Post on 14-Mar-2020
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Chapter No:-3 Company Introduction
3.1. Project Engineering Industrial Unit:-A
3.1.1. History of Alfa Laval
In 2008, - Alfa Laval celebrated its 125th anniversary. With the help of some of the
most important milestones, you can follow Alfa Laval’s growth towards the large
international group it has become today.
1845- Alfa Laval’s founder, Gustaf de Laval, is born in the province of Dalarna in
Sweden.
1877 -After reading an article in the German periodical, Milchzeitung, Gustaf de
Laval starts to work on the development of a centrifugal separator.
1879 - The first continuous separator is demonstrated in Stockholm. This separator
has a capacity of 130 litres per hour.
1883 - Gustaf de Laval and his partner, Oscar Lamm, establish the company AB
Separator. The De Laval Cream Separator Co. is formed in the U.S. which is the
start of a continuously growing international establishment.
1888 - The first pumps are sold. They are used to pump skimmed milk from the
centrifugal separator.
1889 - The German inventor, Clemens von Bechtolsheim’s patent for conical metal
discs is acquired. By using these so called Alfa-discs, the separator’s capacity is
increased many times over.
1890 - Alfa Laval introduces the world’s first continuous separator using the Alfa
disc stack technology. The first continuous milk pasteurizer is introduced.
1898 - The first yeast separator is installed in a customer’s production line.
1910 - Gustaf de Laval begins to work on the design of a milking machine.
1913 - Gustaf de Laval dies at the age of 67. During his lifetime, he acquires 92
Swedish patents and establishes 37 companies. His memorial is engraved with the
inscription: “The Man of High Speed”.
1916 - Alfa Laval sells the first separator for oil purification.
1919 – 1936 - Subsidiaries are formed in Denmark, South Africa, Finland, Australia,
New Zealand, Poland, Yugoslavia and Ireland.
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1933 - The world’s first hermetic separator is introduced by Alfa Laval at an
exhibition in Berlin.
1938 - Alfa-Laval introduces its first heat exchanger. Pontus Hytte, son of the
famous Swedish painter Carl Larsson, moves the development and production of
heat exchangers to Lund.
1951 - Sales of the “self-cleaning” centrifugal separator and decanter centrifuges
begins.
1958 - The first automatic CIP (Cleaning-In-Place) system is installed in a Swedish
dairy.
1961 - The first sterilization processing system is installed in Italy. This marks a
major breakthrough in the dairy and liquid food-processing sector.
1962 - AB Rosenblad’s patents are acquired, bringing the spiral heat exchanger as
well as a series of industrial plate designs into the possession of AB Separator.
1964 - The company changes its name from AB Separator to Alfa-Laval AB. The
name “Alfa” derives from the alpha discs and “Laval” from the founder of the
company.
1965 - The first large computerized control system is delivered to a dairy in
Switzerland. This system makes it possible to supervise and control the entire plant.
1971 - Alfa-Laval acquires a majority interest in the Danish company Lavrids
Knudsens Maskinfabrik (LKM), marking Alfa-Laval’s establishment in the fluid
handling business.
1976 - This is a year of substantial investments. In Sweden, construction begins on a
new manufacturing plant for marine separators in Tumba outside Stockholm. The
Thermal Business Area in Lund starts construction of new offices and an
international production centre for plate heat exchangers. In Spain, Alfa Laval
expands its plants, offices and warehouses.
1981 - Alfa Laval strengthens its foothold in Japan by increasing its holdings in the
Japanese firm Nagase-Alfa to 70 per cent and by establishing Alfa Laval Service
K.K. as a wholly-owned company.
1991 - Tetra Pak, which provides packaging solutions to the food industry
worldwide, acquires Alfa Laval. Tetra Pak is owned by the Rausing family.
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1993 - Alfa Laval becomes an independent industrial group within the Tetra Laval
Group. Liquid food processing activities are integrated with Tetra Pak’s business.
Farm equipment and systems are reorganized into a new industrial group, Alfa Laval
Agri.
1996 - A new factory for heat exchangers, fluid handling equipment and modules for
the food and beverage industry was opened in Kaliningrad outside of Moscow. The
factory is one of the most modern in Russia.
1999 - Alfa Laval launches an innovative oil treatment system for ships as well as
the most advanced automated control of valves in the industry.
2000 - The investment company IndustriKapital buys the Alfa Laval Group.
IndustriKapital’s intention is to further develop Alfa Laval’s global leadership
within its key technologies Separation, Heat Transfer and Fluid Handling, with the
intention of listing the shares publicly within a five-year period.
2001- Major restructuring of Alfa Laval into market-oriented divisions and segments
with distinct customer focus.
2002 - Alfa Laval returns to the Stockholm Stock Exchange. The main strategy is to
create profitable growth, both organically and through acquisitions, which in 2002
include two Danish companies; Danish Separation Systems A/S (DSS), a specialists
in membrane filtration for the pharmaceutical and food industries, and the Toftejorg
Group, the world’s leading supplier of advanced tank cleaning systems.
2003 - AlfaNova, a major breakthrough in heat transfer, is launched. AlfaNova is a
totally new type of plate heat exchanger, based on Alfa Laval’s patented method of
brazing the plates, called AlfaFusion. AlfaNova’s extraordinary strengths in regard
to temperatures, pressures and fatigue resistance open new and interesting
possibilities in existing and future applications.
2004 - Lars Renström is appointed new CEO and President of the Alfa Laval Group.
He has a solid and successful record within Swedish industrial companies. Alfa
Laval and Haldex, a multinational supplier of vehicle technology, form a jointly
owned company, Alfdex AB, to supply jointly developed solutions for cleaning
crankcase gases from diesel engines to meet increasingly stricter emission
regulations.
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2005 - Packinox S.A. in France, a world leader in large, welded plate heat
exchangers for oil and gas and refinery applications, is acquired. The company’s
recognized competence will result in strengthening Alfa Laval within these fields.
