mahan and dairy

7/31/2019 Mahan and Dairy

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MAHARASTRA RAJYA SAHAKARI DUDH MAHASANGH MARYADIT,MAHANAND DAIRY, GOREGAON (EAST), MUMBAI, MAHARASHTRA

UNIT PROFILE:Maharashtra Rajya Sahakari Dudh Mahasangh Maryadit (MRSDMM) is an Apex

Federation of District / Taluka Milk Unions, established to implement the operation flood

programme in the state of Maharashtra. The main objective of MRSDMM is to procure milk fromthe member milk unions at remuneration rates. MRSDMM is working as a vital link between themilk producers and consumers and working for the economic development and upliftment of themilk producers / farmers in the rural areas. MRSDMM is managing a modern dairy plant popularlyknown as MAHANAND DAIRY at Goregaon, Mumbai. Looking to popularity and growing marketdemand for Mahanand Milk, MRSDMM has started milk distribution activities from Vashi (NewMumbai), Byculla (South Mumbai), Nagpur (Vidarbh Region), Kudal Sindhudurg (KonkanRegion), Pune (Western Maharashtra), Latur (Marathwada Region), and Nashik (Nashik Region).This will help in achieving uniform development of various parts in the state and equitabledistribution of benefits to member milk unions.

Mahanand Dairy unit at Goregaon (East), Mumbai has done significant work in the fieldof Energy Conservation since last 15 years and has achieved unbelievable results in this field.As a result of significant results in the field of Energy Conservation, cost control, productivity

and quality improvement, Mahanand Dairy has recurred National Award (Eight times) includingthe award for Best Energy Productivity from National Productivity Council, New Delhi. Accordingly,the Energy Conservation Data, corresponding to milk processing quantities for Mahanand Dairy,Goregaon unit are included / filled up in the Award Questionnaire. Mahanand Dairy Goregaonunit mainly carries out the activities of processing (pasteurization, clarification andhomogenization), packing, cold storage and distribution of cow milk and Tonned Milk in MumbaiMarket. Some small quantities of milk products such as shrikhand and paneer were alsomanufactured till 2001 2002. From the year 2002 2003 onwards some new value added milkproducts such as Curd, Lassi, Flavoured Milk, Ghee, etc. are added in manufacturing range andquite a sizeable quantities of these products are manufactured and marketed. The EnergyConservation measures are mainly taken up for Liquid Milk processing, packaging & coldstorage / Refrigeration activities and accordingly data are confined for Liquid Milk (cow milk andTonned milk) processing only.

PRODUCTION PROCESS FLOW DIAGRAM (COW MILK)


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(ii) ENERGY CONSUMPTION:

Dairy Industry mainly consumes substantial amount of Thermal (Heat) Energy for milkprocessing (pasteurization, clarification & homogenization), Refrigeration (Electrical) Energy formilk pre chilling, chilling of milk after pasteurization, cold storage of packed milk, CompressedAir (Electrical) Energy for pneumatic milk packaging machines. As operations of Dairy units varyfrom activity, type of milk, type of product mix, etc. standard authenticated norms are notavailable for comparison. For example, a Dairy unit carries processing activities withouthomogenization and clarification shall consume very little energy as compared to the units carriesout milk processing activities including homogenization and clarification. Also, units engaged inprocessing and distribution of liquid milk without packaging (loose milk) and cold storage shallconsume less energy as compared to the units carry out processing and distribution of packedmilk (pouch milk). Also, Dairy units engaged in reconstitution /processing of toned milk consumesmore energy compared to Dairy units not engaged in above activity. Hence, it is very importantand essential to have comparison among the identical units only.

Mahanand Dairy is the only unit in the country, processing cow milk with cent-percenthomogenization and clarification activities. Also, Dairy distributes the packed milk after storage incold rooms. Mahanand Dairy, Goregaon, Mumbai has done significant work in the field of EnergyConservation and Water Conservation and achieved significant savings over a period of last 15

to 20 years, details of which are as under :

1) FURNACE OIL CONSUMPTION At our plant due to continuous joint efforts made tosave thermal energy, the furnace oil consumption has reduced from 8.9 ml (1984 85) to2.68 ml (2005 06) per litre of milk processing, resulting into improvement in milkprocessing from 112 litres to 372 litres per litre of furnace oil. This has resulted intosignificant monetary savings (Approx. Rs. 80 Lacs per annum).

