Pulp & Paper - 378 - ITC - PSPD - Unit - Bhadrachalam - 0

ITC Limited
Paperboards & Specialty Papers Division
Unit : Bhadrachalam
Presentation by :
M.Phani Kumar – Manager (ENCON Cell)
T.Murali Krishna – Manager (Energy & Utilities)
ITC PSPD (BCM) Slide # - 1

ITC Bhadrachalam
India`s largest & most technologically advanced Integrated Pulp & Paperboard Manufacturing Facility
Pioneer in Ozone bleaching, BCTMP technology in India

Certifications & Compliances
Category Certification/ Compliance Description
ISO 9001 Quality Management System (QMS)
ISO 14001 Environmental Management
Manufacturing &
OHSAS 18001 Occupational Health and Safety Management
Safety
ISO 50001 Energy Management
BRC Global Standard Hygiene & quality for Packaging & Packaging Materials
SMETA 4 Pillar Member of SEDEX (Supplier Ethical Data Exchange)
Registration, Evaluation, Authorisation and Restriction of
REACH
Regulatory Chemicals (REACH) - a European Union regulation
Restriction of Use of Hazardous Substances like lead,
RoHS
cadmium, mercury
BfR Recommendation XXXVI German Regulations for migration
Food Contact US FDA CFR 21, 176.170 For contact with aqueous and fatty food
US FDA CFR 21, 176.180 For contact with dry food

Company Profile
• 7.4 Lakh TPA Paper and Paper Board Capacity
• 1 Lakh TPA Bleached Chemi Thermo Mechanical Pulp (BCTMP) Pulp capacity
• 100% self sufficiency in power through in-house co-generation power plant
• Green Covered area so far 6.2 Lakh hectares through Social and Farm Forestry
• 47.52% of total energy in 2017-18 is from renewable sources
• Carbon Positive for 13 Consecutive years
• Water Positive for 16 years in a row
• Solid Waste Recycling Positive for the last 11 years
• Green Co Platinum certified by CII-GBC
• TPM Methodology for manufacturing excellence

Our Products End Use Applications
Liquid Pharma
Packaging Cartons Deep
Printing Freeze
Paper foods
Blister
Book
Packs
Covers
ITC PSPD Division Liquor

Paper cups, Cartons
Tubs
Top Liners Cigarette

for CFC HLP
Playing
Soap /Game
cartons FMCG Skin
care cards

Pharmaceutical Cartons
Liquid Packaging Book Covers
Deep Freeze Application Blister Packs Liquor Cartons

Cigarette Packaging Playing Cards Visiting Cards , Tags & Brochure's
Paper Cup Applications

FMCG & Garment Carton Applications
Soap Packaging Applications

Our Esteemed Customers

Process at Unit Bhadrachalam
High Speed Chippers Super Batch Digesters Ozone bleaching – 1st in India
Sp.Steam cons < by 30% & one among 7 in whole world
Installed
Cogeneration
power plant of
capacity 115 MW.
Average connected
load : 95 MW.
State of Art Paper / Board machines & Rewinders High Speed Sheeters Automatic Storage & Retrieval Facility Warehouse

ENCON Projects with “ZERO” investment (2015-16)
Sl. No. Title of projects implemented Annual Savings
Electrical Thermal Monetary
(kWh) (Steam Tons) (Rs Million)
1 Avoiding idle operation of hydraulic motor of Baling 46200 - 0.11
press (at FH-1)
2 UBC reduction in CFB-9 (4.8% to 4.0%) - 7600 4.96
3 Iruvendi water pumps optimization by reducing 200000 - 0.46 Fly ash with high
frequent ON/OFF Unburnt Carbon
4 DM water temperature increase by modification of PHE - 2100 1.37
header & piping (LP steam consumption reduction in
boilers from 0.112 to 0.111 t/t)
5 Avoiding CFB-9 Bed Ash conveyors idle running 32000 - 0.07
6 Avoiding recirculation of water between collection tank 193752 - 0.45
1 and white water tower.
Fly ash with low
7 Interconnection provided between 2 pumps for 140000 - 0.32
Unburnt Carbon
bypassing one pump at FRBT ground floor

