Company Profile

VASAVADATTA CEMENT(PROP. KESORAM INDUSTRIES LTD.)

ISO-9001, ISO-140001 & IS-18001 COMPANY

SEDAM – 585 222, DIST. GULBARGAKARNATAKA STATE

Tel. No. 08441 – 276005, 276391 & Fax No. 08441 – 276139E-mail: [email protected]

DEAR COLLEAGUES:

We in Vasavadatta Cement endeavour to create a congenial atmosphere for personal and

professional growth. Ours is a modern cement plant with distributed control system and

is well known for its efficiency in terms of power consumption and capacity utilization

We at Vasavadatta Cement generate a participative culture and management style, which

will create good in-house working condition and job satisfaction to all employees.

You as a new member of this company shall join hands to achieve our aims and

objectives. We count on your innovative ideas, creativity, result orientation and

dedication.

We hope you will enjoy working and living here and grow even more.

Our best wishes are with you.

VASAVADATTA MANAGEMENT

OUR LOGO THE 21 st CENTURY ATLAS

ATLAS, THE TITAN – COLLECTIVE STRENGTH

Atlas, bearer of the heavens is synonymous with vast, all encompassing strength and is used to symbolize the Group’s own collective strength. It reflects the combined qualities of astute and dynamic management while emphasizing the Group’s tendency, consistency, reliability and overall leadership.

THE SUN – ENLIGHTENMENT AND GROWTH

The Sun, as a source of infinite energy and inspiration, is used here in conjunction with the Atlas head to represent the vitality and powerful presence of the Group-both in its industrial prowess and its financial, technological and intellectual skills.

EARTH SEGMENTS – DIVERSIFIED ACTIVITIES

Each of the latitudes around the Titan represents various sections – industrial, agricultural, financial and other activities of the Group. As with the infinite variety of the world, so is the strength of the Group, made up of its diverse activities.

THE GLOBE – GLOBAL VISION

The Group’s global presence and vision is reflected in the entirety of the Earth’s sphere.

THE BASE – SOLID FOUNDATIONS

The strength of the entire edifice depends upon the strength of the foundation embedded in the bedrock, represented hereby the Group Name.

THE SYMMETRY – THE RESILIENCE, VERSATILITY AND STABILITY

Seen in its entirety, each of the elements – Atlas, the Sun, the Earth divisions, the Globe and the Base, together sum up a well conceptualized and balanced conglomerate.

Strong Foundation Sustained Growth Proven Leadership

VASAVADATTA CEMENT

SN CONTENTS PAGE NO.

1 Company Profile 1

2 Organizational Chart 2

3 Company Policy 3

4 Total Productivity Maintenance [ TPM] 4

5 General Information’s 6

6 Welfare Measures 7

7 Plant Layout 8

8 Flow Diagram 9

9 Process Description 10

10 Career path 13

11 Departments 14

12 Senior Executives of Company 15

13 Awards / Trophies won by Vasavadatta Cement 16

14 Tips for Employees 17

COMPANY PROFILE

The family of Birla Group of Companies has been founded by Syt. G.D.Birla, the

legendary person of Indian Industry and business, a Committed person to the cause of

Swadeshi Movement, a close associate of Mahatma Gandhi, and a leading philanthropist.

This is continued by his worthy son Syt.B.K.Birla.

Syt. B.K.Birla is the Chairman of B.K.Birla Group of Companies of which

Vasavadatta Cement is a unit of KESORAM INDUSTRIES. Under the group there are

many companies, which are effectively running and are engaged in producing wide

variety of products and services.

Vasavadatta Cement is the 2nd Green field project of Kesoram Industries Ltd., located in

district of Gulbarga, 3 Kms. away from the Sedam Town. 1st unit was conceived in the

year 1983-84 and commercial production started in the year 1986. The 2nd line was

commissioned in 1997 having latest state of the art technologies comparable to the best

cement Plant in the World. Within a short span of commissioning, the expansion unit

achieved more than 100% capacity utilization and now the work of the 3 rd unit is in full

progress and the production is likely to start during September, 2006. Accordingly, the

clinker production capacity may go up from 2.05 million tonne per annum to 3.3 million

tonne per annum. We have also set further vision of commissioning of 4th Unit by 2007.