2) ELECTRICITY CONSUMPTION At our plant due to continuous joint efforts made tosave electrical energy, the electricity consumption has reduced from 0.036 KWH (1984 85) to 0.030 KWH (2005 06) per litre of milk processing resulting into improvement inmilk processing from 27 litres to 33.33litres per KWH. This has resulted into significantmonetary savings (Approx. Rs. 70 lakh per annum).

3) WATER CONSUMPTION At our plant due to continuous joint efforts made to savewater, the water consumption has reduced from 4.44 liters (1984 85) to 1.18 liters(2005 06) per liter of milk processed. The reduction in water consumption has not onlyhelped in reducing the cost of milk processing but also helped in reducing HydrologicalLoad on Effluent Treatment Plant, thereby reducing the waste water treatment cost. Thishas resulted into significant monetary savings (Approx. Rs.80 90 lakh per annum).

Remarks : MRSDMM feels that these consumption levels are best among the identical dairyindustry at National level. However, if some best managed dairy plants are havingbetter consumption levels, same may please be communicated, so as to study andincorporate possible improvement at our plant. MRSDMM feels that still there is

huge scope of improvement.

ENERGY-CONSUMPTION-COMPARISON WITH NATIONAL LEVEL NORMS

YEAR ELECTRICITYCONSUMPTION

FURNACE OILCONSUMPTION

NATIONAL LEVEL NORMS

kWh/Lit Lit ofmilk/kWh

ml of F.O./Litof milk

Lit ofmilk/lit of

F.O.

ELECTRICITYLit of milk/kWh

FURNACE OILLit of milk/lit of F.O.


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2003-04 0.029 34 2.43 411

2004-05 0.029 34 2.51 398

2005-06 0.030 33.33 2.68 372

Note:despite of sizeable increase in product manufacturing (Ghee, Shrikhand, Curd, Lassi, UHT

flavoured milk etc.) total energy consumption is kept under control and significantimprovementis achieved as compared to National Level Available Norms. At Mahanand Dairy, milk

processingand packaging operations are energy intensive due to process of homogenization,

clarification andpackaging/ cold storage operation(milk pouch storage).

GRAPHICAL PRESENTATION OF SPECIFIC ENERGY CONSERVATION COMPARED TONATIONAL LEVEL NORMS

0.0350.030

NATIONAL

NORMS

MAHANAND'S

ACHIEVEMENT

Electricity consum ption

(kw h/Lit of Milk) reduce d

28.57

33.33

NATIONAL

NORMS

MAHANAND'S

ACHIEVEMENT

LITRE OF MILK PROCESSE

PER UNIT (KWH) OF ELECTRI

5.00

2.68

NATIONAL

NORMS

MAHANAND'S

ACHIEVEMENT

Furnace oil consumption (ml of F.O./Lit of Milk) is

reduced significantly

200

372

NATIONAL

NORMS

MAHANAND'S

ACHIEVEMENT

Litres of milk processed per litre of


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2

1.18

NATIONAL

NORMS

MAHANAND'S

ACHIEVEMENT

Water consumption (Lit of water/Lit of milk) is

reduced

0.5

0.85

NATIONAL

NORMS

MAHANAND'S

ACHIEVEMEN

Lit of Milk Processed per Lit of

20(iii) ENERGY CONSERVATION COMMITMENT POLICY AND SET UP

Mahanand Dairy considers Energy Conservation and Energy savings as very importantarea for improvement and believes that unbelievable results can be achieved by generatingconsciousness and awareness about judicious use of energy. Mahanand Dairy also believes inthe policy of continual improvement & feels that significant results can only be achieved if properculture, awareness & consciousness is developed through out the plant. Sometime, it is observedthat if proper culture is not there, even by replacement / adoption of highly energy efficienttechnology may not give desirable results. Energy Conservation plans; policy and consumptiondata / trend is reviewed periodically, so as to have corrective actions well in time. Appropriatebudget provisions are made for plant renovations, up-gradation and R & D projects; adoptadvance technology for plant efficiency improvement and energy savings. Looking to potential offurther energy conservation, MRSDMM has constituted separate Energy Conservation Cell, andframed appropriate "Energy Management Policy".

