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TABLE OF CONTENTS
Our Environmental Commitment Our Environmental Mission Future Challenges Pant Management Statement and Policy Environmental Conditions Air Stack and Ambient Air Emission Greenhouse Gas Emissions Ozone Depleting Substances Noise Volatile Organic Compounds Wastewater Recycle of the Treated Wastewater Solid Waste Recyclable Non Hazardous Waste (Scrap) Recyclable Hazardous Waste Hazardous Waste Storm water Groundwater Resource Conservation Introduction to the Energy Utilities Waste Metrics Energy Water Production Material Conservation Non Production Material Conservation Environmental Legal Compliance Compliance Assurance Internal Auditing Corporate Social Responsibility Initiatives Environmental Initiatives by Suppliers Annexure A B Ford India Integrated Policy Environmental Objectives & Targets Year 2006 19 20 - 22 1 2 3 4 4 5-7
1.0 2.0 3.0 3.1 3.2 3.3 3.4 3.5 4.0 4.1 5.0 5.1 5.2 5.3 6.0 7.0 8.0 8.1 8.2 8.3 8.4 8.5 9.0 9.1 9.2 10.0 11.0
7-8 8 - 10
10 10 11 - 15
15
16 - 17 17 - 18
LIST OF FIGURES
1.0 2.0 3.0 4.0 5.0 Noise level trend VOC emission trend WWTP treated water quality Oven waste heat recovery process at paint shop Plant wide percentage of electricity consumption 6 7 8 12 12
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Future Challenges
The environment, or a countrys wealth, can provide a flow of goods and services that are needed for development. The main environmental challenges we are facing today include conservation of water and energy, reduction in volatile organic compounds (VOC) emissions and disposal of hazardous waste. We have already progressed towards conserving various natural resources. Power consumption has come down by 35% while diesel and water consumption per car production has dropped by 18% and 25% respectfully in past four years of operation. By initiating continuous efforts such as waste minimization practices and upgrading our technology, we have reduced the VOC emission from 115 gm / m2 area of car body painted in the year 2003 to 59.1 gm / m2 in the year 2006. Going forward, we would like to focus our efforts in, developing Ford India as zero solid waste disposal facility and zero liquid discharge facility. For zero solid waste disposal option, we are closely working with our Ford Environmental Quality Office, Asia Pacific and USA to identify the possible options of reducing hazardous waste generation at the source and also promoting co-processing of the waste. Apart from the waste elimination, in the year 2007, we would like to focus on the following key issues; Develop web based environmental training module Shop floor improvement in Energy Utility Waste Metrics Sustain the Energy Utility Waste Metrics trend.
S. Ravichandran,
General Manager Launch, Projects & Plant Engineering & Environmental Management Representative Chennai, April, 2007
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3.0 AIR
3.1 Stack and Ambient Air Emission
Air pollution inside the Ford India premises is monitored through two different ways: ambient air quality monitoring and stack emission monitoring. Different locations for the ambient air conditions are monitored a minimum twice a year for particulate matters (Respiratory and Suspended), Sulphur-di-oxide, Nitrogen oxides, Lead and Carbon Monoxide. All the air emission stacks are monitored minimum once in a year for particulate matters, Sulphur-di-oxide, Nitrogen oxides, Carbon monoxide and Carbon dioxide. All the monitored values are with in the permissible limit stipulated by Tamil Nadu Pollution Control Board Ford globally has undertaken staged ozone depleting substance phase out program, which began with the first group of refrigeration systems in 1998. Ford India complies with Ozone Depleting Substances Rule, 1998, framed by Ministry of Environment & Forest, which evolved out of Montreal Protocol, in which India has signed. The ODS containing equipments will be phased out, once such technology is available in India, which is captured in our Environmental Management Program.
Every month, ambient noise monitoring is conducted. The minimum and maximum noise readings carried out during the day and night time is detailed below.
