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M/s. KALEESUWARI REFINERY PRIVATE LIMITED P.RAMACHANDRAN – GM OPERATIONS J.BALAJI – AGM ENGINEERING V.MAGESH – MANAGER UTILITY 1
M/s. KALEESUWARI REFINERY PRIVATE
LIMITED
P.RAMACHANDRAN – GM OPERATIONS
J.BALAJI – AGM ENGINEERING
V.MAGESH – MANAGER UTILITY
1
M/s. Kaleesuwari Refinery Private Limited
Since our inception in 1993, Kaleesuwari Refinery Private Limited,
0.6 Billion USD group has persevered in overwhelming millions of
consumers through our undaunted mission of delivering Health and
Happiness by creating, developing and marketing superior quality
products.
In 1994, Kaleesuwari Refinery Private Limited redefined the refined
edible oil space with the launch of the flagship brand
Gold Winner Refined Sunflower Oil.
Headquartered out of Chennai (Tamil Nadu), Kaleesuwari Refinery
Private Limited has four modernized manufacturing units in India –
Chennai, Palani, Kakinada & Tumkur.
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Major Brand portfolios:
Gold winner Refined sunflower oil, Gold winner Refined Groundnut oil, Gold
winner Vanaspati, Vedhas gold filtered groundnut oil, Fedora olive oil, Cardia life, Orysa
Refined Rice bran oil, Paalm super RBD Palm olein, Pure plus coconut oil, Eldia pure
coconut oil, Dheepam lamp oil, Cream gold bakery shortening, Puff king, Cream gold, Gold
choice, Masterpiece, So soft margarine and Shree gold Range of Dals.
Production of Bio Diesel.
Harnessing and utilizing renewable wind energy from our privately operated windmills
As a high-profile edible oil company, we will strive to lead by example to meet the
highest energy management standards and be at the forefront of sustainable
development as a standard bearer for good environmental and resource management.
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M/s. Kaleesuwari Refinery Private Limited
3
Energy Consumption Overview
ParametersUnit of
Measurements2016-17 2017-18 2018-19 2019-20
Production Data Tons 2,28,494 2,13,025 2,42,624 2,66,571
Annual Electrical
Energy consumptionmillion kwh 11.540 9.814 10.454 11.277
Annual thermal Energy
Consumptionmillion kcal 58,916 52,988 59,867 63,870
Overall energy
consumptionTOE 6884 6143 6886 7357
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Energy Consumption Overview
-
10,000.00
20,000.00
30,000.00
40,000.00
50,000.00
60,000.00
70,000.00
ANNUAL THERMAL ENERGY CONSUMPTION (MKCAL)
OVERALL ENERGY CONSUMPTION (TOE)
ANNUAL ELECTRICAL ENERGY CONSUMPTION (MKWH)
63,870.41
7,356.65
11.28
Va
lue
Energy Parameters
2019-20 Energy Parameters
Annual thermal Energy Consumption (Mkcal) Overall energy consumption (TOE) Annual Electrical Energy consumption (MKWh)
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Sp. Energy Consumption for FY 2016-20
ParametersUnit of
Measurements2016-17 2017-18 2018-19 2019-20
Production Data Tons 2,28,494 2,13,025 2,42,624 2,66,571
Specific electrical energy
consumption
kwh/ton of
Prod
50.51 46.07 43.09 42.30
Specific thermal energy
consumption
kcal/ton of
Prod
2,57,847 2,48,739 2,46,749 2,39,600
Specific Overall energy
consumption
TOE / ton of
Prod
0.0301 0.0288 0.0284 0.0276
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Sp. Electrical Energy Consumption / ton of Prod
5146
43 42
0
10
20
30
40
50
60
SP.
ELEC
TR
ICA
L E
NER
GY
CO
NSU
MPT
ION
FINANCIAL YEAR
Specific Electrical Energy Consumption
2016-17 2017-18 2018-19 2019-20
Percentage of drop
17.65% from 2016 to
2020 by our energy
management measures
51
46
4342
38
40
42
44
46
48
50
52
2016-17 2017-18 2018-19 2019-20
SP.E
LEC
EN
ER
GY
CO
NSU
MPT
ION
FINANCIAL YEAR
Specific Electrical Energy Consumption
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Sp. Thermal Energy Consumption / ton of Prod
Percentage of drop
7.08% from 2016 to
2020 by our energy
management measures257847 248739 246749 239600
0
50000
100000
150000
200000
250000
300000
FINANCIAL YEAR
Specific Thermal Energy Consumption
2016-17 2017-18 2018-19 2019-20257847
248739
246749
239600
230000
235000
240000
245000
250000
255000
260000
2016-17 2017-18 2018-19 2019-20
SP.