2006 - A very high demand in most of Alfa Laval’s end markets – primarily the
energy and energy-related sectors – contributes to the increase in order intake by 30
per cent from 2005. Tetra Pak’s fruit concentrate unit is acquired, which means that
Alfa Laval will penetrate this market through its own sales companies.
2007 - Alfa Laval takes important steps towards becoming a world-leading provider
of air heat exchangers by acquiring Netherlands-based Helpman and Finnish Fincoil,
both leading European suppliers of air heat exchangers. Helpman's products are used
for commerical refrigeration, for example in the sensitive logistic chain for food.
Fincoil is particularly strong within industrial power cooling.
2010 - Alfa Laval is an official partner to the Swedish pavillion at the World Expo in
Shanghai: "Better City, Better Life".
2011 - Alfa Laval acquiries Aalborg Industries and strenghtenit's offer to the marine
and off-shore industry - and beyond. Aalborg Industries is the biggest acquisition so
far for Alfa Laval.
Alfa Laval focuses on energy optimization, environmental protection and food
production through our technological leadership in heat transfer, separation and fluid
handling. With more than 1900 patents, we provide worldwide solutions in areas that
are vital to society both today and for the future.
Energy, Environment and Food With the vision of creating better everyday
conditions for people, Alfa Laval has developed products since 1883. The world is
increasingly focused on saving energy and protecting the environment. Alfa Laval is
committed to those goals. Our products are involved in treating water, reducing
carbon emissions and minimizing water and energy consumption, as well as heating,
cooling, separating and transporting food. These areas represent the core of Alfa
Laval’s expertise.
3.1.2 Technological leadership
Alfa Laval is a leading global supplier of products and solutions for heat transfer,
separation and fluid handling though our key products – heat exchangers, separators,
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pumps and valves. We currently play a vital role in areas that are crucial for society,
such as energy optimization, environmental protection and food production.
Alfa Laval’s products are used in the manufacturing of food, chemicals,
pharmaceuticals, starch, sugar and ethanol. We are also used in nuclear ower, on
board vessels; and in the engineering sector, mining industry and refinery sector as
well as treating wastewater and creating a comfortable indoor climate. More than
1900 patents Good ideas lay the groundwork for profitable development. These good
ideas combined with the company’s pioneering spirit have contributed to Alfa
Laval’s strong global presence. The company is known for focusing on innovation
and new ways of thinking since its inception. Alfa Laval makes continuous and
consistent investments designed to build, strengthen and develop the company’s
global market leadership. Alfa Laval currently holds more than 1900 patents, and
invests approximately 2.5 per cent of its sales in research and development
launching between 35 and 40 new products every year.
3.1.3. Worldwide
Alfa Laval’s worldwide organization helps customers in nearly 100 countries to
optimize their processes. We have 28 major production units (15 in Europe, 8 in
Asia, 4 in the US and 1 in Latin America).
The company has some 16 000 employees, the majority of whom are located in
Sweden, Denmark, India, China, the US and France.
3.1.4. We serve most industries
Alfa Laval's heat exchangers, separators, pumps and valves are used to heat, cool,
separate and transport products in industries that produce food and beverages,
chemicals and petrochemicals, pharmaceuticals, starch, sugar and biofuels. From
biofuels to wastewater treatment, Alfa Laval has continuously extended its business
to cover many different industries since it started its operations in the dairy field in
1883. Our products and solutions excel in heat transfer, seperation and fluid
handling. Alfa Laval's products are also installed on:
a. oil platforms
b. power plants
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c. ships
d. mechanical engineering
e. mining
f. wastewater treatment
g. comfort climate and refrigeration applications
Our technologies are extensively used in the fight for a better environment on land
and at sea.
Key technologies
Alfa Laval is the global leader in its three key technologies
i. heat transfer
ii. separation
iii. fluid handling
all of which are of vital importance for industrial processes.
Heat transfer products accounted for 54%of sales in 2012; separation products for
22% and fluid handling products for 10%.
The strongest market position is in plate heat exchangers, with an estimated market
share of more than 30%. The combined market share for separators and decanters is
estimated to be 25-30%, with fluid handling accounting for a global market share of
10-12%.
3.1.5. Organization for close customer relations
The market strategy at Alfa Laval is based on a sales organization that works close
to the customers. The company markets its products in eight customer segments. To
gain a distinct customer focus, the segments are divided into three divisions: the
Equipment Division, the Process Technology Division and the new (since January 1,
2012) Marine & Diesel Division. In addition, there is a special organization that
serves the aftermarket, Service. Alfa Laval’s procurement, manufacturing and
logistics activities supply the sales organization with the right quality products at the
right time. The majority of these activities are organized in the Operations Division.
The company sells its products in approximately 100 countries and has its own sales
organizations in over half these countries.
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Added value for customers over the years, Alfa Laval has built up a reputation
primarily on the strength of supplying high-quality products. This is still valid, but
we also want to provide value for our customers. This value is summarized in our
mission: To optimize the performance of our customers’ processes, time and time
again. This means that they should be a customer-focused company that supplies
products and solutions that help their customers become more productive and
competitive. They have to define the challenges faced by our customers and offer
them solutions that respond to their true needs. Different customers have different
requirements. They have to treat each one individually and appropriately, regardless
of what they are selling and regardless of which market channel we are using.
Discover a world of opportunities Alfa Laval’s sights have been set on the world
market since its very beginning 130 years ago, and our international position has
been growing stronger ever since. Today, our worldwide organization works closely
with customers in 100 countries. With our international presence and technological
leadership we offer challenging and diversified career opportunities cross
organizational and geographical borders. Working with Alfa Laval will enrich global
experience as they work in areas that create better everyday conditions for people.
For instance, they help their customers purify, refine and recycle materials. They
contribute to reducing the environmental impact of industrial processes. They are
deeply involved in the development of better foodstuffs. These are greatly rewarding
tasks. Get to know us by reading about our philosophy, personality, principles and
values. You can also read about our expectations on our employees and what you
can expect from us.
