more than 3 decades ago, nilkamal had a vision… · more than 3 decades ago, nilkamal had a...

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More than 3 decades ago, Nilkamal had a vision…

• Plastic – a new material, a new opportunity

• Wood & metal conventionally used

Unsustainable

Heavy, damaged easily

Higher carbon footprint

• 3 Core pillars that formed our Philosophy:

• Focus on Quality

• Focus on Customer (Service, Accessibility & Affordability)

• Focus on a Sustainable Future

Focus on a Sustainable Future means

• Taking measures to minimise environmental impact

• Taking measures to maximise organisational impact

• Detailing each process to make enhancements actionable & results measurable

• Making sustainability a part of the company culture

Steps ensuring we are the best in the industry…

Excellence in Manufacturing AwardsFrost & Sullivan :: 2013, 2014, 2015, 2016,2018

National Energy Management Award CII :: 2016, 2017, 2018

National Energy Conservation AwardGovt of India :: 2014, 2015, 2016,2018

…not just once, but consistently

• Audit all processes in plants to identify areas of inefficiency, power

loss and waste generation

• Today, most of our plants are zero waste discharge plants

• Nilkamal plants have been repeatedly recertified ISO 14001 &

50001 for best practices in manufacturing with a focus on energy

efficiency

A glimpse of some of our initiatives…

#1 – Zero Discharge Plants

• Waste & sewage water treatment plant installed at

factories

• Freshwater used for human consumption and cooling

towers

• RO Plant rejected water is re-used for Toilets

• Wastewater used for plants & gardening

• Total Water Saving: 5000 Ltr per day

#2 – Any excess material created is reused

• Six Sigma processes to reduce plastic waste from defects to less than 1%

• Dedicated grinding units at all plants. Material is reused within the factory

• Woven sack bags are scrapped and sold for secondary uses

#3 – Design for energy conservation

• Factory designs have been engineered tomaximise natural daylight and ventilation

• Fitted with energy saving LED lights

• Machines have been redesigned:

• Insulation on injection barrel

• Retrofitting of servo motors from induction

• VFD installed for power conservation

• Sustainable and Profitable

Before After

#4 – Usage of Renewable Energy

• Installed capacity of solar power – 4,000 kW across 4 plants

• Use of Wind energy at Hosur – 7,00,000 kWh / month

• Saving of 60,00,000 Kwh / Year resulting in reduction of 4,970 MT CO2 emissions

#5 – Hydraulic Oil motors to Electric motors

• Indirect Hydraulic drive System Converted into Direct Electrical drive system to reduce energy conversion Losses

• Spent oil is disposed through govt. approved waste collection companies for recycling

#6 – Breaking the myth of “persistent plastic”

• All moulded products made with single type plastics – no multilayers

• All products are RoHS compliant

• All products carry international recycling code

• All products are multi-use

• All products designed to have significant salvage value

#7 – Packaging of products

• Shift to more sustainable packaging methods

• Plastic packaging material is 100+ microns

• Eliminate paper carton packaging by designing returnable solutions – metal stacking frame. Reduction in freight costs

• Ongoing initiatives to reduce and eliminate excess packing

Reflects in our Product approach

Products that promote sustainability

• Low cost toilet developed costing 50% of ceramic pan

• Flushes using only 200 ml water - promoting water conservation

• Waste Bins to promote segregation

• Industrial packaging product series introduced focusing on reusability

• PalletGUARD - Returnable packaging engineered for freight reduction, cost reduction and 1000+ cycles

Collaboration with institutional customers to recycle ::Extended Producer Responsibility

• Crate buyback program with bottlers for dairy and beverages

• Recent project to convert half-depth crates to full-depth; Replacement crates produced contain recycled material

• 0 wastage of material

Initiatives underway

Educate the consumer

• Initiatives taken to educate the distributor, dealers and consumers about plastic

• Create awareness about correct disposal of any plastic waste

• Plastic can be recycled!

• Spread the message about the importance of waste segregation

• Understand the facts about plastic vs. wood, paper, metal and glass

VS

Developing a Circular Economy with partners

• EPR Programmes to bring back products from the retail channel to ensure correct disposal and recycling of materials

• Work with institutional partners to collect products after product lifecycle to grind and repurpose

• Design products that minimise waste and maximise useful life

Piloting series of upcycled products

• Global examples - Adidas, P&G, Fair Harbour, Norton Point, Bisleri and more

• Create product lines with more than 50% recycled material

• Waste plastic sourced from sustainable and fair trade collection centres

• Sales proceeds to be used for greater social impact, awareness and NGO campaigns

We believe we must create processes that first begin within the company, rather than outside.

Give back to nature, first by not giving back to nature.