(The ENERGY MANAGEMENT POLICY is attached separately.)

ENERGY CONSERVATION CELL STRUCTURE

At present, above personnel are working for the implementation of "energy Conservationprogramme" in addition to their regular/routine duties and responsibilities.

20(iv) ENERGY CONSERVATION ACHIEVEMENTS

Mahanand Dairy has achieved significant achievements in the field of energy conservationby adopting following measures:

1) By promoting general energy consciousness & awareness among the staff at grass rootlevel, proper coordination among various energy intensive department, by carefulmonitoring of process parameters, operational parameters at refrigeration section(ammonia compressors); boiler section (consumption parameter), by adopting periodiccleaning schedule for heat transfer surfaces, etc.

2) By replacement of old energy inefficient milk pasteurizer unit with energy efficient milk


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pasteurize plant.

3) Replacement of old ammonia condenser unit, with new one so as to reduce headpressure (discharge pressure) from 200 210 psi to 170 180 psi.

4) By timely arresting of steam leakages, compressed air leakages, hot water leakages, etc.By proper insulation to steam line; heat transfer area, boiler reinsulation, Ghee boilerinsulation, etc.

5) Use of non conventional energy solar water heating system Mahanand Dairyusing solar water heating system (25000 LPD) since 1990, which was commissioned withthe assistance of Department of Non Conventional Energy Sources and Maharashtra

Energy Development Agency. The water is heated from 30 C (ambient water temp.) to

85 C with the help of solar water heating system, which is used for boiler as feed water,etc. This has resulted into saving of 200 250 liters of furnace oil per day, with monetarysavings of approx. Rs. 7 lakh per annum.

6) Use of advanced Anaerobic technology [UASB] for waste water treatment [EffluentTreatment] At Mahanand Dairy, very efficient process of effluent treatment based onAnaerobic Treatment followed by Aerobic Treatment is adopted in the year 1996 97.The plant is based on UASB [UPFLOW ANAEROBIC SLUDGE BLANKET] technologywhere BOD reduction of the tune of 18 19 % is achieved without power consumption,such plants are very efficient, which gives BOD as low as 7 10 BOD (mg/liter), withalmost 25 % power consumption as compared to conventional aerobic treatment plant, inaddition to above benefits, bio-gas generated is used for electricity generation.

7) Use of Tertiary Treatment for Water Recycling For giving maximum treated wastewater for recycling, the tertiary water treatment technology (comprising activated carbonfilters, sand filters, water softener, ultraviolet treatment, chlorination arrangement, etc.)was adopted in the year 2002 03. The capacity of the plant is 300 M

3/day, and the water

treated is of excellent quality, which is being used for gardening, drainage cleaning, floor

cleaning, crate cleaning, etc. The total cost of the project was Rs. 25 lacs & we are ableto save approx. Rs. 50 lacs per annum due to above plant.

8) Electricity Generation From Bio-Gas : At Mahanand Dairy, bio-gas generated from theeffluent treatment plant is being used to generate electricity by using bio-gas generator(dual fuel) and approx. 500 units of electricity is generated per day, which is being usedfor running the electrical motors / equipment at effluent treatment plant (ETP). Theelectricity produced (50 60 units per hour) is sufficient to take entire electrical load ofETP. The system is under operational use since 1998 99. Approx. Rs. 5 lacs perannum are saved because of above system. The bio-gas generator not only helps inmonetary savings but also helps in reducing the pollution, thereby helps in maintaininghealthy environment. The above system was in regular use till 2001 02, but due tosome major problems resulted from moisture, sulphur present in the bio-gas, the set is

under major repairing.

9) Conversion of petrol vehicles with CNG / LPG system.