The company is pioneer in bringing utilization to Sedam, the backward area in Gulbarga

district of northern Karnataka. The company has provided direct and indirect

employment to the people of the surrounding area. A sleepy unknown habitat until 1983,

Sedam is today humming with industrial activities due to Vasavadatta Cement, which has

made a favourable impact on the socio-economics of the region. The company has

contributed significantly to the national exchequer and is committed to the cause of

corporate value addition to the quality of life and standard of living. The company is

using huge quantities of waste products of other industries i.e., Fly ash, Slag & Chemical

Gypsum for making Cement, thus contributing to prevention of pollution and helping

nation to combat pollution in general.

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COMPANY POLICY

We, at Vasavadatta Cement are committed to:

Produce and deliver quality cement & clinker as per customers’ requirement with

an aim to enhance customer satisfaction.

Continual improvement in quality, health, safety & environmental performance.

Compliance of all applicable legal and other requirements.

We will achieve this by:

Improvement in quality of raw material input.

Reduction in chronic losses.

Technological innovations.

Prevention of pollution incidental to plant operation.

Conservation of natural resources.

Reduction of man days lost due to accidents.

Reduction of level of risk by improving working conditions.

Total involvement of employees through participative management activities and

training to create awareness and upgrade skills.

This policy is adopted as an integral part of business performance and we ensure to

provide adequate and appropriate resources to manage the system efficiently.

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TOTAL PRODUCTIVITY MAINTENANCE

TPM POLICY

WE PLEADGE TO ACHIEVE ZERO DEFECT, ZERO FAILURE, ZERO

ACCIDENT, CLEAN ENVIRONMENT, HIGHER PRODUCTIVITY,

REDUCTION IN COST, WITH PARTICIPATION OF ALL EMPLOYEES

THROUGH EIGHT PILLARS OF TPM AND STRENGTHENING ISO-9001/ISO-

14001 ACTIVITIES.

TPM stands for TOTAL PRODUCTIVITY MAINTENANCE. It is about Productivity,

People and Profit. Recently, Indian Industries too have realized its importance and most

of the leading companies have launched the TPM movement. Among them, is our Unit,

which has made lot of progress in terms of Production, reduction in cost of power

consumption.

TPM is a powerful tool for organizational and cultural transformation that brings in total

efficiency of the plant by tackling key aspects of plant utilization, quality and down-time,

with the ultimate goal being Zero Breakdown, Zero Accident, Zero Defect, Optimum

inventory and clean environment with the involvement of each and every employee right

from Top Management to the Bottom Level person in the company.

Let us know what actually TPM stands for?

The letter `T’ stands for:

Inducing total effectiveness by maximizing the overall efficiency.

Increasing total life cycle by reducing life cycle costs.

Improving total employee participation by involving everyone and transfer of

knowledge to everyone.

The letter `P’ stands for Productive to pursue maximization of the production system by

bringing all losses to zero, zero accidents, zero defects, zero breakdowns.

The letter `M’ stands for Maintenance in a much wider sense. It covers the entire life

cycle of the production system – maintenance of individual processes, plants and

production management systems.

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TPM aims at involving all the employees of the organization through eight pillars of

TPM.

They are:

1) Individual Improvement

2) Autonomous Maintenance

3) Planned Maintenance

4) Education & Training

5) Maintenance Preventive System

6) Quality Maintenance

7) Administration & Support

8) Safety & Environment

The activity of each Pillar is related with other Pillar directly and indirectly. We

cannot skip any one pillar to proceed further.

The Equipment efficiency is improved by taking each equipment as Model Equipment

and after its efficiency is achieved, other equipments are made as Model Equipment in

similar manner and thus the plant efficiency is achieved. This process makes use of the

above Eight Pillars in a systematic order to achieve the desired goals.

Through TPM we have been able to reinforce new vigour in our work style and culture.