Sl. No. Title of project implemented Annual Savings
Electrical Thermal Monetary
(kWh) (Steam Tons) (Rs Million)
8 Reduction in steam consumption at hot water tank by - 15144 9.88
improving heat recovery in water
9 Increasing of PSM sheet moisture from 10% to 15% to - 2350 1.53
reduce steam consumption from 1.6 to 1.5 T/T of
sheets
10 Avoiding continuous running of agitators (5 locations) 272160 - 0.63
in Paper Machine stock preparation area (Timer
controlled start & stop without affecting run ability in
particular grade of products)
Total 884112 27194 19.79
~ 0.5% of the Electrical & Thermal Energy saved through zero investment projects

Electrical Monetary
(kWh) (Rs Million)
1 PM#6 Optimization of Vacuum system (Stopping of 1 standby vacuum
1680000 5.07
pump)
2 PM#6 Optimization of Refiners (Increasing the Consistency from 3.6 to 4.1-
1584000 4.78
running 3 refiners against4 refiners (Except 80GSM)
3 VP-2 Pulley size modification in PM3 522720 1.58
4 Efficiency improvement of pumps through coatings on the inside of Pumps
504000 1.52
(12 no’s)
5 Street-F PM7 Pump designed for 3 TPH Capacity, as it is dedicated for dip.
Now we are handling only virgin pulp, so we enhanced the pulp pump 396000 1.20
capacity from 3 TPH to 9 TPH with the same existing motor.
6 PM#6 - Reducing the running hrs of Couch Pit thick stock pump (90KW)
201600 0.61
(Interlock changed to 90% to 80% for couch pit lean stock pump)
7 Broke pumping chest with timer control provision 174240 0.53
8 EOP line B transfer pp can be stopped if take direct line from line B to line A. 168000 0.51
9 Street-B Discharge pump running with higher capacity when availability of
142560 0.43
lower capacity pump
10 Condensate water loop closure for conservation & energy saving. 126000 0.38

Electrical Monetary
(kWh) (Rs Million)
11 Broke tower agitator with timer control 118800 0.36
12 Removal of ON/OFF operation for 334p126 water pump from local for
118800 0.36
avoiding power wastage
13 FL Recovered fiber agitator to be stopped for energy saving 110880 0.33
14 Street-A FC-1 Pump dilution line tapping taken from new back water
102960 0.31
pump
15 Street –F Sump pump running with higher capacity pump when
87120 0.26
availability of lower capacity pump
16 FL Mixing sweetner pump bypassing to avoid energy loss 87120 0.26
17 Sending of RO rejects to Raw water channel directly. 75600 0.23
18 Providing the shower at bottom layer wire B/S trim area 43560 0.13
19 Interlock provision (Street-F lub oil pump doesn’t have any inter lock
3960 0.01
provision after stop condition of Pulper)
Total 6247920 18.87
769 kW of Power ~ 1.01% of the Electrical Energy saved through zero investment projects

Electrical Monetary
(kWh) (Rs Million)
1 Interlock provision for pulp discharge tanks agitators to save power in every 15
656760 1.88
min.
2 Bypassing of conical refiners during tetra run (R004 & R008 Conical refiners to be
592334 1.70
bypassed in TETRA CLC80)
3 SRB4 TA duct insulation improvement to avoid radiation loss 418118 1.20
4 BSW-2 MC Pump RPM reduction by modification of pulley size 198955 0.57
5 Provide Isolation Valve at Service air line hose`s Lance rod of Air Ports to avoid
171777 0.49
service air wastage & Safety improvement
6 Under sizing of BSW1A MC Pump motor change from 110 to 90 kw capacity 129617 0.37
7 Air header leakage to be dummied at E tower side 80557 0.23
8 PO Stage-1 Auto shower timings to be change from 15mins to 1Hour to save
22746 0.07
power
9 Logic to be prepared for at a time single system should be in conveying in one
182927 0.53
group (MDC,APH,BAC,ESP)
10 Level Interlock to be provided for Cloudy filtrate pump (102-P-060) As this pump
is running round the clock with minimum valve opening causing to power 101830 0.29
wastage
Total 2555621 7.33
ENCON Projects with “ZERO” investments
Year No. of Zero Annual Energy Annual Thermal Savings
Investment Saved Energy Saved (Rs. Million)
Projects (Million kWh) (MT Coal)
2015-16 10 0.88 7156 19.8
2016-17 19 6.25 - 18.87
2017-18 10 2.56 - 7.33
Total 39 9.69 7156 46
Total 39 projects with ZERO investments implemented in 3 years resulted

saving of Rs. 46 Millions
ZERO investment projects are coming from
shop floor / TPM where Every employee
irrespective of level contributing in Energy
& Resource Conservation.

