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Jubilant Life Sciences Ltd

TQM FORUM FOR ORGANISATIONAL EXCELLENCE – 2012. Excellence in Water Management. Jubilant Life Sciences Ltd. Nanjangud, Mysore. Company Profile. Preclinical. Clinical. Discovery. Global position # 1 Pyridine and its derivatives Anti depression & Anti epileptic

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Jubilant Life Sciences Ltd

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  1. TQM FORUM FOR ORGANISATIONAL EXCELLENCE – 2012 Excellence in Water Management Jubilant Life Sciences Ltd Nanjangud, Mysore

  2. Company Profile Preclinical Clinical Discovery Global position # 1 Pyridine and its derivatives Anti depression & Anti epileptic Carbamazapine(Nanjangud) Oxcarbazepine (Nanjangud) Lamotrigine (Nanjangud) – Central Nervous system Global Position # 2 Citalopram(Nanjangud)–Anti Depressant Respiridone (Nanjangud) – Anti Psychotic Global Position # 3 – Specialty Chemicals Niacin & Niacinamide Allergenic Extracts Acetaldehyde Vinyl Pyridine Latex Food Polymers Jubilant Group An India Based Multinational group… CMC

  3. Bulk products Manufacturing & their use

  4. Bulk products Manufacturing & their use

  5. Regulatory Approval from Globe

  6. Company Profile- Global Footprint

  7. Aerial View – Jubilant Nanjangud ETP

  8. Chairman’s Msg. - Sustainable Development • Sustainability approach was initiated in 2003. We are continuously working on the “Triple bottom line” - Environmental, Economic, Safety and Social development. • In continuation with our philosophy of Sustainable Development the focus of new Company remains in the areas of the “Triple bottom line”. • The Company makes sure to improve the socio-economic environment. • The Company communicated to employees to use water, paper, steam and electricity judiciously. Employee awareness on energy conservation was enhanced through sharing of knowledge and good practices. • The Company continued various initiatives of energy conservation to mitigate climate change. The activities for utilization of day light, replacement of incandescent bulbs with CFL, creation of Environmental awareness to observe Earth Hour, World Environment Day etc.

  9. Jubilant Policies

  10. Jubilant Policies

  11. Reduction in specific water consumption for last 3 years * Excess water due to New Plant equipment clean-up as per GMP practices, performance & calibration trail Water cost increased from Rs 12 /KL to Rs 24 KL last year

  12. Comparison with Global norms/benchmark data Plant Specific water consumption, m3/ton Jubilant Average water consumption for the Process is in the range of 44 – 60 m3/Ton Source of information: Guideline for optimum water consumption in Bulk Drugs Manufacturing Industry By CPCB,MOEF –August-2007 Programme Objective Series Probes/117/2007

  13. Road map or guideline for optimum water consumption in bulk drugs manufacturing industry

  14. Reduction in Industrial Waste water discharge in last 3 years

  15. Reduction in Domestic Waste water discharge in last 3 years

  16. Per capita Water Consumption • By Photo sensing water flush system in Toilet. • Installation of Press types water tapes. • Reduction in water consumption by providing overhead tank in place of pressurized water • Posters.

  17. Monitoring & Reporting Systems • Daily monitoring Report _ MIS

  18. Monitoring & Reporting Systems • Daily monitoring Report _ MIS

  19. Monitoring & Reporting Systems • Metering & Recording KIADB main incoming meter Water meter after treatment Utility Feed inlet meter Utility Effluent inlet to RO system meter DM Plant outlet meter Log book 10 additional meter was installed in new locations for better monitoring & control on water consumption pattern.

  20. Last 3 yrs Water Conservation Projects

  21. Last 3 yrs Water Conservation Projects

  22. ZERO LIQUID DISCHARGE –ETP TEE PCTP Stripper RO Cooling Tower B/d FCE BTP Inorganic cake ATFD

  23. ZERO LIQUID DISCHARGE –ETP Stripper Effluent from the plant Clarifloculation Equalization & Neutralisation Incinerable Hazardous waste Multiple Effect Evaporator Stationary Pyrolyser 1, & 2 Drum Pyrolyser 1,2 & 3 Concentrate Sludge from filter press Condensate Filtrate Biological Treatment Plant Sludge Post Combustion Chamber Pressure Sand Filter Forced Cir. Evaporator ATFD + Scrubber Reject Reverse Osmosis Plant Ash to Secure land fill Spray Dryer Permeate • Zero liquid discharge • All Solid Wastes Incinerated • All gases treated to meet prescribed norms Cyclone Separator Cooling Tower Makeup Venturi Scrubber CT Blow down Droplet Separator Stack (50 m) Liquid Treatment Zero Liquid Discharge Solid Treatment TreatedGas

  24. 1) Recycling of RO Permeate to Cooling Tower

  25. 2) Rain Water Harvesting - From Roof Top

  26. 3) Flash steam Recovery at Effluent treatment plant • In effluent treatment plant, for concentrating the effluent, it is drying in FCE, ATFD. Steam is a used for evaporation. • The condensates is recycled as boiler feed water. Flash steam generation from these condensate is about 75 kg/hr @ 0.2 bar. This will reduce equivalent make up water addition in boiler. The annual water consumption reduction by this project is 504 KL.

