KIRLOSKAR BROTHERS LIMITED

A Kirloskar Group Company

Kirloskar Brothers Limited Sanand.

Presentation on Material Conservation and
Recycling
Presentation by : MCR Team

This is a proprietary document of Kirloskar Brothers Limited

Corporate Profile
Established

1888

Incorporated 1920
Core
busines
s

Centrifugal pumps,
Valves, Hydro
Turbines, Pumping
Projects

Yamuna Global Headquarter Kirloskar Brothers Limited,

India, LEED Certified Platinum Rated Green Building

Leader in fluid handling and one of the

largest manufacturers and exporters of
centrifugal pumps
This is a proprietary document of Kirloskar Brothers Limited

Kirloskar Brothers Limited Sanand Plant

ESTABLISHED YEAR: 2012

AREA: 14 ACRES
NUAL TURN OVER FY 14-15: 1044 MN

ISO 9001:2008 certified

BS OHSAS 18001:2007 certified
ISO 14001:2004 certified
SA 8000 certified
Nation Award for Excellence in Energy Management 2014 Certified as
Energy efficient unit.
CII - Exim Bank award for Business Excellence: Significant achievement
This is a proprietary document of Kirloskar Brothers Limited
3
award

Green Co Journey

ISO
Waste
management
initiatives
15 KW solar
panel
installed for
running
water
treatment
plant

People
development

Raw material
conservation
projects

3 nos rain
water
collection
tank
Zero
Discharge

Use of wind
ventilators
for better
ambience

93
ISO

29 Nos. Solar
street lights
installed for
campus
lighting

14001,1
998

70% green
land

Energy
conservation
projects

Water
conservation
projects

OHSAS
18001,2

Plant
setup

Use of sky
light sheets
on roof

Continu
al
Journey

9001,19

Use of
recycle
treated water
from ETP/STP
for gardening

008

Use of
thermal
insulation
sheets in
manufacturin
g shed

This is a proprietary document of Kirloskar Brothers Limited

Operation Sequence

RM Store

Machine shop

CED Coating

FG Store

Performance testing

Packing

This is a proprietary document of Kirloskar Brothers Limited

Assembly line

On line Testing
5

Material Conservation Project

Reducing consumption of virgin material :
1. Reducing raw material consumption
2. Reducing Packing material consumption
3. Re use packing material

This is a proprietary document of Kirloskar Brothers Limited

Material Conservation Project

Raw material consumption reduction
We have reduced the consumption of raw
materials through design change with out
affecting the performance of the product.
In this project, we have reduced the material
consumption by Avg. 10 % to 90 % through
material reduction and by changing of material of
construction.
Our internal work, planning and review diary is
made from recycled paper and it inspires us to
achieve company goals for environment
protection and natural resource saving

This is a proprietary document of Kirloskar Brothers Limited

Material Conservation Project

Material of Construction change from Cast iron to Noryl plastic
Material
Code

Description

01543130

Noryl Dol ABCD

Before Moc: Cast iron

Total
Previous Present Reduction Reductio
Qty
Wt.Saved
Wt./ Kg. Wt./Kg. In Wt./Kg.
n%
Procured
in Kg.
0.654

0.067

0.587

89.76%

9457

5551

After Moc: Noryl

Plastic

Breakage issue.

Noryl plastic is 100% recyclable

Machining and coating required

Weight of the component also reduce to

89.76 %

This is a proprietary document of Kirloskar Brothers Limited

Material Conservation Project

Material of Construction change from Sheet Metal to Noryl plastic
Material
Code

Description

01530150

NORYL BOWL KP4N

- 07 SERIES

Before Moc: Sheet

metal

Total
Previous Present Reduction Reductio
Qty
Wt.Saved
Wt./ Kg. Wt./Kg. In Wt./Kg.
n%
Procured
in Kg.
0.077

0.040

0.037

48.05 %

57258

2118.55

After Moc: Noryl

Plastic

Noryl plastic is 100% recyclable

Weight of the component also reduce to
48.05 %
This is a proprietary document of Kirloskar Brothers Limited

Material Conservation Project

Value addition in Thrust bearing by MOC & Design Change
Material
Code
03660160

Description

Previous
Wt./ Kg.