ENCON Projects with Investment (2015-16)
Sl. Title of project implemented Annual Savings Investment Payback
No. Electrical Thermal Monetary (Rs Million) period
(kWh) (Coal Tons) (Rs Million) (Months)
1 Energy Efficient Coating TG-5 CT pumps 93720 0.22 0.34 19
& one raw water pump at Iruvendi
2 TG-7 CT fan VFD installation 160000 0.37 1.03 33
3 SRB 4 ID Fan inlet duct modified to 1158500 2.69 - -
reduce pressure drop & ID fan power
consumption
4 DLM Filter Vacuum pump pulley 722400 1.68 0.45 3
modification
5 LK-3 vacuum pump speed reduction by 432000 1.00 0.02 0
pulley change
6 Real Time Energy Optimization 7629 4.98 13.80 33
Software advisories implementation in
power plant (Reduction in steam in
Power plant)

(kWh) (Steam Tons) (Rs Million) (Months)
7 Replacement of VACCUM PP 8 with energy 720000 1.67 2.71 19
efficient vacuum pp In PM2
8 Reduced drive pulley dia of VP2 from 703000 1.63 - -
450mm to 400 mm dia to reduce the speed
with out affecting the quality
9 Use of Tar to partially replace FO in Lime Kiln 1490 2.71 9.75 43
by processing through Tri canter (FO
reduction)
Total 3989620 9120 16.94 29.35

No. Electrical Monetary (Rs Million) period
(kWh) (Rs Million) (Months)
1 PM3 Vacuum system optimization

(Replacement with energy efficient pumps) 739886 1.96 4.62 28
(Replacing of existing vacuum pump with
energy efficient pumps) 4823280 14.57 12.04 10
5 ETP Secondary Sludge pumps replaced with
high energy efficient pumps. 394200 1.82 6 37
Total 13309819 38.52 55.87
(kWh) (Steam (Rs Million) (Months)
tons)
1
Condensate recovery from traps and drains
3933 2.9 0.7 3
2
Auto traps in Air Compressors
201480 0.6 1.8 36
3
Sun Dome / Light pipes in Buildings
206450 0.6 1.5 30
4
Auto Condenser cleaning in Turbines
620000 1.86 2.8 18
5 Light emitting plasma for HI-Mast towers
(Existing metal halide with LEP Lights) 193815 0.51 4.46 104
Total 1221745 3933 6.47 11.26

ENCON Projects Status past 3 years
No. of Annual Electrical Savings Annual thermal savings Total Investment

Projects achieved Annual Made
Savings
Year Units Million Rs Million Tons of Coal Rs Million Rs Million Rs Million
2015-16 9 3.90 9.25 2400 7.69 16.94 29.35

2016-17 5 13.3 38.52 - - 38.52 55.87
2017-18 5 1.22 2.57 1035 2.9 6.47 11.26
Total 19 18.42 50.34 3435 9.59 61.93 96.48
Total 58 ENCON projects with & without investments implemented in past 3

years resulted saving of Rs. 107.93 Millions

Specific Power Consumption
1400 Due to
1200 BCTMP
97
Sp. Power (kWh/T)
1000
800
600 1128 1116 1103 1097 1012

400
200
0
2013-14 2014-15 2015-16 2016-17 2017-18

Overall Specific Energy Consumption Trend
3.9 %
GJ/Ton
Source: ITC Sustainability Report 2018

