Excellence in Water Management at GlaxoSmithKline Consumer Healthcare Limited, Rajahmundry

12/9/2008 2:40:06 PM cc_20082 Heary PPT-2498 JC CEHS-2.01

Excellence in Water Management@

GlaxoSmithKline Consumer Healthcare LtdRajahmundry

EHS V isio n

To achieve

Compet it ive Business

advant age t hrough

Lead ership

and Exc ellenc e

in EHS

Rajahmundry

GSKCH, IndiaØ Indian br anch of Glax oSmithKline plc U.K.Ø Manufactur ing sites at Nabha, Rajahmundr y and Sonepat

About RajahmundryØ Commer cial pr oduction star ted in 1973Ø Capacity Installed – 24 KT Ø Pr oduct Portfolio: Hor licks, Choco late Hor licks, Boost ChocoblastØ Employees ~ 1500 (Incl. contr actor employees)

www.gsk.com

Site Profile


Mfg Process & Water IPO

HORLICKS - Manufacturing process flow diagram

Mash sep aration

Mash ing

W ort hol ding

Milk h oldin g

Weak Wort

Malt Ext ract

Sa lts & Min e rals

Evaporat ion- 1st st age

Food Transfer for sp read ing on trays

Oven dryi ng

W heat Flour

Malted Barely

CCP - 2

CCP - 1

Wh ea t Glu te n

Hu sk w ashi ng Milk recep tion

Milk Pasteurizat ion

Milk sta ndard iza tion

IS P

SMP

FCS

Dry Vit amin ( B- Comp lex & C)

PART - B

Trays s crap ping

Grind ing

Mixing

Packing i n Drums

O ily Vit amin (A,D ,E,K )

Ir on contaminat ion

Evaporat ion 2 n d s tag e

Steam

Chill water

Raw water

Filtered water

Condensate

Condenser

Waste water

Hot water

Water Out flow

Condensate

Hot water

Condenser water

Waste Water• Util it ies• Other Fu nctio ns• Manufactur ing

Reuse , Recycl e

Reuse

Reuse , Recycl e

Recycl e

3 R (Zero Discharge) - 100% Compliance

Gr o u n d W a t er fr o m Bo r e we ll s

Do m e s ti c P r o d u c ti o n Co o li n g &

B o i l e r fe e d

R e c h a rg e o f wa t e r t o

g r o u n d

Ra i n w a te r

h a rv e s t in g p it

Us e d i n c a n t e e n f o r f o o d p r e p a ra t io n

W a te r r e u s e d f o r g a rd e n i n g

T re a t ed W a t er st o r ed

in la g o o n

E f f lu e n t

Tr e a tm e n t P la n t

Me t h a n e

Ga s

F is h c u lt u re

R e so ur ce su b st i tu t i on ( R e p la c in g LP G )

R e u se

R e so ur ce co n ser va t i on

B i o - di v er si ty

Recharging of ground water


Resource Conservation Strategy

Top Down Bottom up

EHS Plan for

Excellence

GMS – India Strategy

EHS program & procedures at site

Functional & Indiv idual objectives

Idea Cam ps, Suggestion boxes/JDIs

Kaizens & Projects

Baselining & Benchmarking

Innovatio n & Collaboratio n

Corporate program s

Employee Engagement

Training & Education

Visual displays/Controls

Idea Camps

Competitions – Posters/Slogans

Suggestion Boxes

Just Do Its

Rewards & Recognition/ Spirit AwardsAware ness ca mpai gn

Rewar d to Employe e

Site Director observ ing the entries i n Slogan Compe titi on


Brainstormi ng session on water c ons erv ation

Soluti on ide nti ficati on for the opportuni ties

Water Kaizen

Process follow ed

Key Result Areas

Benefits

• Basel ining t he Current performance. • Studied consumption pattern for la st 1 y ear• Identified cros s functional team • Conducted Kaizen event on 21st Sep’06

• End hose control systems put in use• Replacing ra w water points wit h treated ones• Providing push type cocks in toilets • Leak/ spil l contro l clamps • Rational ization of wash po ints (63 to 48)– need based

• 48 UDE’s Identified• Implement ed all Quick win so lutions in

3 months• Water consumption is reduced by 30%

per TOP

Community Involvement

Imbibed EHS concepts in 1550young “ Ignited

Minds”

Slide from ‘Connecti ng LittleHearts’ on wate r conservation

Students witnessing a demonstration during the session

Site Director administering oath to Conserve Natu ral Resources


Monitoring & Review system

Month YTDKPI UOM

2007 actual s

2009 Target

2008 Target

2008 actual s2006 actua ls

Traff ic Light

2010 Target

Month YTD2008 FCSite 2007 Target Q3 2008 Plan

2008

Format for monitoring Specific water consumption

Format for monitoring Absolute water

consumption

Repor ting Water

Consumption

List of Water Conservation Projects

End of hose control

660

365

75

-

5

12

3

-

-

5

1

InvestmentRs. in ‘000

20

55

30

5

20

2

3

100

130

5

5

Water Savings (m3/day)

9782

26900

14673

4891

9782

978

1467

105668

60262

4891

4891

Annual Saving (Rs.)

