Of Heritage Present Capacity is 5.0 Lakhs Lits / day Supplies Milk to Chennai and Tiruapti and Products across Several States Accredited ISO 22000 Certification in 2007 Accredited EIA Certification in 2010 Certified with ISO 50001:2011 EnMS in 2015 Winner of National Energy Conservation Awards in 2008, 2010, 2012, 2015 and 2017. 9 RANGE OF PRODUCTS 10 ENERGY POLICY 11 ISO 50001 : 2011 IMPLEMENTATION 12 EnMS Team GOKUL EnMS team consists of 20 members 1) Production dept’s Heads -7 members 2) Utilities dept’s Heads - 5 members 3) ENCON team - 5 members 4) Plant Manager -1 member 5) QA Incharge - 1 member 6) Stores Incharge - 1 member 20 Members team work extensively and focus in such a way to lay BENCH MARKS in all ENCON aspects in Dairy Industry. 13 EnPI’s 12 Energy Performance Indicators selected each from 7 Production Departments and 5 Utility Departments Given extensive training on variables affecting the EnPI’s in each department to give clarity on the GOAL. This changes the attitude of total staff and the technology transferred to bottom line perfectly. We went for Certification through BSI in 2015 and we are aiming 10% Energy Conservation every year. 14 15 PROPJECTS IMPLEMENTED IN YEAR 2017-2018 TOTAL ANNUAL Electrical Thermal NO TITLE OF PROJECT YEAR SAVINGS (RS M KWh M KCal INR in MILLION) 1 Commissioning of High efficiency 10 KL pasteurizer 2017-2018 33.928 175591.4 0.41 2 commissioning of 125 TR cooling tower for BDF 1&2 2017-2018 32.452 0 0.23 3 Retort Heat recovery by Cooling tower elimination 2017-2018 3.415 12529.13 0.18 Pressure transducer fixing for milk packing line to eliminate the 4 2017-2018 7.665 470848.3 0.52 overhead tanks 5 Commissioning of Telescopic conveyor-4 NOS 2017-2018 5.13 0 0.04 6 Commissioning of Online Check Weigher conveyor 2017-2018 0.519 0 0.00 7 Flash steam Heat recovery from FM sterilizers,kova pans and retort 2017-2018 0 147219.1 0.15 Commissioning of Pneumatic Steam control valve fixing in place of 8 2017-2018 0 954.17 0.00 manual valve 9 Installation of servo controlled voltage stabilizer 2017-2018 11.957 0 0.08 10 Cold store automation for diffuser fans stopping 2017-2018 66.43 0 0.47 20 NB steam TD3 trap replaced with float trap to avoid the steam 11 2017-2018 0 26367.6 0.03 wastage and to get better processing time Commissioned 3 stage lassi chiller for improving the process 12 2017-2018 9.921 0 0.07 performance and energy savings 13 VFD 125HP for Powder plant exhaust fan 2017-2018 23.648 0 0.17 Total 2.35 16 PROPJECTS IMPLEMENTED IN YEAR 2018-2019 TOTAL ANNUAL Electrical Thermal NO TITLE OF PROJECT YEAR SAVINGS (RS INR MKWH Mkcal MILLION) 1 Agitator shuffling to DAF collection tank 2018-2019 14.703 0 0.10 DAF outlet untreated scum shifting by gravity through piping instead 2 2018-2019 24.506 0 0.17 of pumping 3 power saving by reducing the FAT load in aeration tank 2018-2019 10.95 0 0.08 Commissioned the 5 hp kirloskar treated water pump in place of 10 hp 4 2018-2019 5.526 0 0.04 beacon pump 5 Timer arranged for DAF system skimming mechanism to save power. 2018-2019 1.46 0 0.01 DAF/IC reactor running hours reduced by keeping the ms mesh 6 2018-2019 19.165 0 0.13 strainer in the pump suction area 7 Replacement of steam heaters in place of Electrical heater 2018-2019 26.28 0 0.18 8 Commissioning of High speed packing machine 2018-2019 5.224 0 0.04 9 5 Effect Evaporator system for steam conservation measure 2018-2019 63.6878 1416092.4 2.0 10 2 no’s Dimple jacket for cream silos for avoiding pump 2018-2019 13.578 0 0.10 Commissioning of THE for milk pasteurizer in place of hot water 11 2018-2019 0 21057.96 0.02 battery 12 Installed power analyzer for measuring the quality of power 2018-2019 