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80 75 71 70 66 70
60
50
49 46
40
30
20
10
0 Day Noise (06:00 - 21:00) PARAMETERS Night Noise (21:00 - 06:00) Max. Value in Leq dB(A) Min. Value in Leq dB(A) Perm. Limit in Leq dB(A)
VOC emission over the period of years can be viewed in the Figure - 2.
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2003
2004 Year
2005
2006
As part of the WWTP process, effluent treatment plant (ETP) sludge and bio sludge is generated and removed separately. ETP sludge is stored in the hazardous waste storage area, where as bio sludge is used as fertiliser for the green belt area development. The following are the various parameters that are monitored at the frequent interval (weekly / fortnightly / monthly) to check the effective functioning of the WWTP. pH; Total Dissolved Solids; Total Suspended Solids; Turbidity; Total Hardness; Calcium Hardness; Magnesium Hardness; Magnesium Hardness; Phenolphthalein Alkalinity; Methyl Orange Alkalinity; Total Alkalinity; Chlorides; Sulphate; Phosphate; Fluoride; Iron; Copper; Chromium Cr 6+ ; Zinc; Silica; Oil Grease; Dissolved Oxygen; Lead; Manganese; Bio chemical Oxygen demand (BOD3 at 27C); Chemical Oxygen Demand; Mixed Liquid Suspended Solids (MLSS); Sludge Volume Index; Food / Micro organism ratio and Sludge Age. The above parameters were found to be with in the permissible limit stipulated by TNPCB. Fig-3 shows the key parameter trend. Apart from the WWTP monitoring, ground water is also monitored periodically through the samples drawn from the eight monitoring bore wells situated at various locations of the site to determine the impact from wastewater irrigation and bio sludge use. These monitoring reports has not shown any undesirable change in the ground water quality.
4.0 WASTEWATER
Ford India is committed not only treating the sewage and trade effluent generated from its facilities, but also treatment of the sewage generated from the adjacent (Ford India Plant) suppliers. The wastewater treatment plant (WWTP) is designed to treat the trade effluent, sewage and canteen wastewater. WWTP is presently treating around 1100 KL/D (treatment plant capacity is 2000 KL/D). 60% of the wastewater for the treatment in WWTP is obtained from Ford India operation (trade effluent, canteen wastewater & sewage), whereas 40% of the wastewater is received from the suppliers (this includes treated trade effluent meeting TNPCB surface discharge norms, canteen wastewater and sewage). WWTP is manned and operated round the clock, throughout the year. WWTP is designed to treat the wastewater at four different stages Primary Treatment : collection, storage, sedimentation and floating material removal Secondary Treatment : neutralization of the effluent and activated sludge process for sewage Tertiary Treatment : sludge removal, ultra filtration and disinfection Advanced Treatment : Reverse Osmosis (dissolved solids removal)
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300
250 250
VALUE in mg/l
200
150
100
88
The various solid waste is segregated (using different colour bins) at the source of generation for ease of management. The segregated non hazardous solid waste is moved to the scrap yard for further segregation and disposal. The hazardous waste is moved to the hazardous waste storage yard for effective storage and or disposal to the authorized vendors for recycling.
PARAMETERS
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Key environmental management plans initiated in the year 2006 for reducing the hazardous waste generation are detailed below: Paint Sludge: Around 360 MT of wet paint sludge (generated since Ford India plant operation year 1999) was disposed in the month of May 06 to M/s Grasim Cement Industry, Ariyalur, Tamil Nadu. M/s Grasim cement industry obtained a special permission from the Central Pollution Control Board (CPCB) and Tamil Nadu Pollution Control Board to conduct a trial for using the paint sludge as alternate fuel. The above trial results found to be successful and CPCB has permitted to use the paint sludge as an alternate fuel in the cement industries. ETP Sludge: After continuous trials and jar test, lime consumption has been optimized in the WWTP process. Oily Rags: Body shop initiated the process of collecting the used gloves at the separate segregation bin. Based on the contamination nature, used gloves were reused again in the oily contamination area and less contaminated ones were sent for washing, latter the same was used for wiping the dust surface. Waste Sealer: Body and paint shop initiated the process of using the left out sealers in the containers by developing a special devise. Further to that, the left out sealers in the containers (which was not able to recover) were sent back to the supplier on weight basis. The left out quantity (measured) was adjusted against the supply of the fresh sealers.