Present
Wt./Kg.

Fixed Thrust Bearing

1.075

0.375

Before Moc: Cast iron

Total
Reduction Reduction
Qty
Wt.Saved
In Wt./Kg.
%
Procured
in Kg.
0.700

65.12%

18278

12794.6

After Moc: SS investment

casting

Weight of the component reduce by 65.12 % with increased life of

Bearing

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10

Material Conservation Project

Value addition in Thrust bearing by MOC & Design Change
Material
Code
03660170

Description

Previous
Wt./ Kg.

Present
Wt./Kg.

Tilting pad Thrust

Bearing

0.850

0.320

Before Moc: Cast iron

Total
Reduction Reduction
Qty
Wt.Saved
In Wt./Kg.
%
Procured
in Kg.
0.530

62.35 %

2726

1445

After Moc: SS investment

casting

Weight of the component reduce by 62.35 % with increased life of

Bearing
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11

Material Conservation Project

Reduction in Raw material weight of impellers
Material
Code

Description

61008411 SS Imp For KS6D Pump Clock-wise

61008833
IMP For KS6EA Pump Anti Clock-wise
61009152
61008831 SS Imp For KS6F Pump Anti Clock61009151 wise

Total
Previous Present Reduction Reductio
Qty
Wt.Save
Wt./ Kg. Wt./Kg. In Wt./Kg.
n%
Procured
d in Kg.
1.125

0.924

0.201

17.87%

9576

1.416

1.120

0.296

20.90%

4968

1.248

1.107

0.141

11.30%

9792

1924.77
6
1470.52
8
1380.67
2

Benefits :
Increased Pump efficiency.
Motor power consumption reduced
Supplier machining time and power consumption reduced
Reduce product weight and transport cost and Co2 emission
This is a proprietary document of Kirloskar Brothers Limited

12

Material Conservation Project

Reduction in Raw material weight of impellers
Material
Code

Description

Total
Previous Present Reduction Reductio
Qty
Wt.Save
Wt./ Kg. Wt./Kg. In Wt./Kg.
n%
Procured
d in Kg.

61008841 SS Imp For KS6G Pump Clock-wise

1.352

1.25

0.102

7.54 %

4920

501.84

61008851 SS Imp KS8P Dia. 140mm

2.400

2.193

0.207

8.62 %

315

65.21

Benefits :
Increased Pump efficiency.
Motor power consumption reduced
Supplier machining time and power consumption reduced
Reduce product weight and transport cost and Co2 emission
This is a proprietary document of Kirloskar Brothers Limited

13

Material Conservation Project

Material of Construction change from Steel Cast to Sheet metal
Material Code

61009121

Description

Impeller SS 100 HHN Series

Before Moc: Steel

cast

Previous
Wt./ Kg.

Present
Wt./Kg.

0.834

0.365

Reduction Reduction
Qty
In Wt./Kg.
%
Procured
0.469

56.24%

1273

After Moc: SS Fabricated

Benefits :
Weight of the component reduced by 56.24 %
Increase Pump efficiency.
Power Consumption reduce
Reduce product weight and transport cost and Co2 emission
This is a proprietary document of Kirloskar Brothers Limited

14

Total
Wt.Saved
in Kg.
597

Material Conservation Project

Significant Improvement: Packaging waste reduction (KS4 Pump set)
For packing KS4 Pump set twin packing corrugated Kraft
tube was used.

Transit damage issues were there in this type of packing.

Tube is bulky and heavy.

Light weight
developed.

easy

to

handle

Corrugated

Sq.box

Before
Code

After

Corrugated
06080990
640 mm
Corrugated
06081600
760 mm
Corrugated
06081780
855 mm
Corrugated
06081800
940 mm

Previou Present Reduction

Total Wt.
Reduction Purchas
s Wt. Wt.
In Wt.
Saved in
%
e Qty.
(Kg)
(Kg)
(Kg)
(Kg)

Description
Box Sq. For KS4
Box Sq. For KS4
Box Sq. For KS4
Box Sq. For KS4

Details Of Saving

Material Code

Description

Sq. box with 2

tube

2.53

1.752

0.778

30.75%

1483

1153.77

2.97

2.008

0.962

32.39%

2299

2211.63

Wt. Saved / Kg.