Floor cleaning ma chine

Tray cleaning mach ine

Improving con densate reco very

Use of nozzles for drum washing

Modification of flushing at Amen ity blocks

Auto flush for toilets at Admin blo ck

Treated Water for flushing of toilet

Optimization of water pressure

Use of Cooling Tower water for va cuum pump sealing

Introduction of self closing taps

Project/JDI

Floor cleaning ma chine

Treated water for coal wetting


Initiatives : Floor Cleaning machine (2006)

Wastage of water arising fr om conventional floor cleaning is eliminated thr ough use of Floor Cleaning machine

Investment : 6.6 Lakhs

Water savings per annum : 7300 m3

Before

Mechanized Cleaning using Floor Cleaning machine

After

Initiatives : Mechanization of Tray cleaning (2007)

Manual cleaning of food tr ays was r eplaced w ith mechanized cleaning

Investment : Rs. 3.65 Lakhs


Before

After


Initiatives : Optimization of Water pressure

1.5 Kg / cm2

0.9 Kg / cm2

• Reduction of Water pr essur e : 1.5 to 0.9 Kgs/Sq cm• Use of Var iable Fr equency Drive

Investment : Nil


Initiatives : Improving Condensate Recovery

Impr ovement of Condensate r ecover y : 61.7 to 75 %

Resu lt : Reduction in DM water consumption by 28.7 Cu. M / Day

Investment : Rs. 0.75 Lakhs

Befor e implementation : 84.3 m3/day

After implementation : 55 m3/day



Initiatives : Cooling Water for seal cooling of Vacuum pumps

Cooling Tower water was reused for seal cooling of Vacuum pum ps in place of Fresh water

Investment : Insignif icant

Before im plementation : 130m3/day

After im plem entation : Nil (As C ooling Tower water is reused)

Water sav ings per annum : 47450 m3

Fresh water l ine disconnec ted and c onnecte d with Cooli ng water

Initiatives : Auto flush for toilet

Every drop counts …

Small change …

Sustained improvement


Initiatives : Sprinkler & Drip Irrigation

Sprinkler i n use Drip irriga tion on-si te

Performance delivered

Speci fi c Water consumption

38% reductionIn 3 yrs span

21.117.3 15.5

13

0

5

10

15

20

25

KL

per T

on

2004 2005 2006 2007


Performance delivered

Per capit a Water consumption

45% reductionIn 3 yrs span277

255

172 152

0

50

100

150

200

250

300

Lit.

per D

ay

2004 2005 2006 2007

Waste Water Treatment - Process

KITCHEN

Fat Trap

(25 KL)

Eq. Tank

(200 KL)

UASBR

(287 KL)

Aerati on Tank - I

(510 KL)

Clarifier

(271 KL)

Treated Water to Green Bel t

Bio-gas Dome (50 Cu.M)

ProcessAerati on Tank – II (1013 KL)

Canteen / Domestic

Not in use


Waste Water Treatment - Facility

Equalisation Tank UASBR (Anerobic Dig estion) Bio-gas Collecti on Dome

Treated Water S torage Pon d Clarifier Aerati on Tank (A erobic Sys tem)

Supply to Canteen

Green Bel t

Bio-gas Collection

Rain Water Harvesting

Objective :

GSKCH, Ra jahmundr y uses bor e well water for its oper ation. In or der to avoid adverse effect of the oper ations on the water table, implemented Rain water har vesting.

Rain Water Collection Rain Water Harvest ing


Waste Water Generation

22% reductionIn 3 yrs span9.4

8.17.7 7.5

456789

10

KL

per T

on

2004 2005 2006 2007

Laurels

National Energy Conservation

Award 2005

Director of Factories Award’ 05

for “OHSAS 18001”

CEO’s Award 2005 - Vanguard Award presented by JIM in Aug’ 06

CEO’s Award 2005 – First Place

honor for U SE Methane- Aug’ 06

APPC B Award 2004

CEO’s Award 2007 – Special commendation Awards

FAPCCI Award -2008

Internal

External


Way forward…

Installation of s ub me ters at ide ntifie d areas

Conducting Water balance regularly

Year on year stretche d targets

Innov ativ e suggestions / ideas from employees

20 %Reduction

by 2010

20 %Reduction

by 2010