Brakes India Ltd

Foundry Division

Green Manufacturing
K. Suryaprakash
Director Operations

Brakes India Ltd

Foundry Division

PROFILE

Year of establishment

1981

Location

Sholinghur, 120 Kilometer from Chennai

Number of employees

727

Total area

76 Acres

Built up area

28,000 Sq. Mts.

Sales turnover (2012-2013)

Rs 730 Crores

Production volume (2012-2013)

73218 MT

Exports share of turnover

42%

Industries catered to
Automotive

87%

Refrigeration & Air conditioning

13%

Brakes India Ltd

Foundry Division

VISION
Responsibility to Society
Vendors as
partners

Return to
stock holders

PUSH

VISION

PULL

Customer
satisfaction

Employees
quality of life

Brakes India Ltd

Foundry Division

VALUES
Openness

Creative
values
Transparency

Innovativeness

Core values
Harmony &
Cooperation

Excellence

Respect and
Concern for
People

Trust &
Integrity

Commitment

Cultural
values

Basic Values
Fairness

Vibrancy

Humility

Cleanliness

Orderliness

Brakes India Ltd

Foundry Division

TPM Excellence Award

AWARDS & CERTIFICATION

Innovative Project Award

Deming Application
Prize
Best Supplier Award / Best Value
Product from Volvo, Sweden

Brakes India Ltd

Foundry Division

RECOGNITIONS & CERTIFICATIONS

QMS
ISO/TS 16949

EMS
ISO 14001

OHSMS
BS 18001

* - Up grdation to ISO 50001 in progress

EnMS
BS 16001 *
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Brakes India Ltd

Foundry Division

LONG TERM OBJECTIVES

Be a unique solutions provider in the foundry industry.

Work towards achieving customer loyalty.
Improve the quality of work life of our employees.

We Shall

So manage our business which will result in stockholders

taking pride in the company.
Nurture a mutually rewarding long term relationship with our
vendors.
Conduct ourselves as a responsible corporate citizen
recognized for integrity and ethics.

The strategies to Achieve LTO

6. We shall conduct ourselves as a responsible corporate citizen recognized for
integrity and ethics.
6.1

We shall protect the environment and conserve resources.

6.2

We shall Refuse, Reuse, Reduce, Recycle and Restore process waste.

6.3

We shall abide by the laws of the land in letter and spirit.

6.4

We shall continuously identify the needs of the society and contribute.

6.5

We shall promote clean, green technologies, environmental friendly

products and processes.

Brakes India Ltd

Foundry Division

IMPROVING MANUFACTURING SUSTAINABILITY: AN OVERVIEW

Goal of sustainability :
Every company when it comes to green manufacturing should be conserving natural
resources for future generations.

Problem
Statement
Emphasis

Brakes India Ltd

Foundry Division

GREEN FOUNDRY CASCADING THE VISION

Environmental issues
have become part of every
foundrys core activities.

To be successful & to survive,

foundries have to be wise to

how environmental issues
affect our business.

Brakes India Ltd

Foundry Division

GREEN FOUNDRY CASCADING THE VISION

Foundries with their skill, knowledge and

practical information, need to unlock these
resources

to

reduce

impact

on

the

environment.

Recyclability is the

biggest advantage of
the foundry industry.

Good environmental
practice is not an extra
discipline
but
an
integral part of overall
business acumen.

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Brakes India Ltd

Foundry Division

GREEN MANUFACTURING AT BIF

Energy Conservation

Renewable Energy

Green House Gas Management

Water Management

Waste Management

Resource Conservation

Green Supply Chain

Product Stewardship

Life Cycle Assessment

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Brakes India Ltd

Foundry Division

GHG MANAGEMENT

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Brakes India Ltd

Foundry Division

1.5

GHG MANAGEMENT

GHG Emission intensity

75000

70396
54622

1.2

T CO2 / T

0.7

0.5

0.6

0.5

0.3
2011-2012

Intensity (Sales)

25000

44267

GHG Emission in T CO2

0.2

2010-2011

50000

2012-2013

0
2010-2011

2011-2012

2012-2013

Intensity (Metallics)

37% reduction achieved in absolute emissions

53% reduction in GHG intensity

Powered by high proportion of wind energy & efficient operations

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Brakes India Ltd

Foundry Division

WATER MANAGEMENT

Rain water collection pond in Brakes India

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Brakes India Ltd

Foundry Division

WATER MANAGEMENT

Average use of water is 200 kL/day.