3.1.6. We have four Business principles that apply to all of us at Alfa Laval.
These four principles express our aspirations, but we must ensure that the words
are converted into practical action and continuous improvement.
a. Optimizing the use of natural resources is our business
b. Alfa Laval makes a significant contribution to reducing the environmental
impact of industrial processes.
c. Respect for human rights is fundamental
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d. Alfa Laval respects the human rights of its employees and the communities in
which we live and supply
e. High ethical standards guide our conduct
f. Alfa Laval conducts its business with honesty, integrity and respect for others.
g. Our commitment to open dialogue builds trust
3.1.7. Alfa Laval believes in open communication but is careful not to reveal
valuable commercial information.
a. Sustainability - A matter of trust
b. Policy and application
c. Recognized standards
d. Alfa Laval’s Business Principles follow international guidelines and
recognized definitions and they apply to the entire Alfa Laval organization
worldwide.
e. Origin
f. Our Business Principles have been formulated to reflect the principles of the
United Nations Global Compact as well as the Organisation for Economic
Cooperation and Development (OECD) Guidelines for Multinational
Enterprises. United Nations Guiding Principles on Business and Human
Rights. They were originally published in 2003 and updated in 2012
following a consultation process that has included employee representatives
and shareholders.
g. Application
h. The Business Principles apply to all Alfa Laval companies throughout the
world irrespective of the brand name under which they trade. Where our
companies participate in joint ventures and business partnerships the
application of these principles will be actively promoted. An independent
internal audit function provides support in monitoring compliance with the
Business Principles.
i. Management
j. The Management Structure for implementing the Business Principles:
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k. Board: The Company’s Board has the responsibility for agreeing the
Business Principles and monitoring the progress of implementation through
their regular meetings.
l. Management: The Group Management team has the responsibility to
implement the Business Principles including setting and reviewing targets
for improvements. Group Management members are present in the following
councils which develop policy, processes and monitor progress in specific
areas:
i. Commercial Ethics Council (Anti-Bribery & Corruption also Export
Control);
ii. Health and Safety Council;
iii. Environmental Council.
3.1.8. Managing Director of Subsidiary
Managing Directors of subsidiary companies have the responsibility to translate the
Principles and associated policies into local rules and procedures in addition to those
required for compliance with local legislation.
Line Managers have the responsibility to ensure that their employees understand the
Principles and receive relevant education and training in order to implement them.
Employees: Each employee should have a good working knowledge of the
Principles and policies relevant to their jobs and apply them in their work.
Audit: An independent internal audit function provides support in monitoring
compliance with the Business Principles.
Environmental focus for customers’ and our own processes
Everything we do has an impact on the environment. The world is looking for ways
to reduce pollution, supply clean water, consume less energy and find renewable
sources of energy. Alfa Laval’s main contribution to a cleaner global environment
stems from an increased use of our products.
During 125 years, Alfa Laval has been providing customers with solutions that help
them to re-use and protect natural resources such as energy and water in industrial
processes. Today, sustainable development is high on industry’s agenda. Alfa Laval
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continuously innovates and refines clean technologies; supporting this drive to
reduce environmental impact. We call this Green customer processes.
Alfa Laval also endeavours to perform its own operations as cleanly and efficiently
as possible, and to take environmental aspects into consideration when developing,
designing, manufacturing, servicing and marketing its products. We call this Green
operations.
3.1.9. Global social responsibility
Alfa Laval respects the human rights of our employees and the communities in
which we live and supply. This means, for instance, that Alfa Laval will not use any
form of forced or compulsory labour, that we work towards the effective abolition of
child labour in the community and that we work to eliminate direct and indirect
discrimination in respect to employment and occupation.
Alfa Laval’s business is truly global. This means that we are increasing our sales in
many countries with low GDP per capita. Our products are essential ingredients in
the development of infrastructure and industries.
Our global presence also means that we have a global supply chain. As our markets
grow in developing economies so do our supply chains. We have developed
management processes to help deal with the social and ethical dilemmas this
presents.
3.1.10. Supplier relations
Improving suppliers’ social conditions
All Alfa Laval’s suppliers are expected to live up to international standards and local
legislation in regard to working conditions, and health and safety and environmental
protection.
However, in many countries with developing economies, the economic, social and
infrastructure conditions are not yet fully developed for this to be a realistic task
today. Since we have opted to fully participate in these economies with the sale of
our products, we should naturally participate in the development of the supply chain.
Alfa Laval is driving this change through a process of repeated inspections,
education, coaching, and commercial pressure. Our guiding star for this is that the
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working conditions for our suppliers’ workers must be improved at a significantly
faster rate than other enterprises in the same social environment.
Health and safety a prioritized goal
Health and safety of Alfa Laval’s employees is included in the sustainability star-
goals management system focusing on continuous improvement of health and safety
at a local production plant level. These goals are discussed and agreed upon by the
line management.
Alfa Laval monitors the health and safety of its employees in all companies.
Statistics are collected centrally for all employees in manufacturing factories.
Statistics are kept of the total number of accidents (including the number occurring
during travel on company business). The days lost are recorded and we compare
factories based on the accidents per million hours worked and the days lost per
million hours worked.
3.1.11. Development and training
Extensive educational programs
Alfa Laval places a lot of emphasis on training and development of employees.
The Alfa Laval University is an umbrella term for all training activities within the
Alfa Laval Group. Much of the internal training is held in Sweden and Denmark,
where many R&D centers and business units are located, although extensive training
is also conducted in other parts of the world.
The majority of training is led by specialists and line managers as part of their
regular duties. Internal training is supplemented with courses that use external
instructors and mentors.
To ensure that training efforts within Alfa Laval University support the Group’s
business concept and strategies, a board has been appointed to support and inspire
the University. The board is comprised of four members of Alfa Laval’s executive
management and three external university professors.
Having external board members enables Alfa Laval University to stay better
informed about the best educational programs in the market and about developments
within other industries and academic institutions.
