Environment Report
The Takwe factory has been certified to ISO 14001 standards in 2001. We are committed to the cause of environment through an Environmental policy that stresses on continual improvement and prevention of pollution, through recycling initiatives, resource conservation and legal compliance.
During the past few years our focus areas were energy conservation and transport impact reduction, in line with our Global Environmental Initiatives.
Electrical Energy consumption that was 30.9 GJ/ MSP(giga joules per million standard packs) in 2002 has been reduced to 28.02GJ/MSP by 2003 end and is targeted to reach 25.9 GJ/MSP by 2005 end , a 15% reduction in 3 years. The major step in this effort has been the installation of Exhaust heat recovery based chiller of Thermax make on our Diesel generator sets. Diesel engines are able to harness only 38% of the energy content in the fuel, the rest being lost as heat in the exhaust gases and the cooling water. Our new system uses this waste heat to warm up water and this warm water runs a Vapour Absorption Chiller. Thus we are able to utilize about 62% of the energy content in the fuel. About 30% of our total energy consumption was for chilling (used for process water chilling and plant air conditioning). The new waste heat recovery based chiller has reduced our total power demand by 10%. This is borne out by the energy consumption figures given above.
In Tetra Paks manufacturing operations, transport has a very significant impact on environment. Even though our package reduces the transport requirement for food packaging to a very large extent, factory operations necessitate raw material and finished goods transport from and to the factory.
For Pune factory the major transport was of Raw materials from Mumbai port to the factory and of finished goods for exports from factory to the Mumbai port. It was estimated in 2002 that each ton of material required 10.6 Liters of diesel to move from Mumbai port to Takwe factory. By various steps taken the fuel consumption stands at 6.0litres/ton at the end of 2003. This was made possible by the following measures
- Utilizing full capacity of containers by getting paper rolls in high cube containers
- Utilizing containers bringing raw materials from port to factory for transporting finished goods from factory to the port
- Transporting Polyethylene loose in containers instead of cardboard boxes and storing in silos, thus utilizing full capacity of containers
Waste reduction is a continual improvement target for our factory. Production waste results in the loss of many other resources, besides the wasted product, and hence its control is a very important environmental goal. The waste was 8.4% (by value) in 2003 while it is targeted to be reduced to 7.5% in 2004. Waste reduction was possible in 2003 by the following means
- Reduction of trim waste by installation of new die
- Reduction is set up time
- Better print quality control by Futec inspection system
- New rewinder shafts for printer and laminator
The factory handles its waste in line with Tetra Paks corporate guidelines. We recycle 96% of the waste produced in the factory. At present the rest goes into landfill. Laminated paper waste is sent directly to the Ecolink board manufacturing facility set up with the help of Tetra Pak.
We recycle all waste water generated on our factory site. Waste water from printer is filtered for removing color pigments and then treated in the Sewage treatment plant.
The waste water from Product development centre requires special treatment. For this purpose a Pretreatment plant is installed in Takwe factory. The pretreated water is of the quality of ordinary sewage and can be treated in the Sewage treatment plant(STP).The treated water from the STP is used in the garden.
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