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Paint sludge, which has the high calorific value (> 4000 cal / kg), is used as an alternate fuel in their cement kiln, since this is a proven practice in developed countries. At Ford India, we engaged around 850 man-days and 400 hours of the forklift operations to remove the stored paint sludge from the barrel placed inside the 40 feet containers. Paint sludge were first removed from the barrel, latter solar dried, then broken in to granular sizes, then packed in the polythene bags (20 kg size) and finally loaded in the 8 MT carrying capacity trucks and transported to M/s Grasim for the disposal. The whole activity was done in a controlled manner with a standard set of procedures and under strict supervision by the Environmental Management team.
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EUWM has shown an improvement in the trend for the year 2006. Some of the key improvements are mentioned below: Increase in energy efficiency (both electricity and diesel consumption) Decreases in hazardous waste generation Improved environmental training programs Reduced water usage Reduction in VOC emission Improved relationships with communities and regulators Increased waste recycling rates Substitution of less hazardous substances Reduced Inventories of Environmental Managed Materials More effective environmental control procedures Improved housekeeping, cleanliness, and preventive maintenance Better tracking and record keeping Upgraded environmental control equipment and facilities Proactive environmental outreach activities
8.2 ENERGY
Electricity: Annual energy audit is conducted to identify the area of concern or improvement in conserving electricity. Based on the concerns identified, the following initiatives were taken in the year 2005 06: Optimizing the air compressor from 3500 to 1700 CFM with Variable Frequency Drive (VFD), VFD installed for major air supply units in paint shop,
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Optimized the lighting load (lux level) across the shop floor, Energy recovery projects - heat recovery system in ovens, Pump optimization at paint shop (Pre-treatment pump, Electro coat chiller pump, PT/ED pump etc) Sealer oven cooling fan elimination from the process at the paint shop, Effective utilization of the electro coat pumps in the paint shop, Optimizing optimizations, panel air-conditioning
Each shop floor was given electricity consumption targets (minimum 3 5%) based on their consumption pattern. For effective monitoring and energy management, all the major equipments and activities are constantly monitored through energy meters. These energy meters were connected through software application to understand the peak and lean consumption and set the targets on power reduction. In past four year (compare the year 2003 to the year 2006), by implementing the above mentioned initiatives and improving the productivity, around 35% of electricity consumption have been reduced per car production.
Air volume optimization in paint shop ovens, Electrical load optimization at press line and crane OVEN WASTE HEAT RECOVERY PROJECT AT PAINT SHOP In Paint Shop, diesel fired ovens are used to bake the wet painted bodies. These ovens emit waste heat air of 10000 m3/hr at 140 degree Celsius to atmosphere. To recover these waste heats, new Heat Exchanger at the exhaust side at the exhaust side was incorporated. Thus recovered heat is used to preheat the fresh air fed to the oven. Cost Saving per car achieved was INR 53.9
To Atmosphere 75 deg C OVEN
Before
150-190 deg C Fresh Air Heater OVEN 35 deg C Air Seal Fan
Proposed
150-190 deg C To Atmosphere 75 deg C Fresh Air Heater 150 deg C 180 deg C New Heat Exchanger 35 deg C 9000 m3 / hr at Amb. Temp Air Seal Fan
Exhaust Fan
Assembly shop 5%
Plant Engineering 9%
Plant engineering electricity consumption mainly includes common area lighting and air conditioning load. Utility electricity consumption includes consumption of compressed air facility operation, fire hydrant water and industrial water pumping operation. All other shop floor electricity consumption includes the power required for the machinery operations, shop floor lighting load and man coolers consumption.