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GENERAL INFORMATIONS

Category of Employees :

1. Executives ( DGM & Above )

2. Officers ( Engineers and Above )

3. Assistants ( Clerical / Technical Staff)

4. Trainees ( Company Trainees )

5. Workers ( Wage Board Workers )

6. Apprentices ( Engaged under the Apprentice Act )

Shifts :

1. A shift 06.00 AM to 02.00 PM

2. B shift 02.00 PM to 10.00 PM

3. C shift 10.00 PM to 06.00 AM

4. General shift 08.00 AM to 05.00 PM

Facilities given to Employees :

1. Uniform 02(two) pairs per annum

2. Safety Shoes 01(one) pair per annum

3. Rain Coat / Umbrella As per eligibility

4. Personal Protective Equipments As per Factories Act.

5. Furnished Accommodation Nominal Licence Fee basis

6. Electricity As per Company Policy

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WELFARE MEASURES

SCHOOL: We have an English Medium School in the Company township up to 10 th

Standard affiliated to Central Board for Secondary Education, to meet the educational requirement of the employees’ children.

OCCUPATIONAL HEALTH CENTRE : The company has provided health center with X-ray diagnostic facility, ECG, Pathology Lab, Ultra Sound, Spiro meter, Diagnostic Audiometer, for the benefit of the employees with qualified Medical Officers and Para Medical Staff. Visits of specialists like Child Specialist, Gynecologist, Orthopedician, General Physicians, Ophthalmologist, etc., are arranged regularly.

RECREATION CLUB: The Company endeavours to achieve all round development of its employees and their family members. For this purpose two auditoriums are provided to play indoor games like Badminton, Table Tennis, Caroms and for organizing various cultural functions and other activities. We are also providing the following facilities, so as the employees improve their general health and keep them fit : Swimming Pool Gymnasium WORKERS WELFARE CENTRE : The Company not only endeavours to achieve all round development of its officers and staff members but even paying the same attention for the well being of workers and have fulfilled its prime responsibility by providing workers welfare center where the workers are organizing various functions / cultural activities from time to time. LIBRARIES AND READING ROOMS: The Company has provided libraries and Reading Rooms in the plant and also in the Club building for the benefit of employees. All kinds of books, Newspapers and magazines are made available in the library.

HOUSE JOURNAL: An In-house journal, Basantnagar Samachar is brought out quarterly, wherein all important activities of the plant are published.

SPORTS AND GAMES: Competitions in sports and games are conducted every year on Independence Day and Republic Day Celebrations wherein employees are actively participating.

CONSUMERS CO-OPERATIVE SOCIETY: We have a Consumers’ Co-operative Society which is available to meet the needs of the employees for supply of essential commodities.

CANTEEN: Canteen is provided to cater to the needs of the employees. The Company gives attractive subsidy and Tea, snacks and lunch are provided to company workers and contract workers.

COLONY / TOWNSHIP: The Company has a well planned housing colony with about 700 houses for various grades of employees and a Shopping Complex. Round the clock security arrangements are provided in the colony.

BACHELOR’S HOUSING: The Company provides Bachelors accommodation for the freshers who join as Trainees.

WATER SUPPLY: Portable water is being supplied from nearby Kagina River and is made available throughout the day in all the seasons to the Township and to the Factory by storage and overhead Tanks.

BUS FACILITY: The Company provides bus facility for bringing employees to report for duty from Sedam Town and back on nominal charges.

GUEST HOUSE : The company have a well furnished guest house situated inside the colony premises from where tea, snacks, lunch and dinners are provided to company guests including their stay arrangement.

LORD BALAJI TEMPLE : A beautiful Balaji Temple is situated inside the colony premises where every day hundreds of devotees come for pooja and dharshan.

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PROCESS DESCRIPTION

The process of manufacturing Cement involves basically the following sequential unit operations and processes.

Limestone mining Limestone crushing Stacking and reclaiming Raw material grinding Storage and homogenisation of raw meal in continuous blending silo Coal grinding Clinkerisation – (kiln feed, preheating, burning & cooling) Cement grinding & storage Cement packing & despatches

I) LIMESTONE MINING : Lime stone mining is the first phase of Cement manufacturing process. Ours is Open Cast, Mechanized Mining. After removing 2 to 3 Mtrs. of over burden clay, grades will be classified (I bench low grade: 8 to 10 Mtrs. in depth. II and III bench High grade 10 to 12 Mtrs. in depth) then drilling and blasting will be done. The material will be loaded by shovels and transported to Crusher by Dumpers, having capacity of 30 MT in the required ratio.