10) The efforts and attempts made by Mahanand Dairy in the field of Energy Conservationare highlighted in paper published in Indian Dairyman, Electricity Conservation Quarterly,PCRA, etc. The copies of following papers are enclosed herewith.

a. Electricity Energy Conservation In Mahanand Dairy (Electricity Conservation


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Quarterly April 87 Issue)b. Energy Conservation In Dairy Plants A Case Study On Solar Heaters Usage

published by PCRA.c. Energy Conservation In Dairy Plants - A Case Study published in Indian

Dairyman. The above paper was selected for Best Paper Award by Indian DairyAssociation.

d. Conservation of Refrigeration Energy in Dairy Plants A Case Study (ElectricityConservation Quarterly January 1998 issue).

e. Use of Solar Energy for Heat Generation in Dairy Plants - A Case Studypublished by Maharashtra Energy Development Agency.

ENERGY CONSERVATION MEASURES AT MAHANAND DAIRY


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(v) ENERGY CONSERVATION PLANS AND TARGETS

Mahanand Dairy has planned following Energy Conservation measures / project forfuture:1) Use of automatic PF controller, use of variable frequency drive, replacement of old

energy inefficient motors with advanced energy efficient motors. Approx. investment shallbe Rs. 100 150 lakh with anticipated savings of Rs. 50 60 lakh per annum.

2) Eliminating use of compressed air system used for pneumatic milk packaging machines

by using advanced mechanical milk packing machines. Anticipated investment shall beapprox. Rs. 50 60 lakh per annum.

3) Use of energy efficient screw air compressors for pneumatic operations in milkprocessing section.

4) Use of advanced PHE based refrigeration system for I.B.T.5) Use of advanced PHE based glycol chilling system for milk chilling.6) Replacement of old air cooling units by advanced energy efficient air cooling units.7) Installation of new energy efficient homogenizer for milk homogenization.8) Use of waste heat recovery system by installing desuperheater at refrigeration system


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(discharge line hot vapour ammonia).9) Use of advanced solar technology for milk pasteurization / solar hot water generator, so

as to pasteurize milk without using boiler / hot water generator. This project is taken up &sanctioned as prestigious R & D project by MNES & I.I.T., Mumbai. The project is likely tobe completed by the year end (2004 05).

(vi) ENVIRONMENT & SAFETY

Mahanand Dairy is committed to the protection of the environment by prevention ofpollution and continual improvement in the Environmental performance by adopting advancedtechnology. The wastes Treatment Plant, Tertiary Treatment Plant are unique features andeven results and performance are appreciated by MPCB officials time to time. The plant canbe a Trend setter in the Dairy Industry. Also, all the safety measures required are followedand adopted & rate of industrial accidents is almost zero level. The Energy Conservationmeasures adopted has helped tremendously in reducing the use of energy & fuels, whichultimately beneficial to maintain healthy environment, due to reduced CO2 emissions /pollutant emissions. Also, at Mahanand Dairy regular tree plantation campaign are taken up,so as to keep healthy environment.

21.Whether any dispute pertaining to statutory requirements of safety and pollutioncontrol is pending with any Government Agency. If Yes, give details:

----- NO ------22.Summary

NATIONAL ENERGY CONSERVATION AWARD 2006

SUMMARY SHEET

Unit Name: MAHANAND DAIRY, MUMBAI.Sub-Sector:

1 Implementation of energy conservation measures & investment {S.no.16, and S.No.9.3(i)}a. No. of measures implemented, investment made & savings achieved

Year No. of measures

implemented(S.No.16)(i)

Investment

made(S.No.16)(Rs.Lakhs)(ii)

Savings achieved

(S.No.16)(Rs.Lakhs/year)(iii)

Energy Cost

S.No.9.3 (i)(Rs.lakhs/year)(iv)

% Saving

Energy C(iii/iv x 10

2003-2004 _ _ 150 364.65 41.13

2004-2005 _ _ 150 358.12 41.88

2005-2006 10 97 158.83 418.10 37.99

Remarks (if any): Details of EC measures along with savings achieved are given in 20(iv)c

2 Energy Savings (S.No.16, S.No.9.1C (a) and S.No.10R (k)a. Absolute savings

Year Electrical

consumption(Lit of milk/

kWh)(i)

Electrical

consumption(kWh/Lit of

milk)(ii)

Thermal

(Furnace Oil)(Lit of milk/lit

of F.Oil)(iii)

Thermal

(Furnace Oil)(mlof F.Oil/ Lit

of milk)(iv)

% Elect.

