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Decorative Paint Units  

Five of our decorative paint manufacturing operations in India are ISO 14001 certified.

ISO 14001 certification of our Khandala plant is expected to be completed before the end of FY 2016-17.

Report Boundary: Data presented in this section covers our six decorative paint manufacturing units in India. Any exception is mentioned as a footnote. This year we have expanded the report boundary to include our International Business Units. The data for these units has been presented separately.

We endeavour to adopt an inclusive approach to protect and conserve the environment. We have been constantly working towards improving our environmental footprint while optimally utilising natural resources. Our emphasis has been on the entire value chain from addressing raw material vulnerability to reducing environmental impact to creating safe products and services.

We have initiated Project NEW (Natural resource conservation, Energy and emissions reduction, Waste reduction) for six decorative paint manufacturing facilities. We have adopted six key themes under Project NEW. For each theme, we have set performance target with a timeframe of 3 or 5 years against a FY 2013-14 baseline. Each theme is led by a senior management representative. A team of 7 to 8 representatives from different plants and Head Office (HO) supports the leader. This structure enables strong governance, knowledge sharing and horizontal deployment of initiatives across the plants.

Project NEW: Progress on commitments for key themes

Apart from the key themes, we have adopted the following additional themes under Project NEW:
VOCs, Air emissions, Paper and Non-hazardous waste

*Total fresh water consumption in the factory less water added to product as raw material per kl of paint produced
** We have revised this target from 5 years to 3 years on account of an improved performance in FY2014-15
***Total water replenished (kl) per kl of total fresh water consumed in the factory
#We have two targets of 5% in 3 years and 36% in 6 years
##We have revised the target from 25% to 50%

Review mechanism for Project NEW

Water managment 

Water is a critical resource for us – both as a raw material and as an operational requirement and hence it is in our interest to conserve and utilise water responsibly.

Securing the availability of water

Water availability is scarce and its demand is increasing due to population growth, urbanisation and industrialisation. An abundant and stable supply of water is the basic need for all communities and we address it in the immediate ecosystem near our plants through:

Roof-top rain water harvesting and recharge systems
Integrated watershed development in nearby villages
Check dam and lake de-silting
Integrated watershed management at Khandala

The integrated watershed development project at Khandala comprises:

  • Installation of roof top rain water harvesting and recharge systems in village educational institutions
  • Construction of rock-fill-dams, check-dams, earthen check-dams, recharge-pits, open-wells and loose-boulder-structures in villages
  • Water recharge through check dam de-silting
  • Awareness creation on water conservation and its importance
  • Demand management measures by soil testing
  • Creation of self-help groups that enables income generation and maintains the structures

43%
reduction in specific non-product fresh water consumption
13.8%
reduction in total fresh water withdrawn (in spite of about a 4% increase in production)
17%
decrease in specific fresh water withdrawn

Water KPI acheivements

Managing consumption of water inside our factory premises 

We closely monitor the water consumed at every stage of paint manufacturing process and have taken several conservation measures to reduce our water footprint. The volume of water used in our products depends on the product specification. Thus the opportunity to reduce such water is limited. However, there are opportunities for efficient water usage in non-product applications such as steam-boilers, cooling towers, chilling plants, cleaning of process equipment, gardening, domestic purposes, etc. This is the reason behind selecting a target on non-product water consumption.

We have achieved zero liquid discharge outside factory premises across all of our decorative manufacturing units

Cooling tower bypass system

Fresh water is added to a cooling tower during its operation to make-up for the evaporation losses. Our aim was to reduce this make-up water through operational optimisation at Ankleshwar. We acheived this by creating a mechanism to bypass the cooling tower whenever the inlet water temperature decreased below a defined set-point. In this way, by routing the water directly from inlet pump to the collection tank, we could minimise the evaporation losses. The project resulted in the reduction of water consumption by 18.2 kl/day during the winter season.

50%
reduction in specific industrial effluent generation

Waste water KPI acheivement

Waste water management 

We have adopted a two way approach for efficient and effective effluent management. We focus on reducing the trade effluent generated at source and find ways of reusing the treated effluent. This strategy has assisted us in achieving zero liquid discharge outside factory premises across all our decorative manufacturing units.

Raw material pigging* water

In Rohtak and Khandala, treament of the high COD pigging line flushing water was a big challenge. By reusing the pigging water in certain categories of water based paints, we plan to completely eliminate the treatment of pigging water in the ETP. Further, we could potentially save an equivalent amount of fresh water consumed. This project will help us to reduce the effluent load on ETP and fresh water consumption by over 2,500 Kl.