TH
ER
MA
L E
NER
GY
CO
NSU
MPT
ION
FINANCIAL YEAR
Specific Thermal Energy Consumption
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Information on Competitors, National &
Global benchmark
➢ We have 4 factories. We used to benchmark Common
products in terms of Unit per Tons, Steam Kcal /Tons, Water
KL/Tons and Manpower per Tons.
➢ We are collecting the data from CII, BEE, Golden Peacock
Forums against our competitors Marico, Adani wilmar, etc., to
set our long term goal.( TARGET-2022)
➢ We strive to be a global multinational company by the way of
conversation cost reduction using green energy, high
productivity people, using state of art global equipment's
supplied by Desmet Ballestra Private Limited (Belgium based
company, no.1 in edible oil equipment supplier Industry)
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Road map to achieve the target
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Major Encon Project Planned in FY 2020-21
❖ 750Kw Roof Top Solar system.
❖ Ejector Nozzle alteration.
❖ Energy Efficient VAM Optimisation.
❖ PLF Condensate heat recovery.
❖ Waste cartons as fuel for Hot water generator.
❖ Upgradation of windmills.
❖ Re-Engineering to upgrade from 400 to 600 TPD Palm oil
Plant.
❖ Chilled water Vacuum system to reduce 75KLD water and
one ton of steam per Hr.
❖ New Modernized WTP & ETP ( Existing one 15 years Old).
Target- 2021-22.
❖ Fully Automatic Packing automation.(Spanish Technology to
reduce 40 manpower per day)
❖ Utilization of Rainwater harvesting
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Energy Saving projects implemented
Year No of Proposals Investments Savings
2016-18 13 Rs.33.25 lakhs Rs.186 lakhs
2018-19 5 Rs.28.25 lakhs Rs.498 lakhs
2019-2020 8 Rs.78.3 lakhs Rs.143 lakhs
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Energy Saving projects implemented
Sl.
No
Project Details Investments
Rs. In lakhs
Savings
Rs. In lakhs
Payback
1 Ref-4 Energy Efficient
VAM
30 92 4 months
2 Ref-4 Barometric
pump alteration
0.2 33 3 days
3 Elimination of chain
conveyors
0.65 3.20 3 months
4 Ref-4 822 pump pipe
line modification
0.75 3.8 3 months
5 Ref-2 Steam PRV 0.5 9 1 month
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Energy Saving projects implemented
Sl.
No
Project Details Investments
Rs. In lakhs
Savings
Rs. In lakhs
Payback
6 Ref-4 CCT pump
alteration
0.3 30 4 days
7 Ref-4 Steam line
alteration
1 23 1 month
8 Ref-4 801 pump pipe
line modification
0.75 3.8 3 months
9 Ref-2 Vacuum pump
elimination
0.5 4 2 months
10 Ref-1 Barometric
pump alteration
0.15 3.8 1 month
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Energy Saving projects implemented
Sl.
No
Project Details Investments
Rs. In lakhs
Savings
Rs. In lakhs
Payback
11 Ref-4 cooling tower
motor IE3 changeover
1.7 5 5 months
12 Ref-4 Slurry mixer
gearbox alteration
0.25 2.7 2 months
13 Ref-4 682B alternate
Pump arrangement
0.2 2.4 1 month
14 Vanaspati Plant
steam line alteration
1 7.5 2 months
15 Ref-1 Cooling tower
pump alteration
0.35 5.4 1 month
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Innovative Projects implemented
➢ Initially we refined 660 tons per day in our refinery.
➢ We studied and analyzed the entire process like process
vessel capacity, Pumps flow rate, motor current drawn, PHE’s,
existing pipeline etc., and found there is scope to increase the
production capacity by 6 to 8%.
➢ We modified some pipelines in the vessels, added some plates
in existing PHE’s and procured some new PHE’s for the
process.
➢ We achieved 710 tons per day regularly after doing the above
modification.
1) RSF Plant Re-engineering
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Innovative Projects implemented
➢ Total Cost spend for the Re-engineering of RSF Plant is
Rs.26/- lakhs.
➢
➢ Thereby saving Rs.4.66/- Crores per annum with payback
period of 0.5 months (274/MT * 2,27,000 MT*0.75).