Benchmarking
Specific Primary Energy (GJ/T) Including New

45
Facility- BCTMP
40 (Bleached Chemical Thermo
35 Mechanical Pulpmill)
SEC (GJ/T)
30 2.7
25
20 39
15 27.57
25.3 23
10
5
0
National EU BAT* 2017-18
*Best Achievable
Technology
Benchmark Reference:
Centre for Science & Environment study published in 2010 for Pulp & Paper sector

Benchmarking

Strategy & Roadmap
 Energy Efficiency through projects

 Adopting cleaner/ energy efficient technologies - CFBC, TG8, PM1A
 Phasing out old/ inefficient plants & equipment - Old inefficient boilers 4& 5, TG2, Paper m/c
1 replaced with high efficient facilities.
 Optimizing Operational Efficiencies
 Economy of scale - capacity increased from 40,000TPA (1979) to 7,40,000TPA (2018)
 1,00,000 TPA addition of BCTMP Plant
 Maximization of capacity utilization
 Maximize bio-fuels in energy mix (Renewable energy share more than 50%)
 Maximize employee participation through TPM (Productivity improvement)
 Life cycle assessment based approach in the design and development of products
 Continuous identification of potential energy saving opportunities through energy audits
(4 comprehensive & more than 13 system energy audits in last 8 years)

ENCON Projects in Progress & Potential Areas (2018-19)
Sr. No Project Description Annual Energy Saving
Electrical Energy
(Million Units)
1 Replacing existing 3 pumps with energy efficient pumps in PM7 0.380
2 Replacing MV / SV lamps in PM4 area with LED 0.385
3 Optibat for PM-6 (Energy Optimisation Software) 2.190
4 Solar power 58.5kwp @ Laxmipuram 0.076
5 VFD for pumps in PM7 & Pulp Mill MC, TG-7 Cooling tower fan. 0.799
6 Zero air leakage valves for compressors 0.201
7 PM4 Refiners : replacing 3 top layer refiners with 2 refiners 30" 2 extra refiner in bl runs for
6 days during cycy project ( increased through put by 1tph) 1.140
8 PM5 Refiners : Replacing 3 with 1 refiner during tetra run (Saving 10 days in a month) 2.131
9 MBBR blowers for ETP area 1.426
Total 8.730
Continuous focus to identify potential energy saving opportunities through audits & Studies

Innovative Project 1
Improvement in SBD in
both Quality & Productivity

Innovative Project 1: Improvement in SBD in both Quality & Productivity
Problem: Shives in blown pulp resulting in NCP in final products.
Objective:
Quality improvement in Super Batch Digesters
Present operation in Super Batch Digesters:

Impregnation with warm white liquor
 Chips filling and Impregnation
 Hot Liquor Filling
 Heating and Cooking
 Displacement
 Pulp Discharge
Trigger points:
 More Cycle Time
 Product Quality
 More Chemical Consumption

Innovative Project 1: Quality & Productivity improvement in SBD
Root cause analysis:
After brainstorming it is identified the main reason for shives generation is due to
poor/improper packing of chips while liquor impregnation stage.
Solutions Arrived:
Why only liquor for impregnation, what if Steam?
1. Modification in Digester done to replace the existing warm liquor impregnation with Steam impregnation.
2. Modification done for removal of air entrapped in the voids and enable improved penetration of cooking
liquor into the chips, result in more uniform and improved cooking of wood chips, thereby reducing reject
generation in the SBDs.
Results/Benefits:
1. Resulted in reduced cooking cycle time, Cooking chemical(active alkali)
2. Eliminated Shives thereby Improved pulp quality,
3. Increment in pulp production per cook


Benefits:
• Overall blown pulp production increased by 5 % (4 MT per cycle)
• Shives generation eliminated
• Solids generation per ton of blown pulp reduced by 7 %
• Digester cycle time reduced by 7.1 %
• Specific power consumption of bleached pulp reduced by 25 kWh/T
• Specific steam consumption reduced by 0.05 T/ T of bleached pulp
• Overall Investment is 2.8 Crores

• Payback Achieved in 28 days

Optimization of ash handling
compressor running hours.