II) LIMESTONE CRUSHING : Crushing of Limestone is carried in single stage by HAZEMAG IMPACT CURSHER, having a capacity of 800 TPH. The feed size of the material is maximum 1.6 Cu. Mtr. and product size maximum 80 mm. The material, which is entering the crushing chamber, encounters the impact by blow bars mounted on the rotor and revolving at a circumferential velocity of 44 m/sec. The fragments are flung against upper and lower bars. This process is repeated until they have been sufficiently crushed to pass through the blow bars. Grinding path/blow bars can be adjusted if the output material size is more than 80 mm. The crushed material will be transported to Stacker by means of Belt Conveyors.

III) STACKING AND RECLAIMING : For stacking the crushed limestone BELT TYPE BOOM STACKER is in operation, which is having capacity of 800 TPH. The boom stacker has been conceived for material stacking on CHEVRON METHOD. In this method the stacker travels to and fro on a runway between two defined limits, while building up stockpile. The material is always discharged constantly above the middle of the stockpile. With this method piling can be done uniformly with required grades. Four stockpiles of 130 Mtrs. long approximately 25000 MT capacity each can be made by turning the boom to the opposite direction.

RECLAIMING: For this BRIDGE SCRAPER is in operation. A triangular structure called harrows move to an fro across the stockpile width and scraps the material. Scrapped material slides down from face of the stockpile to get blended limestone. The blended limestone, which slides down is scrapped and conveyed by buckets to belt conveyor, which in turn will be transported to Raw Mill Hoppers. By means of stacking and reclaiming, the homogenization of limestone will take place.

IV) RAW MATERIAL GRINDING : Grinding operation is the second stage of operation in unit operation after crushing stage. In this stage crushed material is to be ground into finer material. The VERTICAL ROLLER MILLS of type 43/21/65 of Unit-I and 51/26/400 of Unit-II, supplied by Krupp Polysius are in operation. The capacity of Unit-II mill is 140 TPH and that of Unit-II is 210 TPH.

10The raw materials (Blended limestone, laterite and Bauxite) are fed to the hoppers by belt conveyors. The materials from hoppers, fed to the mill in required proportion by weighfeeders as predesigned by Quality Control Department. In between the grinding table and rollers grinding takes place by hydraulic pressure on rollers.

The ground material is conveyed outward over the edge of grinding bowl, entrained by the air stream emanating from the nozzle ring conveyed to the Electro Static Precipitator through the Static Separator of Unit-I and a dynamic separator of Unit-II, which is built above the chamber. The separator separates the ground material into the finished product (product fitness about 30% on 90 micron sieve) and coarse material. The coarse material drops back to the middle of the grinding bowl, while fines are carried by the air stream to the E.S.P. and then it will be transported through Bucket Elevator or by Airlift to Blending Silo. The hot gases coming out of the Kiln are being utilized for drying the material and entrainment of Raw Meal at required temperature. To control the outlet temperature of the Mill and to maintain constant material bed on the grinding table, water spraying system is provided inside the mill.

Recently the Unit-II Raw Mill has been upgraded by installing single chamber ball mill in tandem with VRM and the output increased from 210 TPH to 255 TPH.

V) CONTINUOUS STORAGE AND HOMOGENISATION OF RAW MEAL IN BLENDING SILO: Continuous flow Silo (capacity 12000 MT for each unit) is being used for storage and blending of Raw Meal. Continuous homogenization can be performed in this Silo to maintain uniform desired quality of Raw Mix.

VI) COAL GRINDING : The Raw Coal, received by rail/road is stored in Coal yard after crushing to 30 mm size by Reversible Impact roll Crusher. Crushed Raw Coal is fed to the Vertical Coal Mill (Capacity Unit-I 19 TPH and Unit-II 26 TPH) for grinding before firing in the Kiln and Precalciner. The coal grinding takes place inside the mill between grinding rollers and grinding table. The ground material (fine coal) is carried by the hot gasses drawn by C.A.fan. The hot gasses are used to remove the moisture from Coal. The ground coal is carried by hot gas stream through Static Separator in which the coarse material will be returned to the mill and fines will be conveyed to the fine coal bins by series of screw conveyors.