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Alfa Laval University is divided into three faculties, each focusing on a different
core area of expertise:
a. Sales and marketing
b. Technology
c. Management
3.1.12 Honesty and sincerity
a. All business transactions by Alfa Laval are based on honesty, integrity and
respect for others.
b. Globalization presents our sales and purchasing employees with new ethical
dilemmas when faced with difficult demands from prospective customers and
suppliers. Our response is to increase our training and review our policies
related to these challenges.
c. Alfa Laval believes in open dialogue with all interested parties. However, the
company is careful not to inappropriately reveal information that is
commercially valuable or that could have an impact on the share value of Alfa
Laval.
d. Whistle blowing
e. Alfa Laval encourages employees and external interested parties to report
breaches, or suspected breaches, of the Business Principles.
f. Alfa Laval takes all reasonable steps to protect any employees (so-called
"whistle blowers") who report suspected breaches of the business principles.
3.1.13. How to make a report:
a. Employees
b. External stakeholders
a. Employees
i. Employees are not just encouraged, but are required to speak up and to report
any suspected or observed violations of the law, the Alfa Laval Business
Principles, or if they are asked to do something that might be a violation.
ii. Normally the first course of action is to report through the relevant channel in
the employing company. Who this is will vary depending on the size of the
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company. If in doubt of the correct channel employees may make a report
directly to the Managing Director.
iii. Managing Directors have the responsibility to ensure that the report is handled
in accordance with Alfa Laval’s policy on whistle blower protection.
iv. If the employee wishing to make a report feels it is inappropriate to report
locally they should e-mail whistleblower@alfalaval.com
v. External Stakeholders
vi. People with whom Alfa Laval has a business or community relationship are
encouraged to speak up and to report any observed violations of the law or the
Alfa Laval Business Principles.
vii. Normally the first course of action is to report to the Managing Director of the
relevant local Alfa Laval Company .
viii. As reported on website of Alfa Laval 65If this is felt to be inappropriate the
person making a report should e-mail whistleblower@alfalaval.com
65Reference:-Retrieved from website of Alfa Laval, www.alfalaval.com india
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3.2. Project Engineering Industrial unit P
3.2.1 Introduction of Praj Industries Limited (PIL),
A global Indian company started way back in 8th November of the year 1985 with the
objective of providing cutting edge solutions to the Distillery Industry. PIL now
spread across 5 continents and 40 countries with over 350 references, which offers
innovative solutions to significantly add value in bio-ethanol, bio-diesel and brewery
plants and related wastewater treatment systems for customers, worldwide. Praj is a
knowledge-based company with expertise and experience in Bioprocesses and
engineering. It delivers know how, License, engineering design, plant & equipment,
project management, commissioning and customer care and turnkey projects.
Beginning of Praj’s journey into Agro-based process industry and the first
opportunity came from a Sugar Mill in India during the inception period. The
Company developed sprannihilator, a zero-pollution system for treatment of distillery
effluents in the year 1986. The system was subsequently given an award for
innovative concept. In the period of 1987-88, PIL had received Venture Capital from
ICICI. In 1991, Praj established an R & D Center. Many new systems had been
developed in this R & D Center, resulted into seven patents. Praj’s expertise in
fermentation and distillation was complemented by its expertise in wastewater
treatment solutions. The Company’s Sprannihilator System was given an award
during the year 1992 by the Government of India, Ministry of Chemicals &
Fertilizers. The Company undertook in-house development of Non-molasses (Starch
based) technology and engineering for grains and tubers in 1993. In the same year
1993, Praj also introduced Brewery Engineering, Plant & Equipment. Praj went to
public in the year 1994 and also the company branched out in the international market
with orders from Indonesia and Philippines. Between the periods from 1996-1999,
PIL had restructured to focus on its primary lines like ethanol technology and
equipment, wastewater treatment and brewery engineering and commissioned several
grain based ethanol plants in India. The Company had ventured into South America in
the year 2000. An office set up in Bogota, Colombia to reach out to South, Central
America and Caribbean and partner customers in the region. In the identical year of
2000, Praj manufacturing facility awarded the ISO 9002 and the prestigious ASME U
& H stamps for pressure vessels and heating boilers, also an energy saving multi-
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pressure distillation systems, introduced by the company, became an Industry
Standard. For production of Fuel grade ethanol in Vapor Phase Molecular Sieve
Dehydration plants the company made collaborates in the year 2000-02. PIL’s first
MSDH plant in India went on stream in May of the year 2002. During the period of
2000-02, the company had entered into East European Market with engineering order
for a grain-based plant, launched Multi-feed & Multi-product Ethanol technology for
round the year distillery operation and also bagged an order for Multi-feed & multi-
product plant in Maharashtra, for Vaidyanath SSK Limited. In the years between
2002-04, after the successful entry in East European Market, PIL made entry in
Australian Market with First technology and engineering order for green-field Fuel
ethanol production plant. Launched the innovation Center for advanced applied
research in the field of ethanol and brewing process under the name of Matrix,
developed Sweet Sorghum to Ethanol process, received ICORE award for the
leadership in Biofuels and commissioned a unique wastewater treatment plant in
Colombia. This technology was developed in-house. During the year 2005, Praj
commissioned two large size ethanol plants in Colombia, exclusive Export Oriented
Unit (EOU) of the company was established and the Brewery Manufacturing facility
near Pune (Sanaswadi, Unit-2) was acquired. PIL had also acquired worldwide rights
for Molecular Sieve based dehydration technology from Delta-T in the same year of
2005. All five large sized ethanol plants of the company in Colombia on stream for
commercial production from March 2006 onwards. During the same year 2006, PIL
had inked alliance with Meura for High Performance Brewery Mash Filters Praj
expands Brewery Business, Skid Mounted Ethanol Plant designed, manufactured and
shipped to CSR Australia and also the company had acquired US Engineering
Company C.J. Schneider Inc. The Company made a Joint Venture with Aker
Kvaerner in the year 2007 and established JV Company under the name of BioCnergy
Europa B.B in Netherlands. PIL’s fifth manufacturing facility in Kandla (SEZ), India
commissioned for bioethanol and biodiesel manufacturing units. In the same year of
2007, Praj had opened office in Brazil made a footprint in Biodiesel business. The
Company conferred Star SME Award 2007’ by The Business Standard. Pantaleon
Group, Guatemala awarded two large ethanol plant contracts to PIL in May of the
year 2008. Out of the two, one for 450,000 LPD (40 MGPY) at Bio Ethanol in
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Guatemala and another for 300,000 LPD (27 MGPY) at Ingenio Monte Rosa,
Nicaragua. As at 2008, Praj had awarded a contract by Maple Etanol S.R.L., Peru, a
subsidiary of Maple Energy plc, a leading integrated energy company, for a 400,000
litres per day distillery for production of fuel grade ethanol based on clarified cane
juice as feedstock. The Company has a vision of expanding in the biofuels technology
arena. For biodiesel projects, the company will offer in-house developed turnkey
solutions including technology, engineering, plant & equipment and project
management services.