Innovative Project 2: Optimization of Ash handling compressor running hours
Problem: Continuous running of additional stand by compressor
in CFBC Boiler.
Objective:
To meet the ash handling conveying air with one compressor
as per design and keep the other standby.
Present operation scenario:

1.Ash will be conveying to ash silo’s thorough Conveying systems
operating pneumatically (Conveying with compressed air).
2.There are 4 groups of conveying systems in CFBC to collect ash.
3.Compressed air supplying by 2 reciprocating compressors
(1R+1S).
4.Compressors are getting loaded and unloaded based on air
pressure(3-4 kg/cm2).
5.If service air pressure is < 3kg/cm2 systems will be stopped by
acting pressure low switch.

Brainstorming : Gemba Visit made in shop floor for solutions.
Root Cause : Operation of 2 or more conveying systems simultaneously in the same

group is leading to pressure drop and auto start of standby compressor.
Solution identification & Implementation :

Two or more systems should not run same time ,So in one group only one system
should run, and second system will run after completion first system cycle.
Auto Logic implemented to run one system at a time in one group.
Scope of Horizontal Deployment:

- Implemented across all groups of systems in CFBC

1.BAC 2. MDC
3.APH 4. ESP

Benefits
• Service air pressure variations are came down.
• Meeting air demand with single compressor.
• Power consumption reduction 125KW x 20 hrs @ Rs 3.5/kwh
• Annual Savings achieved: 32 lacs

Technological
Advancements in Vacuum
Systems

Innovative Project 3: Technological Advancement in Vaccuum Systems
Vacuum Requirement : The Paper machine vacuum system
is an important operation for dewatering of wet web to
increase percentage solids in web. The vacuum required in PM4 – BCM - Board Machine Power
wire part, press part and UHLE boxes. Consumption
Phase 1: Lower capacity battery of liquid ring vacuum
pumps with common connected header across PM4, PM5 38% 25%
and PM6 machines were segregated into low, medium and 23%
high vacuum headers and were replaced with energy
efficient lesser nos of bigger capacity pumps. 15%
Stock Preparation Approach & Wire
Phase 2: In PM7 machine, gone for Turbo pump. Vacuum Dryer & Auxiliaries
(Pump with 6000 rpm coupled with HT Drive)
Phase 3: In PM1A, gone for ECO Pump in 2018.

(Pump with 10000 rpm coupled with LT Drive)

Innovative Project 3: Technological Advancement in Vaccuum Systems
Phase 1 Phase 2 Phase 3
Sp.Power: 89.7 kwh/ton Sp.Power: 69 kwh/ton 1500 KW x 1 Nos. 550 KW x 3 Nos.

20 nos of small pumps Sp Power: 63.7 kwh/Ton Sp Power: 41 kwh/Ton
replaced with 9 nos of big
energy efficient pumps in Savings achieved Savings achieved
PM4,5&6 Machines Rs 37.4 lacs/annum Rs 143 lacs/annum
Savings achieved
Rs 347.4 lacs/annum

Energy Monitoring Systems
Energy consumption is monitored by Energy Meters installed at end users & viewed
in the DCS for effective monitoring & control.
Leveraging technology & latest energy consumption monitoring
systems in place
 DCS – Process & energy control for all facilities.
 SCADA – Electrical energy Monitoring and Load Management
 ABB Smart Client – Real time monitoring at individual desktop
 xMII - Auto generated email reporting for major plant parameters
 SAP – Daily Business Reporting
 ExaQ – Energy optimization Software Energy Monitoring DCS Screen
 Visual Mesa – Real time energy optimization software
 Monthly-mill performance review reports.
 Energy cell monthly report on energy consumption & conservation.

Employee Involvement and Team Work
Encon cell is part of KK Pillar

Which is Focussed improvement pillar

• Ensuring involvement of all employees including Middle & Top Management
• Ideas / suggestions from employees for improvement - PQCDSME Sl. No. Category 2017-18
• Capture benefits through Perfex software 1 Productivity 5667
• Reward & Recognition 2 Quality 2238
Small Improvements / kaizens 3 Cost 1518
4 Delivery 788
5 Safety 7062
6 Morale 16544
7 Environment 463
8 Energy 676
Grand Total 34280