SavingSr.No.16

% Ther

(FueSavin

Sr.No.

BaseYear(National Norms)

28 0.035 200 5.0 - -

2005-2006 33.33 0.030 372 2.68 16% 46.23


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2.b Specific Energy Consumption (SEC) Reduction during the period 2003-2005 (S.No.11)

Year Electricalconsumption(Lit of milk/

kWh)

(i)

Electricalconsumption(kWh/Lit of

milk)

(ii)

Thermal (FurnaceOil)

(Lit of milk/lit ofF.Oil)

(iii)

Thermal(Furnace Oil)(mlof F.Oil/ Lit

of milk)

(iv)

% Elect. SavinSr.No.16

BaseYear(NationalNorms)

28 0.035 200 5.0-

2005-2006 33.33 0.030 372 2.68 16

Remarks (if any): Same as 2a

* or use actual units as requested in Note under Sl No. 11(l) in the case of Refinery, Integratedsteel plants, Cement plants and Fertilizer plants.

2.c Specific Energy Consumption (SEC) Reduction during the period 2004-2006 (S.No.11)

Year Product *kWh/tonne % reduction over2002-2003 *MkCal/tonne % Reduction ov2003-2004

2004-2005

2005-2006

Remarks (if any): Same as 2a

2d. Specific Energy Consumption Comparison(SEC) with National & International Best Values(S.No.12)

Units values National/International Best values

Product Figures for the Current Year (2005-2006) National Internationa

Liquid Milk Electrical: 33.33 (Lit of Milk/kWh)Thermal: 372 (Lit of Milk/Lit of F.Oil)

28 (Lit of Milk/kWh)200 (Lit of Milk/kWh)

Not AvailableNot Available

Remarks (if any): 1.Authentic National/International Best Values are not available with respect to IdenticalDairy Industry. However National Level Norms are available as per study conducted by NDDB/Govtof Maharashtra in year 2000. Accordingly these norms are taken for the sake of comparison.It is

requested tocommunicate National Level Norms with respect to Identical Dairy Plants if available with BEE.

2. MRSDMM feels that this consumption levels are "BEST" among the Identical Dairy Industry at NatioLevel. "MAHANAND-DAIRY'S" efforts in the field of energy conservation may please be reviewed, exami

and analysed critically and compared with Identical Dairy Industry with similar activity. The efforts achievement in the field of Energy Conservation deserves to be complimented, so as to encourage amotivate the personnel engaged for "Energy Conservation Programme".

3. At MAHANAND-DAIRY, the Energy Consumption Data are available since last 20 years, with continuimprovement trend. It is felt that these data along with present energy consumption level may be usefulanalysis and framing "SPECIFIC ENERGY CONSUMPTION" norms for "Bench-Marking" at National Lefor Identical Dairy Industry. In view of above it is requested to kindly give us an opportunity to discuss issue with "Bureau of Energy Efficiency" so as to formulate long term "Energy Conservation Programme"Dairy Industry Sector under the guidance and expertise leadership of "Bureau of Energy Efficiency"


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4. "MAHANAND-DAIRY" is desirous to share our experience with the Identical Dairy Industry. It is requesto kindly communicate the consumption levels of other Dairy Plants, who have secured the eneconservation award for 2004, so as to study and incorporate possible improvement at our plant. MRSDMfeels that still there is huge scope of improvement.

