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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

175

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

180

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