VII) CLINKERISATION : It is combined process of Pre-heating, Calcining, Burning and Cooling operation. Rotary Kiln is the main equipment for clinkerisation. Ours is a dry process plant consisting of DOPOL KILN (Size 3.8 Mtrs. Dia X 56 Mtrs. Length of Unit-I and 4 Mtrs. Dia X 60 Mtrs. Length of Unit-II) having capacities of 1500 TPD of Unit-I and 2000 TPD of Unit-II and are designed by M/S.KRUPP POLYSIUS, GERMANY and their counterparts M/S.KRUPP INDUSTRIES INDIA LTD., PUNE. The capacities have been optimized by carrying out retrofittings / modifications, etc. and present capacity is 2500 TPD for Unit-I and 3500 TPD for Unit-II.

After blending and homgenization process, the Raw Meal is conveyed to the Preheater through Poldos/Solid flow meter system, meant for weighing and feeding the Raw meal and bucket elevator / air lift from C.F.Silo. Kiln Feed is fed into the Cyclone I gas duct. Preheating and calcinations takes place in various stages of Cyclones due to heat transfer.

Fine Coal is fired at Kiln outlet end through a Burner pipe. Poldos SC system is used for main and precalciner firing. The hot gasses generated due to fine coal firing are taken out by Dopol Fan/ESP Fan through Pre-heater, Raw Mill and ESP.

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Heat transfer takes place in Pre-heater as Kiln Feed moves downward and flue gasses move upwards causing counter flow in gas ducts. Kiln Feed after preheating (around 90% calcined material) enters at kiln inlet. Then such decarbonised material will flow to the Burning Zone due to the inclination and rotation of the rotary kiln in the direction of the hot zone (burning zone). The temperature of the Burning Zone is maintained at about 1400 deg.C. for proper clinkerisation. After this stage the material is known as CLINKER. This Clinker gets cooled in the cooler (i.e., combination of static and moving grates).

VIII)CEMENT GRINDING: Cement grinding is the final unit operation of cement making process. We have a Tube Mill of grinding capacity 115 TPH, having 16 Mtrs. length X 4.4 Mtrs. dia supplied by M/s.Buckau Wolf India Ltd., Pune for Unit-I. The material to be ground is extracted in desired proportions of clinker and gypsum from storage hoppers by means of Weigh Feeder and fed to the mill by conveying belt. In Cement Mill the material will ground into fine material by means of impact and attrition. The material is pre-crushed in I Chamber and ground in II Chamber. The final product i.e., CEMENT is conveyed to the silos through bucket elevator.

Recently close circuiting of this mill is carried out and output increased from 115 TPH to 140 TPH. Also started using Polycom of Unit-II as a pregrinder for Unit-I Cement Mill by installing clinker integration belt, for further improvement.

Unit-II Cement Mill is a closed circuit Mill with POLYCOM (Roller Press) of 225 TPH capacity. Its length is 14.5 Mtrs. X dia 4.6 Mtrs. The Polycom Presses clinker into flakes. The fines are separated in the “V” separator circuit and rejects goes back to polycom for further size reduction. The “V” separator product is fed to the Ball Mill for further grinding along with Gypsum. The ground material is then fed to the Sepol dynamic Separator where the coarse and fines are separated. The Coarse material is fed back to the Mill. Fines i.e., Cement is conveyed to the Cement Silos by Bucket Elevator and stored for packing. Total 6 nos. of storage silos are there (3 for each unit).

To manufacture Portland Pozzolana cement and to meet the marketing requirement, 1000 MT capacity fly ash silo with storage and feeding arrangement has been installed.

To meet the power requirement for plant operation, two coal based Captive Power Plants of capacities 15.0 MW and 9.5 MW respectively, have been installed and balance power is taken from KPTCL with contract Demand of 7000 KVA 3 Nos. of Fuji DG sets are available to meet emergency power requirement/during annual shutdown of Captive Thermal Power Plant.

IX) PACKING AND DESPATCH : Cement is extracted from the silo and filled in Packer Hoppers, from where the material will flow to the Packer Machine through bucket elevator and air slides. Six numbers of EEL make electronic Roto Packers of 120 TPH capacity in Unit-I & II are installed for packing purpose. They have high degree of accuracy. Finally the 50 Kg. Cement Bag is transported by Belt Conveyor and stacked inside the Wagon/truck with the help of Wagon Loading and Truck Loading Machines.