  27. 4) Steam Economy Improvement in TEE Design / Target : 0.270 kg of steam / Lt of water evaporation • The annual water reduction by this project is 1380 KL.

  28. 5) Water Seepage arresting in Fire Hydrant System • Annual Water reduction by Fire Hydrant seepage arresting was 2160 KL. And this also reduce the nallah treatment water generation & cost.

  29. 6) EFFLUENT STREAM SEGREGATION - APPROACH Material balance Site water balance Agree upon quantities with concerned generators Identify / Quantify streams Controlled reception of effluent through magnetic flowmeter Characterize streams Streams will technically be reviewed to recover organics/ outsourcing Categorize stream Segregate streams C1 streams (Lean streams) 0<COD<10000 ppm 0<TDS<5000 ppm C2 streams (Concentrated streams) 10000<COD<80000 ppm TDS>5000 ppm C3 streams (Highly concentrated ) COD>80000 ppm RO/STP/BTP PCTP Out sourcing opportunities

  30. EFFLUENT CATEGORY C1 streams Lean streams 0<COD<10000 ppm 0<TDS<5000 ppm Steam condensate Wash basin Eye wash Floor cleaning Utility effluent C2 streams Concentrated streams 10000<COD<80000 ppm TDS>5000 ppm Process effluent Equipment washing C3 streams Highly Concentrated COD>80000 ppm 1. Process effluent

  31. EFFLUENT PIT CATEGORY P-2 lean & Conc. Effl. pit P-4 Conc. Effl. pit

  32. 7) SEWAGE TREATMENT PLANT – 100KLD

  33. 8) Clean In Place (CIP) at, High Pr. Jet cleaning for all process Equipment

  34. 8) Clean In Place (CIP) at, High Pr. Jet cleaning for all process Equipment • Annual Water reduction by CIP is 5040 KL and corresponding Effluent load. • Financial Benefits is Rs 11.0 Lac.

  35. FY 10-11 - Project Summary

  36. Specific planned step for futurity preservation of Environment • 1. New Domestic Effluent Treatment Plant • Existing 20 KLD STP was expanded to 100 KLD capacity in view with increase in No. of employees. • Treated water is used in Gardening in place of fresh water. 2. Green Chemistry

  37. Specific planned step for futurity preservation of Environment 3. Pressure Swing Absorption • Removal of Moisture from Solvents • Improving Solvent Recovery • Reduction in VOC. 4. Environmental Friendly Innovative Design of New Plant

  38. Specific planned step for futurity preservation of Environment 5. Improved Effluent Management Stripper Installation of New Incinerator for better environment friendly solid disposal. Installation of New TEE, FCE, ATFD is under progress for treating the proposed increasing effluent load.

  39. Powder Transfer System (PTS) Installation Eliminate Powder dust to atmosphere and help in maintaining Healthy Environment

  40. Certificates OHSAS 18001:2007 ISO 14001:2004

  41. Initiatives taken awareness to Company employees 1. Internal Team meeting & Awareness training

  42. Initiatives taken awareness to Company employees & nearby Community 2. Awareness Posters 3. Awareness program to Local community on water conservation at Kallahalli Village

  43. Initiatives taken awareness to nearby Community Before Cleaning the drinking water tank at Kallahalli Village Pure it - Water Filter to Anganawadi centre at Kallahalli After Cleaning the drinking water tank & facility Upgraded at Kallahalli village

  44. Initiatives taken awareness to nearby Community 1. Drinking Water Facility implementation at Korehundi School, Nanjangud 2. Water Facility to Kallahalli Village

  45. Targeting anti pollution drives against ground and surface water pollution Jubilant Life Sciences Ltd (JLSL) took a plantation campaign to plant more trees inside the premises and tree saplings across premises as shown in below Sri. A.S.Sadashivaiah, Chairman, KSPCB planting the sapling at site

  46. Targeting anti pollution drives against ground and surface water pollution JLSL took a plantation campaign to plant more trees inside the premises and tree saplings across premises as shown in below Sri. Mr.Somappa, TAC Member, KSPCB planting the sapling at site

  47. Targeting anti pollution drives against ground and surface water pollution JLSL took a plantation campaign to plant more trees inside the premises and tree saplings across premises as shown in below JLSL employees planting saplings at site Crops grown with STP water

  48. Awards Mr. B. Mitra Sr.V.P. (O)receiving Golden Peacock Award 2010 from Dr Ola Ullsten, Former Prime Minister of Sweden and Dr. MadhavMehra, President, World Council for Corporate Governance at National Liberal Club, London on 29th July, 2010 7th National Award for Excellence in Water Management 2010 organised by CII – Godrej Green Business Centre at CII – Godrej Green Business Centre, Hyderabad

  49. Awards CII’s National Award for Excellence in Water Management 2011, 25th November 2011, Jaipur

  50. COST OF WATER AS APPLICABLE TO JUBILANT

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