*Pigging refers to a technique of cleaning or inspection of pipeline through recovering trapped products in the pipelines without stopping operation

0.35
specific energy consumed in GJ per kl of production

19%
reduction specific electricity consumption Energy KPI acheivements

Energy KPI acheivements

Energy management 

Energy management has twin drivers for us – ecological preservation and economic benefit. Additionally, the energy consumed by us has a direct impact on our carbon emissions. We strive to manage our energy demand by improving operational efficiency and adding alternate sources of energy. We have defined targets on reducing specific electricity consumption and increasing the energy share of renewable energy as a proportion of total energy consumption.

Change in raw material addition sequence

The twin shaft disperser (TSD) used in water-base paint processing contributed to about 20% of the power consumed in the plant. This process required addition of thickener before addition of powder raw material resulting resuting in a high viscosity mixture, considerably increasing the energy consumption. By changing the raw material addition sequence and quantity, we were able to reduce the viscocity of the mixture and hence power consumption. This has led to an estimated energy saving of more than 500 MWH. Further, this is projected to help us reduce power consumption by 25% (equivalent to about INR 50 lakhs), raw material usage by 7% (equivalent to about INR 100 lakhs) and a considerable saving in compressed air and fresh water use.

*IPCC conversion factors were used for all the calculations

We have spent ₹ 78.12 crores as capital investment on energy conservation

Our energy conservation initiatives can be categorised# under process optimisation and automation, optimisation of electrical equipment and lighting

Energy investment
Pressure based pumping system

The pumping systems in the Sriperumbudur plant consumed about 13% of the total power consumption as pumps were being used without considering the actual demand. We worked on a simple principle of “pumping what is required” and partnered with few vendors to identify our actual pumping system requirements. Subsequently, we replaced the conventional system with advanced pressure based systems. The new pumping system helped us to save more than 26,500 units every month and also reduced the specific power consumption of the utility cooling tower by around three units.

Replacement of conventional lighting with LEDs

The lighting load contributed to about 7% of total specific power consumption across our plants. We replaced conventional lighting with LEDs to optimise the lighting load. We were able to reduce our lighting load by 50%, thereby decreasing the specific power consumption by three units. Ankleshwar, Kasna and Rohtak plants have replaced more than 90% of their lighting system with LEDs, while Patancheru and Sriperumbudur plants have replaced more than 50%. The total energy saving in the year was more than 2,000 MWH.

We have experimented with an alternate dispersion technology equipment for paint processing at our Khandala plant. This technology will help us in reducing power consumption and cycle time significantly.

This year, we have initiated implementation of a software on Energy Management System (EMS) across all plants. We will commence the pilot at Sriperumbudur plant from mid of FY 2016-17 and plan to cover all plants by end of FY 2016-17. This will help us to generate real-time data and monitor, analyse, report and compare the power consumption across paint-products, across similar equipment and across different manufacturing locations.

#Please refer to our annual report for FY 2015-16 for initiatives taken under the three categories

Emission management 

We have substantially augmented investments in renewable energy projects to reduce our dependency on fossil fuels. As a part of our renewable energy strategy ‘RE36 by 2020’, we are working towards consuming 36% of the total electricity consumption at decorative paint plants as renewable energy.

10.92%
reduction in total GHG emissions

48.8 lakh
units equivalent to

7.59%
under the RE36 target

18%
targeted to be achieved by
FY 2016-17

Emission reduction KPI achievements
Biogas for boiler

At our Khandala plant, we initiated the use of biogas to replace high speed diesel in the thermic fluid heater and boilers. To ensure efficient use of biogas we had to retrofit the existing burners with dual fired burners, install gas decompressing units and execute other modifications. The prevalent practice in India was to use biogas consisting of 60% bio-methane and 40% carbon dioxide. We worked with a vendor to ensure availability of purified bio-methane above 96% purity on a continuous basis, generated through agro waste and waste from sugar industry. Further, as the biogas facility was about 50 km from the plant site, we took a decision to transport the biogas in cascades. This entailed safe transportation and handling of large volumes of gases on a daily basis. The use of biogas has helped us to lower our GHG emissions and also the operational cost. Energy efficiency and renewable energy efforts have also helped us in reducing the overall GHG emissions.

Waste management 

We give highest priority to avoid generation of waste through material efficiency and process improvements. Wherever avoidance is not possible, we focus on recycle or reuse as an alternative. Finally, we try to minimise the environmental impact of the generated waste by ensuring its safe disposal.

