6. dr reddy's laboratories, cto 2, hyderabad

7/23/2019 6. Dr Reddy's Laboratories, CTO 2, Hyderabad

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Greener & Sustainable Practices atDr. Reddys Laboratories Limited

CTO Unit-2


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Agenda

Introduction to the company

Green Co Journey

Manufacturing Activities

Waste Management Practices

Air Pollution Control

New Project undertakings

Material Conservation, Recycling & Recyclability


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Providing affordable and innovative

medicines for healthier lives

Our Purpose


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Green Co JourneyGreen Co Journey

Participated in the Green Co rating system to strengthen our

environmental capabilities

The rating system recognized our achievements and also

identified areas for improvement

We are the First Company in Pharmaceutical Sector to

receive the prestigious GreenCo rating (Bronze)


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Manufacturing

Activities

Manufacturing

Activities

Manufacture Active pharmaceutical ingredients (APIs)

13 production blocks

Each production block consists of reactors, filters, dryers, sieving and

milling equipment

The raw materials are added as per the directions given in the Batch

Production Records

Use organic, inorganic chemicals and solvents

Utilities like RT water, chilled water, brine, hot water, steam, DM water

and electricity are used


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Waste Management PracticesWaste Management Practices

Waste WaterWaste Water

Hazardous WasteHazardous Waste

Alternate ReuseAlternate Reuse

Waste water is segregated as process effluent from production & nonprocess effluent from utilities

Process effluent is pre-treated and evaporated in multiple effect evaporator

Evaporator condensate is bio-treated and further treated by Reverse

Osmosis. RO permeate is used in boilers and cooling towers. RO rejects will

be send back to MEE

Evaporator concentrate is send to dryer to isolate mixed salts. Mixed salts

are send to secured landfill

Non process effluent is pre-treated and bio-treated & further treated in RO.

RO permeate is used for boilers and cooling tower makeup. RO rejects willbe send to MEE

The wastes are segregated as process residues, spent carbon, mixed spent

solvents, chemical & bio sludge and mixed salts

Hazardous waste suitable for co processing in cement industries are process

residues, spent carbon, spent solvents etc.

Waste oil and used oil are send to authorized oil reprocessors

Used lead acid batteries are returned to the manufacturers

Spent catalyst is returned to the manufacturers for recovery

Detoxified containers are reused by sending to authorized agencies

Reuse of MS drums for transport of spent solvents


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Non ProcessEffluent

Treatment

Non ProcessEffluentTreatment

Process EffluentTreatment

Process EffluentTreatment

Hides Filter

Triplelayer bagfilter

Clariflocculator


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Air PollutionControl

Air PollutionControl

In order to reduce the air emissions into the atmosphere and to limit them

within the standards, several strategies were taken up such as:

Boilers provided with bag filters. Boiler emissions like SPM, NOx and SO2

are monitored regularly based on IS standards

Process equipment are provided with multi stage scrubbers

Closed centrifuge operations

Primary and secondary condensers are provided to reactors to minimize

fugitive emissions

Automation of the Solvent Recovery System

Monitoring of all ambient air quality parameters like PM2.5, PM10, SO2,

NO2 to ensure that they stick to the legal norms

Online and portable VOC meters to ensure control over emissions


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Material Conservation, Recycling & RecyclabilityMaterial Conservation, Recycling & Recyclability

Packaging initiativesPackaging initiatives

Yield Improvementthrough Continuous

Improvement

Yield Improvementthrough Continuous

Improvement

During manufacture of Ciprofloxacin HCl compacted material, the packing of

the batch and finished product analysis were being performed two times. This

lead to wastage of packing material and chemicals used for analysis.

o An intermediate step of QC Analysis for input material was eliminated

o Resulted in Material and packaging savings of Rs. 19.65 Lacs/annum and

reduced the cycle time by 72 hours

Replacing HDPE drums with SS drums for packaging recycling so that they

can be cleaned and reused

Introduced plastic pallets in place of wooden pallets which are recyclable and

less prone to damage

Process chemistry change was carried out to improve Atorvastatin Calcium

yield

Two new reagents were introduced to accelerate the reaction

This improved the yield and reduced the reaction time

Yield improvement from 286 kg to 340 kg within six month

Savings: Rs. 33.6 lacs/tonne of product


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Material Conservation, Recycling & RecyclabilityMaterial Conservation, Recycling & Recyclability

Improvement inSolvent Recovery

Process

Improvement inSolvent Recovery

Process

Acetonitrile Recovery improvement was initiated to improve recovery from 50 to

65 %

Steps taken for the improvement:

o Material balance study was carried out to identify the losses

o Additional equipment to minimise loss and improve recovery

o Contamination due to intermixing of methanol & acetonitrile mother liquor

eliminated

o Increased overall utilization of SRS capacity and generated increased amount ofdistilled and reusable solvents.

Fractional distillation was introduced for distillation of IPA MLs to enhance

recovery

The recovery percentage significantly improved from 46% to 79%

This overall annual saving due to introduction of the fractionation distillation

column amounted to Rs.10.8 Million


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New Project UndertakingsNew Project Undertakings

Decanter CentrifugeDecanter Centrifuge

Paddle DryerPaddle Dryer

One more decanter centrifuge will be provided to handle the biological

sludge and chemical sludge separately

The centrate from the bio decanter centrifuge can be directly fed into bio

treatment facility

This will help us in avoiding 3500 KL per annum of load to the multiple effect

evaporator

Paddle dryer will be installed for drying bio sludge to 5% moisture content

This will help us to reduce the hazardous waste generation by 180 TPA

Enclosure for effluentcollection tanks

Enclosure for effluentcollection tanks

Top cover hoods arrangement for open process effluent collection tanks

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THANK YOU !!!

6. dr reddy's laboratories, cto 2, hyderabad

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