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Diesel: Diesel is consumed in the canteen boilers, paint shop ovens, power generators and for the production diesel car testing. The following initiatives were taken in the year 2006 for the diesel conservation. Sequence of operation of paint shop ovens Effective usage of canteen boiler
Water conservation taps has been installed such as aerated taps and improved drip irrigation systems. 65% of the underground raw water and fire hydrant pipes have been modified to the above ground level pipes. This alleviated the un-identified leaks in the underground pipes.
Diesel tank monitoring is followed to identify any loss or leakages. Using six sigma tools, a statistical monitoring measure has been developed to monitor the fuel loss (if any in the tank). In past four year (compare the year 2003 to the year 2006), by implementing the various initiatives such as sequencial start up and shut down of all the ovens, optimization of oven heat up time and improving the productivity, around 18% of diesel consumption have been reduced per car production.
Around 25% of the water consumption was achieved in past four years by mainly conserving the domestic and the process water. At paint shop, the discharge wastewater at various stages of the operation was effectively reused amongst the process before finally letting out in to the wastewater treatment plant.
8.3 Water
Water is getting more scarce and expensive year after year. It's costing us more to supply, to treat raw water and to again treat the generated wastewater. The energy required to meet these demands is enormous and also carries with it an environmental price tag. Hence water conservation is one of the key initiatives driven across Ford India plant. Some of the key measures taken to reduce the water consumption are detailed below. Similar to energy monitoring, water monitoring was also initiated in all the major water consuming areas using electro magnetic water flow meter.
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Different types of cartons with various specifications are received in the warehouse. These cartons are sent back to Ford India's parts distribution center and reused in the process for packaging of sale parts to be sent to dealers.
OLD PRACTICE
NEW PRACTICE
8.4.2 Yield improvement in sheet metals Scrap generation in stamping was reduced by effective utilization of the steel.
The major benefits achieved were reduced blank cost per panel, increase in yield percentage and decrease in blank weights. Benefits due to the yield improvement Increase in the yield percentage are 3% yield improvement achieved in Fiesta 0.75% yield improvement achieved in Ikon model
Total savings per viehicle achieved through yield improvement in USD is 12.7 for Fiesta and 3.18 for Ikon
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Ford India is maintaining the EMS certificate as per ISO 14001 for past seven years. Every year surveillance audit is conducted by TUV SUD South Asia. In May '2006 Ford India got recertified for ISO 14001:2004 standard. There were no major non-conformances identified during the audit.
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Environment and Safety: With the rapidly increasing number of vehicles on Indias roads, the environment and safety are hot topics and Ford India takes them very seriously. Ford India was the first automotive manufacturer to sponsor two lifetime Chairs at the Indian Institute of Technology (IIT). Representing an investment of Rs. 95 lakhs, the Chairs encourage and guide research and development in the areas of automotive environment and safety. The research is independent and results are shared with the automotive industry. The Henry Ford Chair for Vehicle Emission Research was set up at IIT Chennai in March 1998 and exemplifies Fords strong commitment to the worldwide clean air initiative. The Henry Ford Chair for Biomechanics and Transportation Safety was established at IIT Delhi in March 1999. Ford sets industry standards in test requirements, often introducing safety procedures well ahead of legislation. Ford vehicles have advanced safety structures, which exceed local safety legislation and carry additional supplementary restraints. Ford India granted emission testing equipment to the Automobile Research Association of India (ARAI) in Pune. ARAI conducts research and development, testing and evaluation, and certification of vehicles and components for the industry and government. Additionally, Ford India trained a number of ARAI executives at Ford's extensive research and technology facilities in Dearborn, USA. This training provided familiarisation with new techniques, testing procedures and test equipment. Ford India also funds and supports initiatives in and around Chennai, reinforcing our efforts in areas of Education, Road Safety and HIV AIDS. Every Ford India employee is actively encouraged to spend 16 working hours fully paid to participate in charitable work.
The Corporate Social Responsibility Committee continues to meet and implement both local and national initiatives to benefit the people and the environment of India. The Corporate Social Responsibility Committee continues to meet and implement both local and national initiatives to benefit the people and the environment of India.