7% reduction in specific hazardous waste disposal

Waste management KPI achievement

Our Sriperumbudur manufacturing unit was able to reduce its specific hazardous waste by more than 35% over the last year through various initiatives like installation of distillation unit, pre-processing of hazardous waste, usage of intermediate paint waste back in the process and reduction in screw pump leakages.

Non-sticky coating for process equipment

Sticking losses in process equipment were generating significant quantities of hazardous waste. At Ankleshwar, we piloted an initiative to apply a non-sticky coating on the process equipment, leading reduction in hazardous waste generation and water used for cleaning. We could also achieve significant improvement in the hygiene around the equipment. At the Ankleshwar unit, we were able to reduce the specific hazardous waste disposal by 0.06 Kg/kl of product (~400 Kg/month) along with a 30% reduction in water consumed during cleaning of those equipment. We are in a process of replicating this across all plants.

Material management 

More than 50% of our net revenue is spent on raw material and packing material. We also incur cost in treatment and disposal of waste which increases with higher material wastage. It therefore imperative for us to emphasise on material efficiency to reduce our resource consumption, avoid waste generation and reduce expenditure.

Developing nearby and domestic sources is taken as one of the important focus areas. Localisation helps us to reduce cost, lead time and emissions in terms of reduced distance travelled during transportation of goods. For some of the high volume raw materials / packing material categories we work with our suppliers to set up facilities closer to our locations.

7,74,638
tons of Raw Materials (including pigments, solvents, additives, etc.)

82,293
tons of Packing Materials (including tins, drums, plastics & cartons)

Material footprint
Transportation in bulk form

We use, recycle and reuse jumbo bags for transportation and handling of powdered materials such as extenders across our large plants. Specifically for the extenders, a fairly large proportion has been moved to bulk tankers in two of our large plants. We are working towards maximising the supply of the monomers and certain additives in bulk form that helps us to reduce cost and transportation emissions.

Road safety for monomer transportation

As a product, monomers are categorised as hazardous liquids and hence their transportation from ports to plants have to be carried out in a safe and environment-friendly manner. In 2015, we decided to implement transportation of monomers exclusively via ISO tankers in 2015. ISO tankers are inherently more stable than regular road (SS) tankers due their outer frame structure. In addition, by design, the ISO tankers are also less vulnerable to chances of pilferage, thus further reducing the possibility of environmental damage due to mis-handling.

Recently, we have joined Nicer Globe: a national consortium of leading chemical companies initiated by the Indian Chemical Council (ICC). This initiative covers transport and distribution safety, emergency response, transport security, logistic operation efficiency and fleet management. All the ISO tankers carrying monomers are tracked real-time via GPS devices and safety-related exceptions like over-speeding, night-driving can be monitored and regulated. A dedicated helpline provides scientific assistance to the driver in case of an emergency so that the impact on the environment is safely minimised.

Minimising transportation damages

We have adopted multiple initiatives to reduce damage and spillages during transportation ata few selected locations. We have started palletised dispatches leading to lesser damage. We are investing heavily to secure cargo during dispatches by improving loading procedures, by inserting plywood between the stacks and securing the cargo with straps and buckles to unitise the load and reduce target. We have covered all dispatches for high risk/damage routes under these procedures.

Nested storage

We have redesigned our 20L DTS pails from cylindrical to nested design. This has helped us to achieve significant savings in freight cost for transportation of packaging material, reduced emissions, improved operational efficiency and scrap management, streamlined quality checks and also helped our vendors to better manage their own spaces.

Reducing material loss

We ensure de-dusting of powder from the bags across all the plants to reduce wastage. This collected powder is used back in the process leading to saving material and reducing wastage. At our manufacturing locations, with significantly high production volumes, a few powdered raw materials are supplied in pneumatic tankers. This year we have aggressive plans to expand this practice, wherever feasible.

FSC certified cartons

To ensure our commitment towards sustainable sourcing, we have explored the usage of certified cartons. On a pilot project, we have enabled two of our suppliers to be certified to the Forest Stewardship Council (FSC). They have been made capable to handle and fulfil the requirements of certification. We worked with these suppliers to ensure Forest Stewardship Council Chain of Custody Standard certification for their operations. This was a first-of-its-kind project for us.

Saving paper

Reducing paper consumption and replacing virgin paper by recycled paper has been another focus area at Asian Paints. We endeavour to procure stationery paper and secondary packaging that contains 100% recycled content.

One of the interesting initiatives that we have adopted during the year is to move away from paper based clearance of imported consignments. Moving to an electronic clearance system has helped us in saving approximately 50,000 sheets of paper per year.

We have also replaced corrugated paper separators by plastic separators in packing material received in the plants at a few locations.