1) RSF Plant Re-engineering
Parameters Before
Modification
After
Modification
Steam (Kg/MT) 280 272
Power (KW/MT) 26.5 24.25
Operational cost
(Rs./MT)
1440 1166
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Innovative Projects implemented
➢ Initially we refined 200 tons per day in our refinery.
➢ We studied and analyzed the entire process like process
vessel capacity, Pumps flow rate, motor current drawn, PHE’s,
existing pipeline etc., and found there is scope to increase the
production capacity by 40 to 50% by addition of some
equipment's.
➢ We modified some pipelines in the process vessels, added one
more PLF and procured new PHE’s for the process.
➢ We achieved 300 tons per day regularly after doing the above
modification.
2) Palm oil Plant Re-engineering
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Innovative Projects implemented
➢ Total Cost spend for the Re-engineering of Palm oil Plant is
Rs.75/- lakhs.
➢
➢ Thereby saving Rs.1.2/- Crores with payback period of 7.5
months (1143/MT * 14,000 MT*0.75 - 3 months Production)
2) Palm oil Plant Re-engineering
Parameters Before
Modification
After
Modification
Steam (Kg/MT) 565 266
Power (KW/MT) 30.8 22.86
Operational cost
(Rs./MT)
1966 823
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Innovative Projects implemented
➢ Initially we recovered 78% of Olein from Refined Palm Oil.
➢ Initially we operated air compressor for squeezing the filter
press up to 6 bar.
➢ After modification of the above, we recovered Palm olein up to
85% from refined Palm Oil.
➢ We used olein as medium to squeeze the filter press up to 16
bar pressure and thereby avoiding compressed air.
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2) Palm oil Plant Re-engineering
Innovative Projects implemented
➢ Faced frequent problems in Stacker machines, which is used
in warehouse for stacking and unstacking the filled pallets.
➢ Formed Quality circle team to identify the problem and solve
them by using proper QC tools .
➢ Found the machine is improper design and not suitable for
existing operation.
➢ Solution given to them is to place the light weight material in
the top rack and heavy material in the bottom rack.
➢ Thereby reducing maintenance cost and avoided purchasing
of 3 new stacker machines of cost Rs.30 lakhs.
3) Stacker Machine
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Utilisation of Renewable Energy sources
Technology
(electrical)
Year Type of
Energy
Onsite /
Offsite
Installed
Capacity
(MW)
Generation
(million
kWh)
% of
overall
electrical
energy
Windmill 2017/18 Electrical Offsite 2.7 5.57385 56.79%
Windmill 2018/19 Electrical Offsite 2.7 4.77754 45.7%
Windmill 2019/20 Electrical Offsite 2.7 5.08711 45.11%
Technology
(thermal)
Year Type of
Energy
Installed
Capacity of
Boiler
Heat Produced
(million KCal)
% of overall
thermal
energy
Boiler 2017/18 Thermal 4 Ton 550 1.22%
Boiler 2018/19 Thermal 4 Ton 511 1.02%
Boiler 2019/20 Thermal 4 Ton 471 0.88%
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Utilisation of Renewable Energy
➢ Our Own Vegetable oil base Biodiesel as fuel for our
Vehicles
➢ Hot water generation using Waste oil strained carton boxes
and garden waste.
➢ Utilizing the Existing Windmills effectively and planning to
increase the capacity.
➢ Solar Sludge drying bed.
➢ Fixed Polycarbonate sheets for Roof area for natural
ventilation.
➢ Fixed Roof top Air turbo ventilators for natural air movement
➢ Utilized the existing resources to produce 720 tons per day
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Waste utilization and management
Sl.
No
Year Waste
Details
Qty
(MT)
GCV Heat value
(Mkcal)
Waste as %
of total fuel
1 2017-18 Carton box, wood
& waste oil367 2500 550 2.18%
2 2018-19 Carton box, wood
& waste oil340 2500 511 2.03%
3 2019-20 Carton box, wood
& waste oil314 2500 471 1.87%
Sl. No Type of
waste
generated
Quantity of waste generated (MT/year) Disposal
method
2017-18 2018-19 2019-20
1 Paper 64.5 72.5 59.63 Recycle
2 Plastic 77.64 95.4 50.73 Recycle
3 Metal 130.259 210.898 92.614 Recycle
After starting implementation of 5S, waste generation reduced in 2019-2020
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GHG Inventorisation
➢ We have our own State-art Biodiesel Plant. Biodiesel is generating from
Vegetable oil and are supplying to various industries to reduce diesel
consumption and improve unconventional energy.