3.2.2. Bio Engineering Products Praj is a global Indian company that offers innovative solutions to significantly add
value in bio-ethanol, alcohol, brewery plants, process equipment and water distillation
and wastewater treatment systems for customers, worldwide. Praj is a knowledge
based company with expertise and experience in Bioprocesses, yeast products and
engineering. It has one of the largest resource bases in the industry with over 500
references across all five continents. Led by an accomplished and caring leadership,
Praj is a socially responsible corporate citizen. Praj, which is the founding member of
Global Growth Companies (part of World Economic Forum), is listed on the Bombay
and National Stock Exchanges of India.
3.2.3 Beer.
A drink soaked in tradition of malted barley, hops and water. A tradition, which has
been integrated with science to deliver varied flavors and drinking pleasure. And,
providing seam-less integration is what the Brewery Technology Solutions (BTS)
has set as its mission. Whether it is a first time customer or an existing brewery
plant, BTS provides total brewery engineering/technology services. The key lies in
integration for optimum performance. Praj supplies Brewery Plants having world
class manufacturing capability to achieve excellent and consistent product quality at
lower cost with environment friendly technology. The final product quality
characteristics of the brewery plants depend greatly on the ingredients used and the
process conditions delivered by the Brew house technology. This is where the sound
equipment design capabilities and experience comes into picture.
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3.2.4. Waste Water Treatment & Recycling
The latest waste water treatment & recycling technologies like biomethanation,
water recycle & reuse and zero liquid discharge have been mastered at Praj.
Being a knowledge based company with over 25 years of experience, we have
the ability, technology & facility to design the most effective biomethanation,
water recycle system, water reuse options and zero liquid discharge process as
per the client’s unique requirements, no matter in which part of the world.
3.2.5. Praj Industries acquires water treatment company Neela Systems for Rs.
64 crore
a. Zero Liquid Discharge
Regulatory norms are becoming stringent concerning the limits of liquid
discharge & Wastewater treatment. To reduce impact on the environment,
increasing number of industries are going in for Zero Liquid Discharge (ZLD).
A ZLD system implies that practically no liquid waste goes outside the
boundary of the manufacturing facility. Praj offers various combinations like
Recycle & Reuse, Evaporation & Crystallization in designing Zero Liquid
Discharge Systems in accordance with the unique requirement of the
customer.
b. Recycle & Reuse
Praj is helping to meet the demand with the basket of proven technologies,
innovations and years of experience in treating most difficult effluent.
Praj’s Recycle and Reuse solutions integrate 173hysic-chemical, biological and
membrane separation process for efficient Recycle and Reuse. Solutions include
advanced effluent treatment processes like Micro filtration, Ultra filtration,
Nano filtration, Reverse Osmosis systems and Membrane Bioreactors.
3.2.6. Praj Membrane filtration systems
Praj Membrane filtration systems Consist of ecofil- ro/uf/mf/nf ecobrane-sb/xt
ecobrane is membrane Bioreactor with submerged and external configurations.
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Advantages :
a. Higher Mix Liquor Suspended Solids (MLSS) up to 25 g/L is maintained.
b. Higher organic removal efficiencies
c. 66-75% reduction in footprint as compared to conventional systems.
d. Safe, Easy and Economical Cleaning
e. Low membrane fouling and less waste sludge production.
f. Modular In design and construction
g. Minimum Civil Work
3.2.7. Demineralization (DM) Plants
Demineralization is the process by virtue of which the ions present in water are
removed using Ion Exchange Processes. It is achieved using Ion exchange resins.
Resin is an inert, insoluble polymer which has exchangeable ions. The resins that
exchange cations are cation exchange resins and those that exchange anions are
the anion exchange resins. The cation exchange resins are used in the sodium (Na+)
and hydrogen (H+) forms and the anion exchange resins are used in the hydroxide
(OH-) or free base form.
3.2.8. Waste to Energy
Waste-to-energy or energy-from-waste is the process of creating energy in the form
of electricity or heat from the incineration of waste source such as effluent with
higher COD and BOD. Praj has developed various Waste– to – Energy conversion
processes and can offer customized solutions.
3.2.9. As mentioned in Website of Praj India ltd66.Engineering Services Praj offers
the following services on End-to-End basis :
a. Design and Engineering
66Retrieved from official Website of Praj India ltd, www.praj.com
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b. Equipment Supply
c. Project Management
d. Erection and Commissioning
e. Turnkey Contracting
f. Water/Wastewater Audits and Consultancy
g. After Sales Services
3.2.10. Advantage Praj :
a. Energy Integrated systems with lowest footprints
b. End-to-End solutions for water and Wastewater treatment
c. Well-equipped manufacturing facilities
d. State-of-the-art R&D facilities
e. Leading EPC Capabilities
As mentioned in website of Praj India Ltd.67
67Retrieved from official Website of Praj India ltd, www.praj.com
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3.3. Project Engineering Industrial unit F
3.3.1 Introduction of Filtron Group
It has been providing equipment and turnkey systems to the food , beverages and
other processing industries for over two decades now. With a network of five
manufacturing units, the head office in Pune, Filtron is also associated with well-
known European process equipment manufacturing companies. Each of our Group
companies deals with a specific field of activity, i.e. Hygienic S.S. Pumps, High
Pressure Homogenizers, Centrifuges, Compact Heat Exchangers, Flow meters and
valves. We are proud to say that, our plants and equipment are well accepted
worldwide with numerous installations in India, Russia, the Gulf, Lithuania, Yemen,
East Africa, etc.