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CAREER PATH

GRADES POSITIONS

GRADE – VIII GENERAL MANAGER

GRADE – VII DY.GENERAL MANAGER

GRADE – VI SR.MANAGER

GRADE – V MANAGER / DY. MANAGER / CA

GRADE – IV ASST.MANAGER / SR.ENGINEER / MBA

GRADE – III SR.OFFICER / SR.CHEMIST/ENGINEER

GRADE – II OFFICER / PS / CHEMIST / ASST.ENGINEER

GRADE – I ASST. / STENO / TYPIST / FOREMAN / TC / SUPERVISOR / CHARGEHAND

TRAINING GRADE GET / MGT.TRAINEE / TRAINEE

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DEPARTMENTS

SNo. Name of Departments

1 Accounts

2 Stores

3 Purchase

4 HRD

5 Sales & Marketing

6 Mechanical

7 Process & Quality Control

8 Electrical

9 Civil

10 Mines

11 Power Plant

12 Packing Plant

13 Instrumentation

14 EDP

15 Safety & Environment

16 TPM

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SENIOR EXECUTIVES OF COMPANY

SNo. Name of Executives Designations

1 Mr. K C Jain Senior President

2 Mr. P.K.Goyenka President

3 Mr. P.R.Sharma Joint President

4 Mr. C Kr Jain Joint President (Eng & PP)

5 Mr. A.C.Basak Vice President (Mines)

6 Mr. I.K.Purohit Vice President (Sales & Mktg)

7 Mr. Viswanathan.R Vice President (Projects)

8 Mr. Rajesh Singhi Vice President (Mechanical)

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AWARDS / TROPHIES WON BY VASAVADATTA CEMENT

SNo. Description of Awards Year01 National Award for Second Best Improvement in Energy Performance

from NCCBM & Ministry of Power.1990-01

02 National Award for Best Improvement in Energy Performance from NCCBM & Ministry of Power

1991-92

03 National Award for Best Improvement in Electrical Performance from NCCBM & Ministry of Power

1991-92

04 Award for Outstanding Contribution towards Growth of Industries from Hyderabad Karnataka Chamber of Commerce

1993

05 National Productivity Award from Hon’ble Prime Minister 1994-0506 Environmental Award from Dept. of Ecology & Environment, Govt. of

Karnataka1996

07 National Award for Third Best Improvement in Energy Performance from NCCBM & Ministry of Power 1994-95

08 National Award for Best Improvement in Energy Performance from NCCBM & Ministry of Power

1994-95

09 Awards from Central Institute of Professional Management1.Best Problem Solver in Technical Support2.Best Case Study Presentation in Production3.Best Theme under Production4.Best Permanent Solution under Technical Category

1994199419981998

10 Best Improvement in Thermal Energy Performance (line-II) Award from NCBM

2003-04

11 Second Best Environmental Excellence in Limestone Mines Award from NCBM

2004-05

12 CII-National Energy Management Award, Excellent Energy Efficient Unit

2004

13 CII-National Energy Management Award, Excellent Energy Efficient Unit

2005

14 Three Leaves (Rank 10) in the Green Rating Project of the Indian Cement Industry by Center for Science and Environment 2005

15 Global Cement Award Lowest Specific Energy Consumption, Raw Meal Grinding -Second

2005

16 Global Cement Award Lowest Specific Energy Consumption, Clinker Grinding – Third

2006

17 Global Cement Award Lowest Specific Energy Consumption, Clinkerisation- Third

2006

18 Global Cement Award Kiln Reliability- Honorable mention 2006

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TIPS FOR EMPLOYEES

Be punctual at your work place and for all meetings / appointments. Give credit to others for their achievements and also share the credit with others

for your achievements. Recognize need of inter-dependence and cultivate an attitude for team work. Share Knowledge, Information and expertise with others and respect knowledge

and expertise of others. Communicate about anything going wrong or getting delayed to all Concerned.

Do not presume others know about it. Help others in solving problems. Politeness and courtesy always pays. Keep proper records of all problems, their analysis and action taken. These will

be useful as reference material for future. At the start of the day plan, make it a point to check your equipment/materials

needed, and information needed to perform your job effectively. Avoid wastage in all forms. Always try to learn/improve your knowledge/skills/Attitude continually. Ensure your innovative ideas are expressed through suggestion scheme. Ensure that you abide by all the safety Rules.

All of us, by exercising these common habits, can make our organization excel continually and can create a place where we will enjoy working and feel proud to be a member of this Group.

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