Sundram Fasteners Limited

Established in 1966
Sales: US$ 555 million
Global manufacturing presence: India, China, UK and Germany
Comprising of 12 manufacturing plants
First Indian company to get ISO 9000

Winner of TPM special/ TPM excellence/ TPM consistency award

Global customer base
Unique IR record: not a single working day lost since inception

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SFL ,Krishnapuram Plant

Establishment

16th March 1981

Location

Aviyur Village , Virudhunagar District.

Products Manufactured

High Tensile Fasteners - Bolts, Nuts, Studs, Screws

Powder Metallurgy Parts

No. of Employees

408

Annual Sales -

(2014-15)

USD 52.66 million

Export Sales - (2014-15)

USD 6.48 million

Total Land Area

85 Acres ( 360,000 Sq.M )

Total Built-up Area

23,178 Sq.M (6.5%)

Green Cover & Open areas

93.50%

Varieties & Range

2000 parts nos

High tensile fasteners - Bolts, Nuts, Screws,sockets
Powder Metal Parts

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Milestones of KPM
2012
TN Govt.
GREEN
Award

2008
TPM
Special
Award

2001
ISO 14001
2006
SHE Award
1998
TPM
Excellence
Award

1981
Start of
Production

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2013
Greenco
Gold

1990
ISO 9002

Journey to become a Greenco

Registration with CII and Training Nov12
Formation of CFTs - Dec13
Awareness and Training programmes - Jan13 to
Mar13
Handholding visits by CII -Feb13
Celebrating Greenco Month - Jun13
Document Submission Oct13
Final assessment Nov13
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Schematic Process Flow Chart - Fastener

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Best Practices in Waste Water Management

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Background of the project

Factory Location
Krishnapuram
40-60 cm. annual
rainfall

Located in dry area

Has scanty rainfall
Ground water at high depths

Even that water not suitable for

industrial use
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Stream segregation
Sources of effluent
Metal
finishing

Zinc
plating

Acid/
alkali
wash

Domestic
(canteen, toilet)

Zinc
phospahting

Zinc wash

ETP
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Coil
phosphating

Chrome
wash

STP

Early Days
190 KL / Day

IETP
190 KL / Day
220 KL /day

B/O
Water

Process
30 KL / day

Domestic
usage
220 KL /
day

Bought out water 100 %

Recycle 0 %
Water consumption 220 KL / day
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Sewage
Treatment
30 KL
day

Dischar
ge to
ground

Recycle Stage 1 RO I
Reuse
175KL
250 KL / day

IETP

RO I stage

250 KL / day

Process
B/O
Water

Domestic
usage

125 KL /
day

Sl No Item

RO
Reject

50 KL / day
KL/Day

STP

40 KL / day

1 Consumption

300

2 Bought out

125

42

3 Bore water

4 Recovery

175

58

5 Recycled

300 100

6 Discharge

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50

17

Discharge
to ground

High
Dissolved
solids

75 KL / day

Solar
pond

Recycle Stage 2 UF& RO II 2

Reuse
400 KL / day

IETP

Ultra
Filteration

360
KL

RO 2 stages

400 KL / day

Process
B/O
Water

Domestic
usage

100 KL /
day
Sl
Item
No

50 KL / day

STP

KL/Day %

50 KL / day

1 Consumption

450

2 Bought out

125

28

3 Bore water

4 Recovery

360

80

5 Recycled

400

89

6 Discharge

50

11

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Discharge
to ground

High
Dissolved
solids

RO
Reject
40 KL / day

Solar
pond

Recycle III & IV stage

Two stage recycle in evaporation

I stage by Mechanical Vapour Recompression (MVR)

II stage by Triple effect evaporation (Crystallizer)

Advantages of 2 stage evaporation

In MVR, running cost is one-tenth of Crystalliser, 90% of
effluent volume can be evaporated, even treated sewage can be
added
The 10% reject from MVR alone need to evaporated
thro Crystalliser

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Details of III stage recycle

Details of Mechanical Vapour Recompression (MVR) and
Crystalliser for evaporation

Reduction in boiling point at vacuum used

At 180 mbar vacuum, boiling point reduces to 58 deg C

Vapour is also recompressed and recycled

Evaporation is done till crystallization occurs

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Schematic of MVR for evaporation

MVR fan

Vacuum
pump
58 0C

Feed

Heat
exchanger

Condensate
Out

Condensate
pump

Concentrate
pump

To crystalliser
section

Concentrate is pumped to crystalliser

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Recirculation
pump
Condensate
tank

Evaporation stage 1 -MVR

Bought out 10 KL/ day

From RO 360 KL
/ day

To O/H tank 460

KL /day
MVR
UNIT

RO plant
100 KL /day

Permeate
RO reject
40 KL / day

Treated
sewage
MVR
Reject

70 KL / day
Sl
No

Item

1 Consumption
2 Bought out
3 Bore water
4 Recovery
5 Recycle
6 Discharge

KL/ day

470
10
0
460
470
0

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Solar
Pond

2
0
98
100
0

10 KL / day

Triple effect evaporation for crystallizer

Cooling
CONDENSER

Water

Vapour
Feed

Vapour

Vapour

Vapour

Steam
Vapour
Waste Heat
Concentrate
Primary Condensate

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Condensate

Evaporation stage 2 Crystallizer

To O/H tank 466 KL /day

MVR
UNIT

From RO 360 KL / day

RO

6 KL / day
100 KL / day

Crystallizer

Permeate

Permeate

10 KL / day

MVR
Reject
Sl No Item
KL/ day %
1 Consumption
470
2 Bought out
10 2
3 Bore water
0 0
4
Recovery
466 99
5
Recycle
470 100
6
Discharge
0 0

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2000
Kg

Slurry

Solar Pond

Water Management
Journey Towards 100% Recycling

Ultra Filtration

Effluent Treatment
Plant

Reverse Osmosis

% Reocvery

Zero discharge plant since with 100%

recycle of both Industrial effluent and
Sewage effluent

100
80
60
40
20
0

Series1

Recovery

Befor
e RO

RO I

UF/
RO II

MVR

MVR/
Crys

57

80

98

99

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Crystallizer

Mechanical Vapour
Recompressor

Water Conservation
12 % reduction in water consumed in last 3 years
through various projects Industrial use
20 % reduction in water consumed in last 3 years in
domestic use
Rain water harvesting improved water table and
quality

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Challenges

ETP: For effective metal precipitation, stream segregation

is a must

One of the first RO plants for recycling metal finishing

effluent and recovery was limited to 75% (I stage RO)

Oil carry over issue solved by effective oil removal

To filter organics and colloids, Ultra Filteration was added

RO II was added to recover 90% of effluent

Effective cleaning of membranes at designed frequency

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Challenges (contd..)

Concentrate chemicals to be treated separately

Premature failure of heat exchanger bags in MVR design

changes were done

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Details of III stage recycle

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