kcmmf ltd. central products dairy details milma mango 2009 0 1000 2000 3000 4000 5000 6000 apr may...
TRANSCRIPT
KCMMF Ltd.
CENTRAL PRODUCTS DAIRYALLEPPEY
WELCOME TO THE WELCOME TO THE
PRESENTATION OF TOTAL PRESENTATION OF TOTAL
ENERGY MANAGEMENTENERGY MANAGEMENT
GENERAL INFORMATION
�Started in 1974, Capacity: 2000 LPD
�Expanded to: 60,000 LPD on Dec 1987
�Aseptic Packing station commissioned on Dec 1988
�Milk Powder Factory commissioned on Sep 1996
� Capacity enhanced to 1,00,000 LPD in 2005
�Mango Juice Production Started in Pet Bottles on 2007.
PRODUCTS HANDLED
�� TONED MILKTONED MILK
�� DOUBLE TONED DOUBLE TONED
MILKMILK
�� CURD CURD
�� GHEEGHEE in 2 Brandsin 2 Brands
�� PEDAPEDA
�� STERILIZED STERILIZED
FLAVOURED MILKFLAVOURED MILK
�� MANGO DRINKMANGO DRINK in in
Tetra packs & Pet Tetra packs & Pet
Bottles.Bottles.
�� DAIRY WHITENERDAIRY WHITENER
AVERAGE MILK HANDLED
2009
0
500000
1000000
1500000
2000000
2500000
3000000
JA N . MAR. MAY. JULY SEP. N OV.
Av. MilkHandled (lts)per day
PRODUCTION DETAILS
CURD 2009
0
10000
20000
30000
40000
50000
60000
70000
JAN. MAR. MAY. JULY SEP. NOV.
KGS
PRODUCTION DETAILS
CURD 2009
0
5000
10000
15000
20000
25000
30000
APR MAY JUN JUL AUG SEP
KGS
PRODUCTION DETAILS
GHEE
0
5000
10000
15000
20000
25000
JAN MAR. MAY JULY SEP. NOV.
KGS
PRODUCTION DETAILS
MILMA PLUS 2009
0
10000
20000
30000
40000
50000
60000
70000
JAN MAR MAY JUL SEP NOV
BOTTLESB
PRODUCTION DETAILS
MILMA MANGO 2009
0
1000
2000
3000
4000
5000
6000
APR MAY JUN JUL AUG SEP
TRAYS
ENERGY CONSUMPTION
DETAILS FURNACE OIL
(2009)
20000
20500
21000
21500
22000
22500
23000
JAN. MAR. MAY. JULY SEP. NOV.
LTR
ENERGY CONSUMPTION
DETAILS POWER(2009)
0
20000
40000
60000
80000
100000
120000
JAN. MAR. MAY. JULY SEP NOV.
KWH
ENERGY EXPENCE DETAILS
POWER(2009)
0
50000
100000
150000
200000
250000
300000
350000
400000
450000
JAN MAR MAY JUL SEP NOV
Rs
UNIT COST-,FURNACE OIL,ELC
(2009)
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
JAN. MAR. MAY. JULY SEP. NOV.
FURNACE OIL(Rs)
ELC(Rs)
3-D Column 3
PRODUCTION
COMPARISON MILK
22000000
23000000
24000000
25000000
26000000
27000000
28000000
29000000
2007 2008 2009
LTR
PRODUCTION COMPARISON
GHEE
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
2007 2008 2009
KGS
PRODUCTION COMPARISON
CURD
0
100000
200000
300000
400000
500000
600000
700000
2007 2008 2009
PACKETS
PRODUCTION COMPARISON
MILMA PLUS
0
100000
200000
300000
400000
500000
600000
2007 2008 2009
BOTTLES
ENERGY CONSUMPTION
850000
900000
950000
1000000
1050000
1100000
1150000
2007 2008 2009
ELECTRICTY
ENERGY CONSUMPTION
160000
170000
180000
190000
200000
210000
220000
2007 2008 2009
FURNACE OIL
FURNACE OIL
ENERGY EXPENSE
DETAILS
0
500000
1000000
1500000
2000000
2500000
3000000
3500000
4000000
4500000
5000000
2007 2008 2009
ELECTRICTY
ENERGY EXPENSE
DETAILS
0
50000
100000
150000
200000
250000
2007 2008 2009
FURNACE OIL
Energy Saving activities
undertaken
� We have replaced 4 sachet filling machines with mechanical filling machines.
� Only one Ammonia Compressor is being used in dairy
� The Head cooling water from Air Compressor diverted to Boiler feed & sump of Ammonia Condenser
SAVING ACTIVITIES cont..SAVING ACTIVITIES cont..
�30 T capacity refrigeration plant of MPF is not
being operated in this flush season due to
sufficient ice obtained from our Dairy
refrigeration plant for MPF use also. This was
achieved by maintaining 100 % efficiency in
the Dairy refrigeration plant after some
modification.
SAVINGS
� The temperature of Pasteurization was reduced from 790C to 780C.
� It will be further reduced to 770C in the next phase
� Installation of 4 mechanical filling machines has saved Rs. 2000 per day in power cost
� Due to non operation of 2nd Compressor, the energy cost saved Rs. 40,000 / month & non operation of MPF refrigeration plant during flush season 15 KWH energy saved every operational day
COMPARISON OF REFRGN
HOURS
7000
7200
7400
7600
7800
8000
8200
8400
8600
2007
2008
2009
ENERGY SAVING OPPERTUNITIESWITH INVESTEMENT
(A)Boiler
1 Installation of new Water Pump and
Furnace oil Pump
2 Replacing the insulations of Boiler and
Connected steam line
3 Installation of flow meter for oil and feed
water
4 Utilization of fuel gas temp for feed water
heating.
(B) STEAM LINES
1 providing Insulations on identified Area
2 Replace Steam traps with Good quality Steam traps.
(C) GHEE Vat.
Replace Thermo dynamic steam trap with Ball float steam trap.
(D ) REFRIGERATION
Providing separate Energy meter to the Ref: plant to monitor the Power consumption
(A) BOILER
Utilization of head cooling water from
Air compressor in feed water ( 48 0c )
ENERGY SAVING
OPPORTUNITIES
WITHOUT INVISTEMENT
Energy Mngmt CommitteeEnergy Mngmt Committee
� K P Rajan – Manager & Chairman
� V Unnikrishnan – A.M(P&M) & Energy Manager
� V.S. Murukan- QCO
� Rajive Zachariah – Asst. Manager
� K Raveendran – Refgn Mechanic
� C S Chandralal – Boiler Operator
Energy Mngmt CommitteeEnergy Mngmt Committee
� V Unnikrishnan – Electrician
� Satheesan – Fitter
� K C Joseph – Plant Operator
� V K Manoharan – Plant attender
Proposed Ivestments
� Lightings to be changed to CFL.
� Continuous ghee packing machine to be purchased saving upto 80 labour hours daily
� Pasteurizer plant to be replace with a higher Capacity including Homogenizer.