Greener & Sustainable Practices at
Dr. Reddys Laboratories Limited
CTO Unit-2
Agenda
Introduction to the company
Green Co Journey
Manufacturing Activities
Waste Management Practices
Air Pollution Control
Material Conservation, Recycling & Recyclability
New Project undertakings
Our Purpose
Providing affordable and innovative
medicines for healthier lives
Participated in the Green Co rating system to strengthen our
environmental capabilities
Green
Green Co
Co Journey
Journey
The rating system recognized our achievements and also
identified areas for improvement
We are the First Company in Pharmaceutical Sector to
receive the prestigious GreenCo rating (Bronze)
Manufacture Active pharmaceutical ingredients (APIs)
13 production blocks
Each production block consists of reactors, filters, dryers, sieving and
milling equipment
Manufacturing
Manufacturing
Activities
Activities
The raw materials are added as per the directions given in the Batch
Production Records
Use organic, inorganic chemicals and solvents
Utilities like RT water, chilled water, brine, hot water, steam, DM water
and electricity are used
Waste
Waste Management
Management Practices
Practices
Waste water is segregated as process effluent from production & non
process effluent from utilities
Process effluent is pre-treated and evaporated in multiple effect evaporator
Evaporator condensate is bio-treated and further treated by Reverse
Osmosis. RO permeate is used in boilers and cooling towers. RO rejects will
Waste
Waste Water
Water
be send back to MEE
Evaporator concentrate is send to dryer to isolate mixed salts. Mixed salts
are send to secured landfill
Non process effluent is pre-treated and bio-treated & further treated in RO.
RO permeate is used for boilers and cooling tower makeup. RO rejects will
Hazardous
Hazardous Waste
Waste
be send to MEE
The wastes are segregated as process residues, spent carbon, mixed spent
solvents, chemical & bio sludge and mixed salts
Hazardous waste suitable for co processing in cement industries are process
residues, spent carbon, spent solvents etc.
Waste oil and used oil are send to authorized oil reprocessors
Alternate
Alternate Reuse
Reuse
Used lead acid batteries are returned to the manufacturers
Spent catalyst is returned to the manufacturers for recovery
Detoxified containers are reused by sending to authorized agencies
Reuse of MS drums for transport of spent solvents
Process
Process Effluent
Effluent
Treatment
Treatment
Clariflocculator
Hides Filter
Non
Non Process
Process
Effluent
Effluent
Treatment
Treatment
Triple
layer bag
filter
In order to reduce the air emissions into the atmosphere and to limit them
within the standards, several strategies were taken up such as:
Boilers provided with bag filters. Boiler emissions like SPM, NOx and SO2
Air
Air Pollution
Pollution
Control
Control
are monitored regularly based on IS standards
Process equipment are provided with multi stage scrubbers
Closed centrifuge operations
Primary and secondary condensers are provided to reactors to minimize
fugitive emissions
Automation of the Solvent Recovery System
Monitoring of all ambient air quality parameters like PM2.5, PM10, SO2,
NO2 to ensure that they stick to the legal norms
Online and portable VOC meters to ensure control over emissions
Material
Material Conservation,
Conservation, Recycling
Recycling &
& Recyclability
Recyclability
During manufacture of Ciprofloxacin HCl compacted material, the packing of
the batch and finished product analysis were being performed two times. This
lead to wastage of packing material and chemicals used for analysis.
o An intermediate step of QC Analysis for input material was eliminated
Packaging
Packaging initiatives
initiatives
o Resulted in Material and packaging savings of Rs. 19.65 Lacs/annum and
reduced the cycle time by 72 hours
Replacing HDPE drums with SS drums for packaging recycling so that they
can be cleaned and reused
Introduced plastic pallets in place of wooden pallets which are recyclable and
less prone to damage
Process chemistry change was carried out to improve Atorvastatin Calcium
yield
Yield
Yield Improvement
Improvement
through
through Continuous
Continuous
Improvement
Improvement
Two new reagents were introduced to accelerate the reaction
This improved the yield and reduced the reaction time
Yield improvement from 286 kg to 340 kg within six month
Savings: Rs. 33.6 lacs/tonne of product
Material
Material Conservation,
Conservation, Recycling
Recycling &
& Recyclability
Recyclability
Acetonitrile Recovery improvement was initiated to improve recovery from 50 to
65 %
Improvement
Improvement in
in
Solvent
Solvent Recovery
Recovery
Process
Process
Steps taken for the improvement:
Material balance study was carried out to identify the losses
Additional equipment to minimise loss and improve recovery
Contamination due to intermixing of methanol & acetonitrile mother liquor
eliminated
Increased overall utilization of SRS capacity and generated increased amount of
distilled and reusable solvents.
Fractional distillation was introduced for distillation of IPA MLs to enhance
recovery
The recovery percentage significantly improved from 46% to 79%
This overall annual saving due to introduction of the fractionation distillation
column amounted to Rs.10.8 Million
New
New Project
Project Undertakings
Undertakings
One more decanter centrifuge will be provided to handle the biological
sludge and chemical sludge separately
Decanter
Decanter Centrifuge
Centrifuge
The centrate from the bio decanter centrifuge can be directly fed into bio
treatment facility
This will help us in avoiding 3500 KL per annum of load to the multiple effect
evaporator
Paddle dryer will be installed for drying bio sludge to 5% moisture content
Paddle
Paddle Dryer
Dryer
Enclosure
Enclosure for
for effluent
effluent
collection
collection tanks
tanks
This will help us to reduce the hazardous waste generation by 180 TPA
Top cover hoods arrangement for open process effluent collection tanks
THANK YOU !!!