No. of Kaizens/Month & Kaizen/Person Index
YTD Avg. 2889, Index 1.18
4000 1.27 1.17 1.25 1.26 1.50
1.06 1.14
3000 0.98
0.85 1.00
2000
0.24 0.32 3116 2855 2603 2783 3064 3083 0.50
1000 0.10 0.19 2074 2409
254 454 579 793
0 0.00
2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 Apr-18 May-18 Jun-18 Jul-18
Avg. Avg. Avg. Avg. Avg. Avg. Avg. Avg.
Innovators, Nos. / Month Individuals Contributed, Nos. / Month

500 1600
1400
400
Employees 149 126 118 128 294 296
300 111 105 1200 Employees 334 290
275 285
Managers 125 1000
284
200 35 800
309 289 270 304 333 344 600 104
100 205 202 400
1026965 881 96910681035
771
0 21 60 53 57 200 449 554
0 101 224 302
Dec-18
Jun-18
Jan-19
Aug-18
Sep-18
Feb-19
Oct-18
Jul-18
Mar-19
2010-11 Avg.
2011-12 Avg.
2012-13 Avg.
2013-14 Avg.
2015-16 Avg.
2016-17 Avg.
2017-18 Avg.
Apr-18
May-18
Nov-18
2014-15 Avg.
Dec-18
Apr-18
May-18
Mar-19
Oct-18
2010-11 Avg.
2011-12 Avg.
2012-13 Avg.
2013-14 Avg.
2014-15 Avg.
2015-16 Avg.
2016-17 Avg.
2017-18 Avg.
Aug-18
Jan-19
Jun-18
Jul-18
Sep-18
Nov-18
Feb-19
Employee Involvement - Energy Conservation Campaign
• Campaign launched at the Factory Gate on 1st February '18
• February '18 and March ‘18 declared & observed as the month of “Energy Conservation“ across all
JHs/DMTs
• Out of overall PQC category 1100 Kaizens – 347 No’s were towards “Energy Conservation” theme
• Total 42 JH teams from 15 DMTs, actively participated in this event
• Resulted savings through all forms of Energy
Projected Annual Savings
Energy Type UOM Energy Savings
in Rs.Lakhs
POWER SAVINGS kW/Hr 697.6 114.08
STEAM SAVINGS Tons/annum 622.1 1.32
CONDENSATE SAVINGS Tons/annum 432.0 6.55
COMPRESSED AIR SAVINGS Nm3/annum 931000 4.93
WATER SAVINGS (PROCESS WATER) m3/annum 22550 1.99
Total Savings 130.5
All the above ideas were conceived and implemented by Shop floor people
Employee Involvement - Energy Conservation Campaign

Implementation of ISO 50001:2011 (EnMS)
Continual improvement of energy performance by
complying with the requirements of ISO
50001:2011 Energy Management System (EnMS)
standards. (The PDCA approach)
• Formulation of Energy Policy

• Initial Energy Review, Baseline establishment
• Identification of EnPIs
• Identification of objectives, targets & management
programs
• Operational Controls, Documentation Certification Date: 09.02.2017
• Internal auditor Training
• Internal audit
• Audit findings closing
• Management Review
• Certification Audit Stage-1
• Certification Audit Stage-2

Green Co Certification
As a part of our commitment to sustainability,
Green Co is a driving tool for continual
improvement in:
 Energy Conservation(Power, Water & Steam)

 Increasing renewable energy
 Reduce GHG Emissions
 Material conservation , Reuse & Recycling
 Waste management & reduction
 Sustainable Product design & End of life
management
 Environment Impact reduction in Supply chain
Management
Certification Date: 17.06.2016

BEE Award – Best Achiever PAT Cycle 1
"BEE Awards Unit Bhadrachalam for being the best performer in Pulp & Paper Sector under
PAT Cycle-1"
Unit Bhadrachalam Awarded : Achieved 54747 Escerts

Best performer in “Pulp & Paper Sector under PAT Cycle-1" in PAT Cycle -1

Renewable Energy Sources Utilization
Renewable Energy Share 2017-18
Renewable Energy Share % Fossil Energy Share %
47.52%
52.48%
 Improved utilization of Black Liquor Solids

 Improvement in Biomass through Internal
efforts
 Efficiency improvement in Green energy
systems.