3. Annual Energy Savings and Annual Sales Turnover (Ref.S.No.17)

Year Annual Energy Savingsachieved (Rs.Lakhs)

(i)

Annual Sales Turnover(Rs.Lakhs)

(ii)

Annual Savingsachieved/Annual Sal

Turnover (in%)(i/ii) x 100

2003-2004 150 41500 0.36

2004-2005 150 39000 0.38

2005-2006 158.83 38491 0.41

Remarks: Considering available National Norms

4.Specific Energy Consumption Target as achieved during 2005-06 (Ref.S.No.19(a)

Specific energy consumption or use actual unitsPlanned target for 2005-06(a)

Actually achieved in 2005-06(b)

% Reduction (+} orincrease (-)(a-b)x100

a

Money savedduring 2005-06

Lit ofmilk/kWh

Lit of milk/lit offurnace oil

Lit ofmilk/kWh

Lit of milk/lit offurnace oil

*Electrical *Thermal Rs.Lakhs

34 397 33.33 372 1.97 6.29-

Remark: Specific energy consumption is increased due to manufacture of milk products

5. Planned Specific Energy Consumption Target for the year 2006-07 & 2007-08 (Ref.S.No.19(b)

Year Electrical* Thermal* Reduction over he year 2004-05Lit of milk/kWh Lit of milk/lit of

furnace oilElectrical % Thermal %

2005-06 (baseyear)

33.33 372 - -

2006-07 36 386 8.0 3.76

2007-08 38 400 14 7.52

23. a) DOCUMENTS ATTACHED:I. Copies of certificates (with year wise marking) pertaining to statutory requirements suchas safety and pollution control for the period 2003-06 are enclosed.

II. One copy each of the audited annual reports for the years 2003-2004, 2004-2005 &2005-2006 (or 2003,2004 & 2005) are enclosed.(Note: If audited report for the latest year is not available, the pre-audited report may please

be enclosed indicating the same.)III A brief write up of the unit as mentioned at S.No.22 along with photographs depictingequipment/locations where energy efficiency activities have been undertaken and a FloppyDiskette/CD containing the entire write-up is enclosed (Please ensure that name of the unitis written on the Floppy Diskette/CD and it is virus free).

b) JUSTIFICATION FOR CONSIDERING OUR UNIT (MAHANAND DAIRY) FOR THIS


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PRESTIGIOUS STATE LEVEL ENERGY CONSERVATION AWARD.

1.ENERGY CONSUMPTION PATTERN IN DAIRY INDUSTRY: Dairy industry mainlyconsumes substantial amount of Thermal (Heat ) Energy for milk processing (pasteurization),Electrical Energy ( Refrigeration requirement for milk prechilling, chilling of milk afterpasteurization, cold storage of packed milk, compressed air requirement for pneumatic milkpackaging machines, milk homogenization and clarification operations etc.)

2. As operations of Dairy plant units varies from unit to unit depending upon type ofactivity(milk pasteurization with homogenization and clarification or without homogenizationand clarification); loose milk disposal/distribution or packed milk disposal/distribution, type ofmilk {whether cow milk with homogenization or without homogenization, buffalo milk(whichdoes not require homogenization), Toned Milk(which requires high refrigeration requirement)etc.},it become extremely difficult "SPECIFIC ENERGY CONSUMPTION(SEC)", which ismain yardstick fro comparison. Because of this complexity nature of industry, standardauthenticated norms are not available for comparison. For Example - a Dairy unit engaged inmilk processing/ pasteurization activity without homogenization, clarification shall consumevery little electrical energy as compared to the units engaged in milkprocessing/pasteurization activity with homogenization and clarification. Also, units engagedin processing and distributing of liquid milk without packaging (loose milk) and without cold

storage shall consume less energy as compared to the units engaged in processing anddistribution of packed milk in pouches. Also, Dairy units, engaged inreconstitution/recombination/processing of toned milk consume more energy compared toDairy Units not engaged in above activity. On account of above complexity and in theabsence of 'BENCHMARK'/Specific Energy Consumption, it becomes extremely difficult tocompare the energy consumption trend in Dairy Industry. Hence it is "VERY IMPORTANT"and "ESSENTIAL" to have comparison among the "IDENTICAL-DAIRY UNITS" only, whichare carrying out similar activities.

3. "MAHANAND-DAIRY" is the only unit in the country, processing cow milk with centpercent homogenization and clarification activities. Also, Dairy distributes the packed milkafter storage in cold rooms. Hence, it is requested to kindly compare our energy consumptiontrend with Identical Dairy Industry.