➢ 40 no's of our own Vehicles are using 50% of Biodiesel mixed with
Diesel. We are planned to increase 50% to 80% of usage.
➢ Year on year 10% increase in Renewable energy implementation.
➢ Emission Details: (7.08% drop from 2016 to 2020)
Year
Kg of Co2 per
ton of Prod
16-17 127
17-18 122
18-19 121
19-20 118
25
127
122121
118
112
114
116
118
120
122
124
126
128
16-17 17-18 18-19 19-20
KG
OF C
O2 P
ER
TO
N O
F P
RO
D.
FINANCIAL YEAR
Kg of Co2 per ton of Prod
❖ Usage of Bio-diesel – to reduce the fossil fuel.
❖ Recyclable plastic used in pouch packing.
❖ Successful Implementation of SAP S4 HANA Server to
get quick data.
❖ Truck utilization increased from 96% to 98% by
rearrangement, thereby reducing transportation and fuel
cost.
Initiatives taken in supply chain
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Energy Management Team
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Employee Involvement & Monitoring
M/s. Kaleesuwari Refinery Private Limited is committed to
minimizing our impact on the environment as far as possible, in order
to preserve our environment for the benefit of present and future
generations. We aim to deliver on this commitment by: -
• Promoting the concept of energy efficiency at all levels in the
organization among the workforce and top management.
• Identifying and implementing energy efficient technologies.
• Developing energy conservation maps and setting energy
conservation Key result areas to the team.
• Continuous training on energy conservation and new technologies.
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Employee Involvement & Monitoring
• Ensuring that adequate resources to enable the energy
policy to be implemented.
• Benchmarking energy usage with international / national
industry.
• Ensure continual improvement, Kaizen in energy
performance on electricity, steam, water and waste
reduction.
• Minimize the environmental effects as a part of social
responsibilities.
“We are committed to reduce the specific energy consumption per ton
of production in our organisation and conserve the precious energy”
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KAIZEN SHEET
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ENERGY ACTION PLANNING
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Training Photos
SYSTEM CERTIFICATION
❖ ISO 9001:2015 (Quality Management systems)
❖ ISO 22000:2005 (Food safety Management)
❖ HACCP (Food safety Management)
❖ BRC (Food safety Management)
❖ HALAL (Export –Islamic regulation)
❖ KOSHER (Export – Jewish regulation)
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Investment of Energy saving Projects
❖ ISO 45001:2018 (OHSAS, Target: 2021-22)
❖ ISO 14001:2015 (Environmental Management, Target: 2021-22)
❖ ISO 50001 (Energy Management system, Target: 2022-23
CERTIFICATION PLANNED
❖ 1.8% investment of energy saving projects on total
turnover of the company.
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Other Innovative technologies implemented
➢ IOT – Monitoring of Packing Operation & Refinery operation
offline. (Sep-2019)
➢ Boiler Operation Monitoring using video camera.( Dec2019)
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Other Innovative technologies implemented
Robot based Palletization in the
packing department.
Planning to replace Cupronickel
Condenser to use High TDS
water.
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Other Innovative technologies implemented
ETP Sludge, Garden waste, animal waste all are blended and
mixed with biodegradable enzymes for Decomposition (90 days).
Thereby using for our own agriculture activities.
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Long Term Vision on Energy Efficiency
To become a best 5 energy efficient Edible oil FMCG company in 3
years time.
Being an Edible oil FMCG ,to build a good rapport with FMCG’s, MNC’s
to understand and implement best practices, energy efficiency
measures, waste management to achieve an long term business goals.
Strived by Top management strategy to implement Energy efficiency
measures to make factory as profit centre instead of cost centre.
M/s. Kaleesuwari Refinery Private Limited is committed to minimizing
impact on the environment in order to preserve our environment for the
benefit of present and future generations using Systematic
implementation
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OTHER INFORMATIONS
# Awarded APPRECIATION SAFETY AWARD for Highest safe
Manhours by Directorate of Industrial safety and Health, Government
of Tamilnadu.
# Implemented Quality Circle - Identified the problems and solved
them by using proper QC tools.
# Kaleesuwari Foundation with the help of our workforce donated
essential things like Atta, vegetables, rice and Dal to 5000 families in
and around our factory.
# 5s Implementation
UNDER PROGRESS.
( 2s completed…)
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