0.063 0 0.00 13Air purgerunit 2018-2019 0.929 0 0.01 Total 2.88 17 PROPJECTS IMPLEMENTED IN YEAR 2019-2020 TOTAL ANNUAL Electrical Thermal NO TITLE OF PROJECT YEAR SAVINGS (RS MKWH Mkcal INRMILLION) Installation of Bio-gas balloon and utilization of bio 1097085 1 gas to 3 ton IFB boiler to improve the steam fuel 2019-20 0.00 ratio 3.78 tp 4.29 1.85 Replacement of IE3 Grundfos pump in place of 2 2019-20 2.02 0 normal pump 0.01 Installation of Steam flow meter in process and 3 2019-20 0.00 773997 boiler for measurement of steam 0.77 4 Single cooling tower for both the Condensers 400 TR 2019-20 51.84 0 0.36 Combining 2 conveyors in Sachet curd with chain 5 2019-20 6.42 0 and sprocket arrangement 0.04 Commissioning of Continuous SFM batch 6 2019-20 20.42 132109 preparation against batch method 0.27 7 VFD systems for CBMM 2019-20 2.55 0 0.02 8 PHE arranged for RCM cooling to reduce load on IBT 2019-20 3.84 0 0.03 PHE for Panner cooling vat temperature 9 2019-20 1.68 0 maintenance 0.01 VFD arranged for Cooling tower fan for VAM in line 10 2019-20 3.58 0 with load 0.03 Operating Crate washers with full capacity which 11 2019-20 7.08 0 saves almost 2 hours of operation per day 0.05 12 VFD for kc6 180 HP refrigeration compressor 2019-20 3.22 0 0.02 3.46 Total 18 PROPJECTS PROPOSED TO IMPLEMENTE IN THE YEAR 2020-2021 SAVING(R SAVINGS INVESTMEN INR S (RS T INR NO TITLE OF PROJECT YEAR MKWH Million Wood in KG MILLION) MILLION) MILLION) COMMENTS Screw 205 TR for ammonia refrigeration 2020- 0.8 KWH/TR compressor planned 1 system 2021 0.24 1.76 0.00 0.00 1.76 12.60 to install in place of 1 Kwh/TR 3.8 units per litre capacity DG is 750 KVA DG 2020- going to replace with old DG 3.5 2 set(Commins) 2021 0.13 0.91 0.00 0.00 0.91 4.00 units per litres Utilization of ETP BIO GAS-800 m3 per day from UASBR and IC 100 m3 bio gas storage ballon reactor to BOILER with blower to be arranged to expansion 800-1200m3 2020- utilize the excess bio gas after 3 capacity 2021 0.00 0.00 240000.00 1.57 1.57 0.40 canteen to wood boiler ETP power reduction Separation of COD by separating by separating the milk flushout of all the milk handling flushouts from all and milk touching equipmnet process sources to and area's , if diverted to USAB optimize the DAF 2020- can eliminate running of the DAF 4 system 2021 0.15 0.00 0.00 0.00 0.00 0.20 system Air cooling Thermoking unit was planned to fix at one dedicated Air Cooling area , and all PUF to be cooled unit(Thermokig)fixing by flexible cooling system at constant plance and 2020- instead of fixing individual 5 cooling every PUF 2021 0.11 0.00 0.00 0.00 0.00 0.80 cooling system Glycol system capacity 2020- 2Kl tank glycol system to avoid 6 enhancenment 2021 0.11 0.00 0.00 0.00 0.00 0.50 individual glycol package system Optimization of air 2020- Air compressor optimization 7 compressors utilization 2021 0.04 0.00 0.00 0.00 0.00 0.20 plan VFD for cooling tower- 2020- 10 hp -VFD to be planned for 400 8 400 TR -10 HP fan 2021 0.01 0.00 0.00 0.00 0.00 0.03 TR cooling tower fab Total 4.2491 18.73 19 MILK PROCESS AT GOKUL PLANT MILK TANKER MILK STORAGE PASTEURIZER HOMOGENIZER CHILLER UNLOADING AREA TANK LOADING MILK STORAGE COLD STORAGE MILK PACKING PUF TANK ROOM MILK HANDLING PER UNIT TREND MILK LIT/UNIT 25 21.71 20 20.07 19.69 18.21 18.93 18.93 17.38 16.98 16.88 17.90 15 10 5 0 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 MILK LIT/UNIT 23 22 21.84 21 20.87 20 20.18 19.93 20.12 19.97 19 19.18 18.82 18.59 18.64 18 17 16 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20 2020-21 21 22 Ours is new generation Sterilization system, where all PP bottles are kept in baskets which are in rotation and immersed in hot water.