Based on the practical experience gained over the years of serving this sector ,
Filtron has an edge over the competition in providing equipment that keep customer
requirements and economics in balance. Filtron delivers what is expected out of
major engineering group viz capabilities in designing, fabrication, erection and
commission backed by excellent technical guidance and a good after sales service.
Filtron ensures Product quality by Safe and hygienic processing equipment’s with
due concern for Environmental protection through the latest designs. Filtron offers
equipment’s for: dairy farm systems, milk transportation, and milk reception, liquid
milk processing Milk storage concentration and drying complete milk handling
plants milk product manufacture we are experienced in supply of turnkey
installations of beverage processing plants and have adequate know-how of
international standards and regulations. We have a dedicated team of experts and
engineers capable of offering service worldwide. Our expertise has enabled us to bag
repeat orders from reputed clients at home and abroad.
3.3.2 Services Provided
Services Provided by Filtron as mentioned in website of Filtron India Ltd.68
68Retrieved from Website of Filtron India ltd. www.filtron.com
177
is committed to provide the customer with latest developments in food
engineering coupled with universally accepted methods of manufacture, which
can stand up to most rigorous inspection norms We supply processing plants
which can handle fruits such as: Tropical Fruits, Continental Fruits ,Citrus Fruits
We can supply vegetables processing plants encompassing vegetables washing,
cleaning, sorting, dicing, shredding, heat treatment and shrink / pouch packaging
as mentioned in Website of Filtron India ltd.69
Filtron range of manufacture covers following process equipment’s and they
offer them individually as well as either add-ons or for expansion of existing
process plants as mentioned in:
Flow Equipment’s: S.S Flow Meter, hygienic S.S pumps of both centrifugal &
positive displacement design, S. S. flow control valves and special fittings..
Compact Heat exchangers. Gasketed plate heat exchanger. Welded plate heat
exchanger.Corrugated tube heat exchanger.
Centrifuges : Batch, Basket, Vertical or horizontal centrifuges, Disc Seperators,
Decanters Evaporators & Dryers :Falling Film Evaporators, Forced circulation
or Scraped surface. Spray Dryers, Centrifugal or nozzle atomisation, Single or
multistage drying. Homogenisers &Mixers : High pressure piston type,
homogenisers and centrifugal shear mixers.
69Retrieved from Website of Filtron India ltd, www.filtron.com
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3.4 Project Engineering Industrial Unit M
3.4.1.History of MOJJ
1986 - MÖJJ was started by Highly qualified Engineers with combined experience
of 25 years, for providing Innovative solutions to Chemical and Food Industry.
Incorporated in 1986 as a Project Engineering Company to Design and deliver
custom built process Plants including Drying, Evaporation & Distillation systems,
on turnkey basis.
1991- Comp Engineering And Exports was established for Overseas Marketing of
Engineering Systems, specifically dryers & evaporators meeting International
Quality Standards, at competitive prices. The company offers a complete range of
Process Systems and Equipment for the Chemical and Food Industries
1995 - Indus Fabricons Pvt. Ltd. was acquired to create own fabrication facility
conforming to International Standards of quality construction and maintaining the
strict delivery schedules.
2005 - Comp Engineering embarked on a significant expansion plan with the setting
up of a 100% Export Oriented Unit in Pune. Today with a team of 150 dedicated
technical personnel, we offer a wide range of Turn Key Process Plants, Systems &
Equipment in the field of: Drying ,Evaporation ,Bio Ethanol, Bio Diesel
2007-08 - Today with the total team of 150 dedicated technical personnel the Group
offers a wide range of Innovative Turnkey Solutions, Systems and Equipment in the
field of Drying, Evaporation, Mixing and pollution Control. Bio-ethanol from
various feed substrates, Bio Diesel from oil bearing seeds.
3.4.2. Service Domain Provided by MOJJ
a. MÖJJ Fermentation System
b. MÖJJ Distillation System
c. MÖJJ Fuel Ethanol Plants
a. MÖJJ Fermentation System
Feed Stocks Highlights of our Fermentation System
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MÖJJ is a true blue industry leader constantly seeking innovation and
pioneering new developments. They were among the first to have expertise
and capability to deliver systems compatible with the complete gamut of raw
materials:
a. Cane molasses, cane juice, cane syrup
b. Beet molasses, beet juice
c. Grains (wheat, rice, sorghum, corn, bajra)
b. Cereals, tubers (cassava / tapioca)
c. Maximum yield
a. Highest alcohol content in fermented wash
b. Minimum side products of fermentation
c. Over 200 genetically marked stains in our yeast bank
d. Special designs for better contact between yeast and
fermented sugar
Pre-clarification / Post - clarification of cane molasses.