8.086

3.47

2.272

1.198

34.52%

2827

3386.74

Purchased Qty

10587

3.81

2.492

1.318

34.59%

2245

2958.91

Purchase in Kgs.

12946

KS4 Single Craft Tube

4.25

2.405

1.845

43.41%

1462

2697.39

KS4 Single Craft Tube

4.91

2.925

1.985

40.43%

271

537.94

Total

Particulars

Average reduction in
36.02% 10587
%

Conv. Factor per

Kg to 1 Tree.
Number of
Trees Saved

12946

This is a proprietary document of Kirloskar Brothers Limited

15

54
240

Material Conservation Project

Significant Improvement: Weight reduction in plastic cap in packing (KS4
pump set)
For packing KS4 Pump set in twin packing corrugated Kraft tube
twin caps were also used.
Since new corrugated box was developed with 2 separate thin
inner tubes hence there are four small low weight caps are used
instead of two twin caps.

After

Before

Code
06080990
06081600
06081780
06081800

Description
Corrugated Box Sq. For
Corrugated Box Sq. For
Corrugated Box Sq. For
Corrugated Box Sq. For
KS4 Single Craft Tube
KS4 Single Craft Tube
Total

KS4
KS4
KS4
KS4

640
760
855
940

mm
mm
mm
mm

Present
Previous Wt./
Reduction In
Total Wt. Saved
Wt./Kg. (4
Reduction % Purchase qty
Kg.(2Pc)
Wt./Kg.
in Kg.
Pc)
0.18
0.072
0.108
60.00%
1483
160.164
0.18
0.072
0.108
60.00%
2299
248.292
0.18
0.072
0.108
60.00%
2827
305.316
0.18
0.072
0.108
60.00%
2245
242.46
0.18
0.072
0.108
60.00%
1462
157.896
0.18
0.072
0.108
60.00%
271
29.268
Average weight reduction
60.00%
10587
1143.40

This is a proprietary document of Kirloskar Brothers Limited

16

Material Conservation Project

Significant Improvement: Packaging waste reduction (BIGflow Pump
set)
Supplier box
For packing BIGflow Pump set twin packing corrugated Kraft
tube was used.

Transit damage issues were there in this type of packing.

Tube is bulky and heavy.

Suppliers box which was scraped earlier is used as internal

packing and a light weight easy to handle Corrugated box
developed for external packing.

Before

Code

After

Description

06089490 CORR BOX.BIGFLOW

Previou Presen Reductio

Total Wt.
Reductio Purchase
s Wt.
t Wt.
n In Wt.
Saved in
n%
qty
(Kg)
(Kg)
(Kg)
(Kg)

2.53

0.581

1.949

77.04%

9621

18751

Particulars

Details Of Saving

Material Code

06089490

Description

Corr. Box Sq. BIGflow

3Ply X 570 X 225 X130
mm

Wt. Saved / Kg.

1.949

Purchased Qty

9621

Purchase in Kgs.

18751

Conv. Factor per Kg to

A Tree.
Number of Trees
Saved

This is a proprietary document of Kirloskar Brothers Limited

54
347

17

Material Conservation Project

Significant Improvement: Elimination of use of plastic cap in packing
(BIGflow pump set)
For packing BIGflow Pump set in twin packing corrugated Kraft
tube twin cap was also used.

No Twin cap
required

Since new corrugated box was developed hence there is no twin

cap required in that packing.

After

Before

Code

Description

0608949 CORR BOX SQ. BIGFLOW

0
3PLYx570x225x130mm

Weight of Reduction
cap (Kg)
%

0.18

100.00%

Purchase
qty

Total saving
(Kg)

9621

1732

This is a proprietary document of Kirloskar Brothers Limited

18

Material Conservation Project

Significant Improvement: Horizontal deployment of twin tubes
Supplier box
reduction initiative
For packing KS3 Pump set twin packing corrugated Kraft tube
was used.

Transit damage issues were there in this type of packing.