 Wind Energy
 Commissioned 46 MW wind power generation
facility for replacing electrical energy generated
through coal.
 Biogas plant
 Generating biogas from food waste & ETP
secondary sludge and used in Canteen for
cooking.

 Green Boiler
 A biomass fired boiler to fire plantation
biomass and coal at 70:30 ratio to utilize the
waste from plantation & Wood Bark.
 Solar PV - Laxmipuram
 80 kWp SPV plant installed at plantation
facility in Laxmipuram near Bhadrachalam.

 Light pipes
 Avoiding energy consumption for electrical lighting at daytime
 Installed in TGs, Coal Bunkers, DG Plant and Work sheds

Utilization of Waste
 100% solid waste utilization/ recycling in

Bhadrachalam unit.
 Chipper dust & bark used in Green Boiler for
steam generation (Also contributing in renewable
energy generation)
 100 % Fly ash utilization by way of manufacture of
Fly Ash Bricks and in cement industries.
 Lime sludge recycled with Lime Kiln.
 Andritz Press sludge is utilized by external agency
for card Board manufacturing & Egg tray
manufacturing
 Effluent Treated discharge for irrigation /
plantations.

Associates Involvement
 Conducted audits for Associate manufacturers & worked on targets & ways to achieve them
 Introduction of excellence levels to all associates
 Format developed for selection of Associates & explained to them based on their specific
energy consumption & reduction trends
 Identification of best practices, sharing & rewarding the performers
 Awareness creation programs conducted for Associates

Associates Involvement – M/s Fimakem
FIMAKEN ACHIEVED GOLD RATING

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ITC Limited

Paperboards & Specialty Papers Division

ITC PSPD (BCM) Slide # - 1

ITC PSPD (BCM) Slide # - 2

ITC PSPD (BCM) Slide # - 3

ITC PSPD (BCM) Slide # - 4

ITC PSPD Division Liquor

Top Liners Cigarette

ITC PSPD (BCM) Slide # - 5

Liquid Packaging Book Covers

Deep Freeze Application Blister Packs Liquor Cartons

ITC PSPD (BCM) Slide # - 6

Cigarette Packaging Playing Cards Visiting Cards , Tags & Brochure's

Paper Cup Applications

ITC PSPD (BCM) Slide # - 7

ITC PSPD (BCM) Slide # - 8

ITC PSPD (BCM) Slide # - 9

ITC PSPD (BCM) Slide # - 10

ITC PSPD (BCM) Slide # - 11

ITC PSPD (BCM) Slide # - 12

ITC PSPD (BCM) Slide # - 13

Total 39 projects with ZERO investments implemented in 3 years resulted

ITC PSPD (BCM) Slide # - 15

ITC PSPD (BCM) Slide # - 16

ITC PSPD (BCM) Slide # - 17

1 PM3 Vacuum system optimization

Total 1221745 3933 6.47 11.26

ITC PSPD (BCM) Slide # - 19

No. of Annual Electrical Savings Annual thermal savings Total Investment

2015-16 9 3.90 9.25 2400 7.69 16.94 29.35

Total 58 ENCON projects with & without investments implemented in past 3

ITC PSPD (BCM) Slide # - 20

600 1128 1116 1103 1097 1012

ITC PSPD (BCM) Slide # - 21

Source: ITC Sustainability Report 2018

ITC PSPD (BCM) Slide # - 22

Specific Primary Energy (GJ/T) Including New

ITC PSPD (BCM) Slide # - 23

ITC PSPD (BCM) Slide # - 24

 Energy Efficiency through projects

ITC PSPD (BCM) Slide # - 25

ITC PSPD (BCM) Slide # - 26

ITC PSPD (BCM) Slide # - 27

Present operation in Super Batch Digesters:

ITC PSPD (BCM) Slide # - 28

ITC PSPD (BCM) Slide # - 29

ITC PSPD (BCM) Slide # - 30

• Overall Investment is 2.8 Crores

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Present operation scenario:

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Brainstorming : Gemba Visit made in shop floor for solutions.

Root Cause : Operation of 2 or more conveying systems simultaneously in the same

Solution identification & Implementation :

Scope of Horizontal Deployment:

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