More than 55 water meters installed
Dedicated Water Manager
2 rain water collection ponds
Daily reporting of water consumption

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Brakes India Ltd

Foundry Division

WASTE MANAGEMENT

Waste Management
Material Conservation & Recycling

Top view of the

Administrative building at
Brakes India Foundry
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Brakes India Ltd

Foundry Division

WASTE MANAGEMENT

Wage War on Waste

Refuse

Reduce

Waste

Recycle

Reuse

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Brakes India Ltd

Foundry Division

WASTE MANAGEMENT

Waste Management Cycle @BIF

Sludge

Packing
wood

External
environment

Leaves

Incoming
materials

Paper

Office
materials

Buildings
Roads

RDM in
Cement plants

Generation
Cycle
Generation
cycle

Utilization of solid waste

Utilization
Cycle cycle
Application
Green belt

Sand

Dust

Manufacturing

Slag

Recycling
Stillages

Lining

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Brakes India Ltd

Foundry Division

WASTE MANAGEMENT

New Market Value in foundry Utilisation of solid

waste
Support from IISc
Concepts from
French Architect
Stricter
statutory and
regulatory
compliance
3-4% of the
top line

PUSH

Maximize Revenue from

waste

Solid Waste
Disposal
Problem

Core Team
Formation

Improvement
in bottom line
PULL

Bench Mark
Status in EMS
performance

Allocation of
resources
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Brakes India Ltd

Foundry Division

WASTE MANAGEMENT

Solid Waste Management Utilisation

Brick
Manufactu
ring

For
making
roads

Developm
ent of
Green Belt

Utilisation
of Solid
Waste

Raw
Material to
Cement
Plants

Concrete
Manufactu
ring

Patent for Stabilized mud block

using foundry solid waste
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Brakes India Ltd

Foundry Division

WASTE MANAGEMENT

Solid Waste Management Utilisation

Administrative building

X Ray laboratory

Construction of compound wall

Buildings constructed with stabilized mud blocks using foundry return sand

Roads constructed with return sand

For Cupola lining & as base sand for

floor moulding

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Brakes India Ltd

Foundry Division

WASTE MANAGEMENT

Solid Waste Management Utilisation

Return Sand as raw
material to Cement
industry

Utilisation in
Cement plants as
RDF / RDM
RDM Refuse Derived Materials
RDF Refuse Derived Fuels

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Brakes India Ltd

Foundry Division

WASTE MANAGEMENT
Zero discharge and reuse of solid waste

Return sand / slag are used as base sand for developing green belt
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Brakes India Ltd

Foundry Division

WASTE MANAGEMENT
Specific Solid Waste Reduction

Hazardous Waste : Metallics

500

245

476
gm/ t

240

gm / t

450

250

Non Hazardous Waste : Metallics

248

437
400

235

235

230

230
225
371

350
2010-2011

2011-2012

2012-2013

Reduction in amine usage by 50%

50% reduction in waste oil generation
by using synthetic oil in compressors
Introduction of Tornado hoods for
effective capture of fumes

220

2010-2011

2011-2012

2012-2013

Water treated in STP is used for

Green Belt Development &
process cooling.

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Brakes India Ltd

Foundry Division

RESOURCE CONSERVATION
Specific Consumption of Materials - Melting

0.1500

0.020

0.142
0.013

0.015
0.118

0.1000

0.0500

0.0000

0.010
0.0705

0.084
0.006

0.0615

0.0535

0.010

0.005

Kg of Rare earth : T of metallics

melted

T of Materials : T of metallics melted

0.2000

Pig Iron
Rare Earth
Treatment
Materials

0.000

2010-11

2011-12

40% reduction in rare

earths

2012-2013

9.8% reduction in virgin material

consumption achieved in 3 years

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Brakes India Ltd

Foundry Division

GREEN SUPPLY CHAIN

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Brakes India Ltd

Foundry Division

GREEN SUPPLY CHAIN

Reusable Volvo Emballage

Reusable Steel Pallet

Material Used : Heat Treated Pinus Silvestre's, Picea Abies & Steel

Benefits:

Reusable

Collapsible

Facilitates easier loading

Environment Friendly

Quality
Economies of Scale
Standardization Benefits
No disposal
No decanting direct to line.