4. The main activities/processing operations (energy intensive operations) at"MAHANAND-DAIRY" are as under:a) Liquid processing of cow milk with cent percent homogenization andclarification.Approx.4.5 LLPD (Lac Liters per Day).b) Toned milk processing with cent percent homogenization and clarification.Approx.2.2LLPD.c) Packaging and distribution of milk in pouch with cold storage operation. Approx.4LLPD.d) Total Milk processing (pasteurization, homogenization and clarification).LoadApprox.7LLPD.e) Manufacturing of Ghee 37707 Kg, Curd 455860 Kg, Lassi 91735 litres,Shrikhand 67460 Kg, long life UST milk 62108 litres, Paneer 34620 Kg., approx. 0.033LLPD.

5. Mahanand Dairy is engaged in Energy Conservation activities since last 20 years andbelieves in the policy of continual improvement. Some of the important Energy Conservationmeasures adopted by Mahanand Dairy are as under

a) By promoting general energy conservation consciousness and awareness among thestaff at all levels.

b) Proper coordination among various energy intensive departments.c) By careful monitoring of process parameters, operation parameters at Refrigeration

Section, (ammonia compressors); boiler section (consumption parameter)


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d) By adopting periodic cleaning schedule for heat transfer surfaces (Atmosphericcondensers, evaporating coils, Boiler water side, fire side etc).

e) By Power Factor improvement and efficient utilization of pumps, motors and dairyequipments.

f) USE OF NON CONVENTIONAL ENERGY : FOR SOLAR WATER HEATINGSYSTEM : Mahanand Dairy is using solar water heating system (20000 per day)

since1989-90, which was commissioned with the assistance of Department of NonConventional Energy Sources and Maharashtra Energy Development Agency. Thesystem is well maintained and even working efficiently till date. The system is one ofthe best managed and maintained system giving extremely good results since last

16years (savings of 200 250 litres pr day with monitory savings of Rs. 7 lakhs

perannum.).

g) By replacement of old energy inefficient milk pasteurizeration unit with new energyefficient milk pasteurization plant, thereby improving heat transfer efficiency andregeneration efficiency.

h) Replacement of old ammonia condenser unit, with new one so as to reduce head

pressure (discharge pressure) from 200 210 psi to 170 180 psi., thereby improvingrefrigeration effect with reduced power consumption.

i) By timely arresting of steam leakages, compressed air leakages, hot water leakages,etc. By proper insulation to steam line; heat transfer area, so as to reduce the heatlosses.

j) Use of advanced Anaerobic technology [UASB] for waste water treatment [EffluentTreatment]

Mahanand Dairy has adopted this technology in the year 1996 97. The plant consumesnegligible energy as 80 90 % B.O.D. reduction takes place in the anaerobic digestion.The results are very good (B.O.D. achieved as low as 7 10 B.O.D. Mg. per litre). Theplant gives the power saving of 1.5 units per cubic metre of effluent water (approx.savings Rs. 18 lakh per annum).

k) Tertiary Water Treatment Tertiary Water Treatment facilities are used for treatment of

300cubic metre water per day after waste water treatment for recycling (this has givenapprox. savings of 40 lakhs per annum)

l) Use of mechanical machines instead of conventional electro pneumatic machines for milkpackaging. Mahanand Dairy is in the process of phasing out electro pneumatic machinesby mechanical machines in phased manner, so as to eliminate compressed air use,thereby achieving power savings. Already 8 no.s of machines are replaced withmechanical machines. We are in the process of replacing other machines shortly.

m) ONGOING ENERGY CONSERVATION PROJECTS IN HAND :USE OF SOLAR ENERGY FOR MILK PASTEURIZATION WITHOUT USING FUEL:Mahanand Dairy envisaged the substitution of fuel used for milk Pasteurization bydeveloping SOLAR MILK PASTEURIZATION SYSTEM way back in the year 1991-92.