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To enable and ensure the success of this massive project, Ford India formed the Supplier Technical Assistance (STA) group to partner with purchasing team to work on the following objectives: Identify Indian component manufacturers with the potential to supply world class products Facilitate the formation of business links and joint ventures (JVs) between established Ford suppliers with Indian partners.
their efforts. Eighty Indian suppliers lined up to deliver high quality parts when the production lines start rolling in November, 1999. Around 75% of the local supply base is located within 50 km of the plant. Only a few of the major components such as some parts of powertrain, AC compressor and EEC modules are imported. As a result of the successful partnership between best in class Indian suppliers & global suppliers and STA groups pioneering work, several existing Ford suppliers came into India. And those companies, with their established expertise, improved technology, design capability and quality standards of many Indian suppliers. In turn, some Indian companies won business from other vehicle manufacturers. The result is a more effective, high technology supply base, an integrated auto industry and more business for India thereby providing employment and export opportunities. Ford India ensured that all its Tier -1 level suppliers are ISO 14001 certified or have a plan towards ISO 14001 certification (a period mutually agreed) for the supply of parts or components to Ford. Communication is a critical enabler of the supply process and instant interaction is guaranteed as all suppliers are linked both to Ford and each other online. Suppliers are linked to Fords Material Planning and Logistics (MP&L) system and, at any time, they can see daily production figures, the schedule, their own stock levels, and how much is held in the plant. India is only the third country in the Ford world to use this highly sophisticated & integrated supply system.
Ensure the necessary transfer of technology from Ford and established suppliers to new companies and JVs The team trained in Ford systems and worked in close co-operation with the Ford global purchasing managers and the suppliers for many months. Suppliers were also exposed to Ford quality systems and procedures to better understand the companys expectations. As each new supplier came on board, a member of the STA group went through a 23-step process known as Advanced Product Quality Planning (APQP) with them. This includes detailed schedules for Ford programme pre-production and production milestones, facility planning, design-related issues, design failure mode analysis, process failure mode analysis, and quality systems and processes. Additionally, against each of the 23 points, daily-monitoring systems guided components through to final production and delivery Some of the smaller companies, meanwhile, changed their entire operations to embrace APQP, after recognizing the benefits. While technology flowed through partnership with global suppliers, a major shift in standards for all these companies resulted from Fords STA group and
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Annexure - A
FORD INDIA QUALITY & ENVIRONMENT (INTEGERATED POLICY)
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ANNEXURE B
The key environmental objectives and targets achieved by various shop floors in the year 2006 are detailed below:
S. No Objective Target 5% reduction in usage of the water compare to the year 2005. 15%reduction in panel rejection compare to year 2005. 3% reduction in the scrap generation compare to the year 2005 3% reduction in scrap percentage generation 2% reduction in consumption of electricity compare to the year 2005 1% reduction compare to the year 2005 5% reduction compare to the year 2005 25% reduction compare to year 2005. 5 % reduction in the consumption compare to the year 2005. 1% reduction in waste generation compare to the year 2005 20 % reduction compare to the year 2005. 5% reduction in the electricity consumption compare to year 2005. 3 % reduction in the generation of the used electrodes compare to the year 2005 Performance Indicator Water consumption trend Reduction trend
Stamping 1 Reduction in consumption of water (Die washing and Filter washing) 2 Reduction of rejected panels due to quality concern 3 Reduction in the generation of the sheet metal scrap. Reusing of scrap directly as supplementary component Reduction in consumption of electricity at stamping shop.