Cost Effective

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Brakes India Ltd

Foundry Division

GREEN SUPPLY CHAIN

Sustainable Packaging Increasing share of reusable packing

90

Re-usable Pallets as % of Exports Sales (MT)

85

85

Percentage

80
75

75

70
65
60

61

55
50
Pallets

2010-11
61

2011-12
75

2012-2013
85

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Brakes India Ltd

Foundry Division

GREEN SUPPLY CHAIN

Sustainable Packaging Closed Loop Pallet Handling

First Phase

Brakes India

Second Phase

TRW Warehouse
(Queenford/Elsen)

TRW
Warehouse
Brakes India

EMPTY
TRW plant
(Jablonec/Koblenz)

EMPTY

EMPTY
TRW plant
(Jablonec/Koblenz)

Volvo
Warehous
e

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Brakes India Ltd

Foundry Division

GREEN SUPPLY CHAIN

Raw Material Sourcing

175.00
150.00

T of CO2

160.41

139.71

125.00

134.02

Reduction of 16.45% in
GHG emissions in Raw
Material Sourcing

100.00
2010 - 11

Year

2011 - 12

2012-2013

Distance Covered for Fuel Consumption in

RM Transport (km)
RM transport (L)

Metallics (T)

Fuel : Plant
Output

GHG Emission
(kg of CO2)

2010-2011

1588149

5784710

129429.7

44.69

160409

2011-2012

1383436

7499418

166003.2

45.18

139714

2012-2013

1326830

7079287

178225.9

39.72

134017

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Brakes India Ltd

Foundry Division

PRODUCT STEWARDSHIP & LIFE CYCLE ASSESSMENT

Incepti
on

Recycle
/ Reuse

Design

Product

Stewards
hip
Manufa
cture

Sell
Transp
ort

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Brakes India Ltd

Foundry Division

LIFE CYCLE ASSESSMENT

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Brakes India Ltd

Foundry Division

LIFE CYCLE ASSESSMENT

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Brakes India Ltd

Foundry Division

LIFE CYCLE ASSESSMENT

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Brakes India Ltd

Foundry Division

LIFE CYCLE ASSESSMENT

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Brakes India Ltd

Foundry Division

PRODUCT STEWARDSHIP

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Brakes India Ltd

Foundry Division

PRODUCT STEWARDSHIP & LIFE CYCLE ASSESSMENT

Conducted LCA study for 2 products

LCA conducted for Gate to Gate scope to compare the
following parameters
Environmental Impact

Unit / ton of casting

SF

Climate change

Kg CO2 eq.

131.52

Acidification

kg SO2 eq.

0.065

Particulate Matter

Kg

1.06

Eutrophication

Kg PO43- eq.

0.0003

Photochemical Ozone
Creation

Kg of C2H2 eq.

0.002

Human Toxicity

Not Traceable
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Brakes India Ltd

Foundry Division

PRODUCT STEWARDSHIP & LIFE CYCLE ASSESSMENT

There are NO hazardous substances in the product

Certification from Bureau Veritas

laboratory for presence of heavy
metals

1.
2.

50% reduction in restricted substances in

manufacturing
Improved machinability of our products in
comparison with competitors.

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Brakes India Ltd

Foundry Division

Design

PRODUCT STEWARDSHIP & LIFE CYCLE ASSESSMENT

Manufac
turing

Transport

Use of
Recycled
Materials

Recyclable
packing for
85%+
products

Simulation for
reduced field
trials

Less virgin
materials
consumed

Optimum route
for
transportation

Proactive
approach to
design &
manufacturing

Energy
efficient
operation

Anywhere
recyclable
product

Stringent &
Robust
process
control

In-house reuse
of waste

Customer
interaction for
better design

(sea/barge/rail)

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Brakes India Ltd

Foundry Division

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Brakes India Ltd

Foundry Division

Green Co Gold Award

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