Tube is bulky and heavy.

Initiative taken to replace BIGFlow pump set twin packing Kraft

tubes with corrugated box was deployed in this also.

Before

Code

After

Description

CORRUGATED BOX SQ.

0608533
FOR KS3
0
735x180x102MM
CORRUGATED BOX SQ.
0608532
FOR KS3
0
660x180x102MM
CORRUGATED BOX SQ.
0608534
FOR KS3
0
810x180x102MM

Total

Presen Reductio
Total Wt.
Previous
Reduction Purchase
t Wt. n In Wt.
Saved in
Wt. (Kg)
%
qty
(Kg)
(Kg)
Kg.
1.53

1.53

1.53

0.59

0.55

0.62

0.94

0.98

0.91

Average reduction in
%

61.45%

64.06%

10422

422

9796.68

413.78

59.49%

2065

1879.15

65.51%

12909

12089

Particulars

Details Of Saving

Material Code

Description

Sq. box with 2 tube

Wt. Saved / Kg.

2.83

Purchased Qty

12909

Purchase in Kgs.

12089

Conv. Factor per

Kg to A Tree.
Number of Trees
Saved

This is a proprietary document of Kirloskar Brothers Limited

54
224

19

Material Conservation Project

Significant Improvement: Packaging waste elimination (KS4 Stator &
Rotor)
Stator and Rotor received from Supplier were supplied in
Kraft tubes.

Supplier trolley

This tube was scraped.

We have developed new MS trolleys/pallets for receiving

material from supplier.
These trolleys resend to supplier for reuse.
Kraft tube usage is 100% eliminated in this supply.

After

Before
Code

Description

Stator Rotor
Craft Tube

Reduction
Total Wt.
Previous Present
Reduction Purchase
In Wt.
Saved in
Wt. (Kg) Wt. (Kg)
%
qty
(Kg)
Kg.
0.86

0.86

100.00%

26922

This initiative also results into saving plastic caps of Kraft

tubes which were also scraped.
Cap weight: 0.013 Kg/Pc
Saving in plastic waste = 834 Kg

23153

Particulars

Details Of Saving

Material Code

Description

St_Rt Tube

Wt. Saved / Kg.

0.86

Purchased Qty

26922

Purchase in Kgs.

23153

Conv. Factor per Kg to

A Tree.
Number of Trees
Saved

This is a proprietary document of Kirloskar Brothers Limited

54
429

20

Material Conservation Project

Craft tube and Plastic caps of Stator and Rotor are
Reused

Previously these tubes and plastic cap sold as Scrap

Now, Stator and Rotor Packing tube with Cap re send to supplier for reuse

Year

Total packed
Stator and
Rotor receipt

Total Scrap tube

% Recycled
back to vendor as
Material
reuse

2012-13

20673

10489

50.74%

2013-14

22231

10270

46.20%

2014-15

22755

11650

51.20%

Total

65659

32409

49.38%

In addition to above saving we have also reused 64819 plastic caps worth
6.42 Mt weight.

This is a proprietary document of Kirloskar Brothers Limited

21

Material Conservation Project

Result: Packing Material
40000

34876

35000

600

30000

500

25000

400

20000

300

15000
8910

10000
5000
0

700

200
100

165

646

0
FY 12-13

FY 13-14

FY 14-15

Number of Trees saved

Packing Material saved in Kg

Number of Trees saved

Packing Material Re used in Kg

Total Tree Saved:

1411 Nos.

This is a proprietary document of Kirloskar Brothers Limited

22

Material Conservation Project

Result: Plastic Material
2400
2350

2330

2300
2250
2200
2150
2100

2097.8
2054

2050
2000
1950
1900

FY 12-13

FY 13-14

FY 14-15

Plastic Material Resued in kg

Plastic Material saved in kg

This is a proprietary document of Kirloskar Brothers Limited

23

Material Conservation Project

Result: SS and CI Material

Stainless steel Material

saving in Kg

Sheet Metal Material saving

in Kg

This is a proprietary document of Kirloskar Brothers Limited

24

THANK YOU
This is a proprietary document of Kirloskar Brothers Limited

25