i. Multi feed fermentation module
ii. Yeast recycling to increase productivity
b. MÖJJ Distillation System
At they are customer driven to the core. Our distillation plants are
customized for quality, consumption and operational ease. We have state of
the art specially designed equipments enabling efficient separation of
impurities with reduced scaling and down time. MÖJJ, for the first time
introduced the concept of integrated evaporator for substantial reduction of
spent wash volume at no extra steam as provided in website of MoJJ 70
Highlights of Distillation System
i. Atmospheric, multi pressure distillation system available under one roof
ii. Better quality of all grades of alcohol due to better removal of impurities
iii. Multi-pressure distillation operates under vacuum and at low operating
temperatures which avoids hard scale
iv. Formation Improved steam economy Reduced impure spirit production
v. Less impurities hence better organoleptics
70Retrieved from Website MoJJ Engineering Systems, www.mojjpune.com
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vi. Reduction in effluent quantity by integrating by the evaporation system
vii. Optimum utility consumption fermented sugar
viii. Pre-clarification / Post - clarification of cane molasses
ix. Multi feed fermentation module
x. Yeast recycling to increase productivity
xi. Removal of impurities in fermentation stage ensures low impurities in
alcohol
c. MÖJJ Fuel Ethanol Plants
MÖJJ is driven by a passion to excel, a commitment to redefine industry
benchmarks. Their fuel ethanol plants are based on molecular sieve
technology
Highlights of our Molecular Sieve Dehydration System
i. Three bottle pressure swing adsorption enables soother transition and
longer sieve life
ii. Lowest utility consumption per liter of fuel alcohol
iii. Maximum alcohol yield (typical loss less than 0.03%)
iv. Moisture content up to 0.1% V/V
v. Component design and selection to guarantee extensive service life
vi. Fully automated with PLC/DCS based system
vii. Customised design and plant layouts to suit all customers requirements
3.4.3. Arena of Site Activities:-
a. Large Bio Ethanol Plants/Spray Dryers are constructed at site from shop
fabricated equipment’s, components and Bought out items.
b. On request civil & structural work also can be undertaken.
c. Storage tanks are generally manufactured & erected at site.
d. Trained and skilled technical fabrication professionals build / assemble at
site Large dryers from shop fabricated components.
e. Experience of erection at various locations , altitudes, Nations.
f. Timely completion using advanced modern tools.
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3.4.4. Chemical process industries
Aluminium Hydroxide, Sodium Sulphate, Pharmaceutical , Organic Metal
Formaldehyde Resins ,Fine Chemicals, Polymer Emulsions, LignoSulphonates
Dicalcium Phosphate, Mangenese Sulphate , Polystyerene Beads ,Metal Salts
3.4.5. Dyestuff & auxillaries
Reactive Dyes, Dispersing Agents, Acid Dyes, Direct Dyes, Organic Pigments
Detergents, Disperse Dyes, Inorganic Pigments, Optical Brightener, Leather
Chemicals, Basic Chromium Sulphate, Sodium Lauryl Sulphates
3.4.6. Carbohydrates
Starch, Gum, Maize / Wheat Gluten, Wheat Flour, Soya Flour, Sorbitol Malto
dextrin, Glucose / Dextrose,
3.4.7. Ceramics & minerals
Kaolin, Silica, Enamels, Sand, Coal, Limestone Ferrites, Metal Oxides
Tableware
3.4.8. Activated Earths
Mica, Alumina, Tile Slip, Insulators,
3.4.9. Natural products as mentioned in the Website of MojjIndia
Plant Extracts, Yeast,Herbal Extracts
3.5.0. Hydrolyzed Protein, Tannins, Spirulina Algae
3.5.1. Enzymes
Cellulose, Cellulose Acetate, Woods Chips, Animal Feed / Waste
3.5.2. Food stuff
Whole / Skimmed Milk, Fruit Pulp & Juices, Tea and Coffee Extract, Lactose
Egg Cheese, Casein, Food Colours, Cereals Salts
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3.5. Project Engineering Industrial Unit K
KBK Engineering Pvt Ltd.
3.5.1 Vision Statement:
To become global top three Ethanol & Renewable Energy technology company by
year 2015.
Mission Statement: To serve global customer needs with innovative applied
technologies, superior products, improved delivery cycle & products, productivity
through value & quality systems for customer satisfaction. Our products are cost
effective yet performance oriented, which are backed by proficient technical
services. At KBK, the primary focus is always on customer satisfaction. KBK
provides comprehensive training in application, analysis and up-gradation to ensure
that customer benefits are maximized. “KBK“ has the right technology, know-how,
infrastructure and project management capability to solve problems at an affordable
and reasonable cost .
“KBK” has been considered now in the industry as the “Friendly Supplier“ due to
our sincerity, honesty, transparency and ‘Solution Provider‘ attitude.
3.5.2. A Group Company of:
Shree Renuka Sugars Ltd. (www.renukasugars.com)
Head office:
Pune- Western India Multi storeyed modern corporate office & design Hub for all
KBK Engineering services across the globe.
Regional Presence: Bangalore, Belgaum, Delhi, Mumbai, Jakarta, Manila, Ethiopia.
Workshops: Two workshops in Pune, an industrial, Information Technology &
Engineering knowledge hub in western India.
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Fabrication capacity: ASME U stamping Fabrication facility with Approx 1000 Tons
Carbon Steel & 500 Tons Stainless Steel per month.
Manpower Profile: Highly qualified manpower comprising of Alcohol technologist,
Chemical Mechanical, Electrical, Instrumentation and Civil Engineers
Area of Business: Distillery, Ethanol, Bio-fuels & Cogeneration Power plants.
Product Lines : EPC turnkey plants for Potable grade alcohol (ENA), Fuel grade
Ethanol, Alcohol derivatives, Cogeneration power plants, Water & Waste water
management plants.
Raw Material: Sugarcane, Molasses, Sweet Sorghum, Grain, Corn, Cassava, Tapioca
& Cellulose.
Turnover: Postulated 09-10: INR 222.37 Crores (US Dollar 49.41 Million)
Engg Standards: Designs as per European, American, British & Japanese stds
3.5.3. Scope/ EPC Services
KBK has supplied numerous plants on Turnkey basis which includes design
engineering, supply, erection and commissioning with civil works of complete plant
including Milling, liquefaction, fermentation, distillation, evaporation, dehydration,
boiler, Turbine, cooling towers, WTP & WWTP etc. Due to this single source
approach client can optimize on the allocation of man-hours, efforts, resources,
multiple contracts, multiple vendor payments etc. Thanks to this approach, KBK is
able to incorporate the best engineering practices and optimize project costs on an
overall basis.
a. Flexibility in Scope of work:
Having said this, they at KBK do not lose any opportunity of serving the industry.