The issue was discussed at various forums and as a result of this, MNES and IITMumbai has taken up the above project under R & D. The advanced solar concentrator isalready installed at Mahanand Dairy, Latur unit and initial trial runs are beingundertaken. The results are very much encouraging and milk pasteurization activity isbeing carried out WITHOUT USING BOILER/ FUELS. Looking to heat requirementfor the pasteurization activity in the dairyindustry, this achievement will prove boon to dairy industry in future. The system will notonly give significant fuel savings, but also will be helpful in protecting the environment byreducing CO2 emission. (As per KYOTO protocol, it is mandatory to reduce CO2emissions in the environment.)


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6. ACHIEVEMENTS :

a) FURNACE OIL CONSUMPTION: At our plant due to continuous joint efforts to savethermal energy, the furnace oil consumption has reduced from 8.9 ml (1984-85) to 2.68 ml(2005-06) per liter of milk processing, resulting into improvement in milk processing from 112liters to 372 liters per liter of furnace oil. This has resulted into significant monetary savings(Approx.Rs 80 Lacs).b) ELECTRICITY CONSUMPTION: At our plant, due to continuous joint efforts to saveelectrical energy, the electricity consumption has reduced from 0.036 kWh(1984-85) to 0.030kWh(2005-06) per liter of milk processing, resulting into improvement in milk processing from27 liters to 33.33 liters pre kWh. This has resulted into significant monetary savings(Approx.70 Lacs pre annum).c) WATER CONSUMPTION: At our plant due to continuous joint effort made to savewater(precious natural resource), the water consumption has reduced from 4.44liters(1984-85) to 1.18 liters of water (2005-06) per liter of milk processed. The reduction inwater consumption has not only helped in reducing the cost of processing but also helped inreducing "Hydrological Load" on Effluent Treatment Plant, thereby reducing the waste-watertreatment cost. This has resulted into significant monetary savings (Approx.Rs.80 Lacs perannum).

d) The efforts and attempts made by Mahanand Dairy in the field of Energy Conservation arehighlighted in paper published in Indian Dairyman, Electricity Conservation Quarterly, PCRA,etc. The copies of following papers are enclosed herewith.

(1) Electricity Energy Conservation In Mahanand Dairy (Electricity ConservationQuarterly April 87 Issue)

(2) Energy Conservation In Dairy Plants A Case Study On Solar Heaters Usagepublished by PCRA.

(3) Energy Conservation In Dairy Plants - A Case Study published inIndian

Dairyman. The above paper was selected for Best Paper Award by IndianDairy Association.

(4) Conservation of Refrigeration Energy in Dairy Plants A Case Study (Electricity

Conservation Quarterly January 1998 issue).Use of Solar Energy for HeatGeneration in Dairy Plants - A Case Study published by Maharashtra EnergyDevelopment Agency.

7. At MAHANAND-DAIRY, the Energy Consumption Data are available since last 20 years,with continuous improvement trend. It is felt that these data along with present energyconsumption level may be useful for analysis and framing "SPECIFIC ENERGYCONSUMPTION" norms for "Bench-Marking" at National Level for Identical Dairy Industry. Inview of above it is requested to kindly give us an opportunity to discuss the issue with"Bureau of Energy Efficiency" so as to formulate long term "Energy ConservationProgramme" for Dairy Industry Sector under the guidance and expertise leadership of"Bureau of Energy Efficiency"

8.Mahanand Dairy feels that these consumption levels are best among the identicaldairy industry at National level. Mahanand Dairys efforts in the field of EnergyConservation may please be reviewed, examined and analyzed critically and comparedwith identical dairy industry with similar activity. The efforts in achievements in thefield of Energy Conservation deserves to be complimented, so as to encourage andmotivate the personnel engaged for Energy Conservationprogramme."MAHANAND-DAIRY" is desirous to share our experience with theIdentical Dairy Industry. It is requested to kindly communicate the consumption levelsof other Dairy Plants, who have secured the energy conservation award for 2004, so as


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to study and incorporate possible improvement at our plant. MRSDMM feels that stillthere is huge scope of improvement.

Recently Mahanand Dairy has been rewarded the 2nd

prize for STATE LEVEL ENERGYCONSERVATION AWARD 2005 by Maharashtra Energy Development Agency

In view of the above, Mahanand Dairy feels that the unit is eligible for the prestigiousaward.

mahan and dairy

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