Scrap yield improvement trend Scrap disposal Trend Electricity consumption trend
4 5
Body Shop Reduction in sealer backup 6 sheet waste generation Reduction in highlight oil 7 consumption Reduction in the 8 consumption of anti-spatter spray Reduction in the 9 consumption of the used PPE Reduction in generation of 10 sealer waste per car Reduction in consumption of abrasives and back up pads Reduction in the electricity consumption at the body shop Reduction in the generation of the used copper electrodes
Back up sheets generated trend Highlight oil consumption trend Anti-spatter consumption trend PPE cost trend per person Sealer usage trend per car Abrasives and back up pads consumption trend Electricity consumption trend Electrodes waste generation trend
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13
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S. No
Objective
Target 2 % reduction in power consumption per car, compare to the year 2005. 25% reduction of air leak reported compare to the year 2005. Reduction in the consumption from 50 Liters per car to 40 Liters per Reduction in the wastage generation from 50 Liters to 20 Liters 10% reduction in the consumption of the filters compare to the year 2005 Reduction in the consumption 3 3 from 1 m to 0.75 m . 10 % reduction in consumption of air dry sealer cartridge from 1010 to 909 no's. 10 % reduction in the total paint consumption compare to the year 2005 5 % reduction in the sanding paper consumption compare to the year 2005. 10 % reduction in the solvent consumption from 1.40 to 1.26 Liters per car 10 % reduction in the consumption of the aluminum and polythene sheets VOC reduction from 90 gram 2 per m area of the car body 2 painted to 60 m area of the car body painted. Reduction in number of leak tags by 5 % compare to the year 2005. 5 % reduction compare to year 2005
Paint Shop Reduction in paint shop 14 electricity consumption Compressed air lines leakage reduction Reduction of diesel consumption Reduction of Electro coat paint wastage Reduction in the consumption of the filters Reduction of water consumption at paint shop Reduction in the consumption of the air dry sealer cartridge Reduction in the paint consumption Reduction in the sanding paper consumption at primer sanding operation. Reduction in the solvent consumption
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16
17
18
19
20
21
22
23
Reduction in the consumption of the 24 aluminum and polythene sheets Reduction in the volatile organic compounds 25 emission (VOC) from the paint & related operation. Trim Chassis Final Shop (TCF) 26 Compressed air lines leakage reduction 27 Reduction in TCF electricity consumption
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S. No 29 30
Objective Reduction in parts rejection and scrapping of parts Reduction in generation of glass breaking during handling and assembling Consumption of fuel for vehicles Reduction in water consumption Reduction of waste coolant, brake fluid and washer fluid generation
Target Achieve budgeted Scrap cost model wise 75% reduction in breakage compare to the year 2005 Achieve the budgeted fuel consumption Reduction of water consumption by 5% compare to the year 2005 20% reduction in the consumption compare to the year 2005.
Performance Indicator Scrap cost trend Glass breakage trend month wise Fuel consumption trend Water consumption trend per car Consumption trend per car against engineering requirement. Trend of packaging material reuse & generation
31 32
33
Material Planning & Logistics (MP&L) Reduction in the generation of the packing material waste received through Nondurables items Plant Engineering 35 Bio remediation of the diesel contaminated soil 34 5% reduction in the generation of Packing material waste received through Non-durables Bio remediation of around 85 MT of contaminated soil
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37
38
39
40
41 42
Effective collection of R-22 gas (otherwise leakage to atmosphere), while maintenance of split AC's to prevent ozone depletion Reduction in electricity consumption per car production (plant wide) Reduction in water consumption per car production Reduction in the noise level to Leq 80 dB(A) at the four existing diesel generators. Meeting the drinking water standard as per the IS 14543: 2004 standard. Usage of left out food waste by turning into compost Disposal of the paints sludge as an alternate fuel
Procurement of the gas collection kit for effective usage during maintenance activity Reduction in the electricity consumption from 964 kWH to 656 kWH Reduction in the water consumption from 6.6 KL to 5.0 KL Provision of acoustic enclosures for all the DG's Provision of the reverse osmosis treatment and other systems to meet IS standard Initiation of the vermi-compost treatment system. Disposal of around 160 MT of the paint sludge to cement manufacturing unit.
Total Petroleum Hydrocarbon values with in the permissible value R-22 gas leak to the atmosphere prevented
Electricity consumption trend per car Water consumption trend per car Acoustic enclosures in place Drinking water complying with the IS 14543 standard. Availability of the compost Records and necessary permissions
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