They also undertake projects or service contracts which comprise of value added
services pertaining to only design engineering or Co-generation systems or even
those comprising of technical services related to plant modifications or plant
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capacity increase. This flexibility in scope of work has been much appreciated by
our patrons and the industry in general.
b. Project management Services:
KBK being a company operating in Project business understands the nuances of
the same and provides its management inputs for effective project handling. Our
long term association with reputed clients is on account of lending our project
management expertise to clients.
c. Project integration services:
As a corporate policy KBK service portfolio extends itself to Project Integration
services thereby helping clients to integrate fermentation distillation with co-
generative power, water management services & pollution control.
3.5.4. Local standards and practices:
KBK engineering team believes in continuous upgradation of its knowledge base
with projects undertaken in India and across the globe. Implementing the local
design codes and adherence to international standards coupled with sustained
documentation of local codes helps the team in implementing the same in various
projects thereby saving costs.
3.5.5. Dedicated Vendors:
Today KBK is able to pass on the benefits of developing dedicated vendors for
machining, fabrication, steel procurement, bought out equipments etc. The cost
benefits on account of such loyal dedicated vendors are passed on to the client
thereby optimizing the project investment.
3.5.6. Project Management services:
KBK serves its customers with 200 strong team consisting of engineers and alcohol
technologists. The project management department provides project management
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solutions for overall plant configuration, speedy execution with a focus on quality
engineering. The activity starts with pre-order and post order site visit, and the
following activities sequentially follow:
a. Allotment of a single window project manager
b. Kick off meeting at site
c. Internal project scheduling, bar chart making
d. Allotment of resources for detailed engineering
e. Monitoring of drawings progress
f. Site mobilization
g. Co-ordination with purchase department for vendor order placement and
h. Material / equipment dispatch at siteAfter Sales engineers and coordinators.
The after sales service department is fortunate to have a collective site
experience of 250 years.
As provided in Website of KBK Engineering Pvt Ltd71.All site related issues are
sorted out by the engineers on field in India and abroad within a reasonable time.
While rectification of unstable process operation takes a longer time but mechanical
and operation related issues are sorted out within 48 hours.The team consists of
engineers from different faculties like civil, structural, mechanical, chemical,
electrical, instrumentation & alcohol technologists.
71Retrieved from Website of KBK Engineering Pvt Ltd. www.KBKchem.com
186
3.6. Project Engineering Industrial Unit Z
3.6.1. History of Ziemann
About Us
It is not only the experience and reliability, and it is not only the innovation and
know-how that make customers around the world rely on and trust Ziemann group as
brewery technology and turn-key solution provider, it is the vision their customers
share with them.The vision of developing and implementing brewery plants that
operates most efficiently and effectively in the long run while producing optimum
product quality together with a fast return on investments and low life-cycle costs.
Aim / Vision / Mission
The vision of developing and implementing brewery plants that operates most
efficiently and effectively in the long run while producing optimum product quality
together with a fast return on investments and low life-cycle costs.
Testing Facilities
“Pioneer and Innovator”–these are words that describe Ziemann best.
More than 150 years have passed and Ziemann still continues to search for and to
develop new and reliable technological and technical solutions for breweries.
“Trial and Error not at Ziemann. Ziemann uses a scientific approach in its research
and development of new technologies and techniques. The unique Pilot Brewery at
the Ziemann headquarters in Ludwigsburg/Germany enables us to thoroughly test
new technologies to ensure optimum performance and reliability.
Fast and up-to-date reports on special highlights and interesting background
information on Ziemann’s global activities: The „Brewing world“is packed with
details on international projects and innovations of the Ziemann group.
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3.6.2 Filling Solutions Services
Palletizing units of Ziemann-bms in portal design are robust, compact and tried
and tested machines. By means of their modular design any kind of
depalletzing, palletizing or the combination of both functions is easily possible.
The stable stainless steel frame in welded design guarantees a secure, vibration-
free movement of the lift truck. Manifold gripper systems, such as clamping
grippers, hook grippers, combined hook grippers, roll conveyor grippers make
our palletizing units flexible for the handling of any kind of beverage crates,
trays and shrinks. Compact design and precise functionality – our palletizing
units are designed for highest load requirements. The programmable axe control
system and our product-optimized gripper systems ensure rapid operation, an
optimal and gentle handling of the crates as well as a high stacking quality.
3.6.2. Packaging Solution Services
Our modular packaging machines are designed for low, medium and high
capacity ranges – depending on the performance required. A compact design, a
robust stainless steel construction and a specifically developed fully-automatic
control system guarantee long-life cycles and reliability in daily use.
Our pick-and place packers are robust, tried and tested precision machines for
packing and unpacking of all common containers such as bottles, glasses,
plastic cans, cans in wooden or low-wall crates and trays. The basic machines of
the intermittent working pick-and-place packers are designed in resistant
welded construction made of stainless steel and can therefore meet the high
mechanical demands on the packing head in each capacity range.
3.6.3. Design Services
a. Why taking care of design ?
b. Your brewery is not only a production facility but also a "brand icon"
c. A brewery designed by Ziemann stands for :
d. Highest manufacturing standards
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e. Cleanliness and hygiene Added value
f. Becomes a show piece for the brewery and its brand
g. Enhanced corporate image
h. Ziemann is proud of having implemented many economic but also appealing
designs for breweries worldwide. Have a look at our credentials and see for
yourself!
3.6.4. Documentation Services
In addition to thorough and intensive training of the brewery staff by our
experts, Ziemann also provides detailed operation and maintenance
documentation. This documentation will provide the brewery and its operators
with clear guidance and manuals to ensure effective and efficient operation of
the plant. As mentioned on Website of Ziemann India Pvt Ltd .72
3.6.5. Conveying Solution Services
Our conveying systems in modular design offer all vertical and horizontal
transportation and conveying options for bottles, containers and pallets. Even
within a limited space Ziemann-bms conveying systems provide for an
orderly and rapid material flow. Due to our modular system, subsequent
modifications in the route
72Retrieved from Website of Ziemann India Pvt Ltd , www.Ziemann.com pune