JK Organization (EZ) –Group Profile

 Reputed and diversified group in business for over 125 years

 Turnover of $ 4.0 billion.
 Sales and Service network of 10,000+ distributors and retailers.
 Multi - business operations; footprint across 6 continents, 100 countries & 29
Late Lala Late Lala
manufacturing facilities across India.
Juggilal Singhania Kamlapat Singhania
 A team of 40,000+ committed and motivated managers and workers.

2
 JK Tyre : Vision ,Mission, Values
 Vision  Core Values
 To be amongst the most trusted companies with  Caring for people
global tyre brand  Integrity including intellectual honesty,
 Mission openness, fairness & trust
 Be a Customer Obsessed Company–Customer First  Commitment to excellence
24x7
 Most Profitable tyre company in India – Deliver
Enhanced value to all stakeholders
 No.1 Tyre Brand in India and amongst Leading tyre
brands globally
 Lead with Premium products through Technological
Edge
 Enhance global presence through Acquisition / JV /
Strategic Partnerships
 Be a socially responsible corporate citizen
 Be a Learning &Innovative organisation with 3
motivated team
 Our Manufacturing Plants and Brands
Manufacturing Plants Our Brands
• 9 Plants in India
• 3 Plants in Mexico Corporate Office

Lashkar Radial Plant

Kankroli Bias Plant

Banmore Bias Plant

Mysore OTR Plant Chennai Tyre Tyres in the Range:

Mysore Vikrant Radial Plant
Plant
Mysore Truck Radial Plant -
• Truck & Bus Radials • OTR Bias
• Truck & Bus Bias • Specialty, Industrial & Implement
• Light Truck Radials • 2 & 3 Wheeler
• Pass Car Radials
• Farm Bias & Radials

4
 Fact Sheet – Chennai Tyre Plant
Sriperumbudur, Chennai Tyre Plant in Tamil Nadu is the 6th manufacturing
Location Kanchipuram District,
plant of JK Tyre
Tamilnadu : 602106
Went on stream from 05th February 2012
Distance from
49.6 k.m Investment of 24680 Million Rupees
Chennai City
Capacity: 4.5 Million Passenger Car Radial (PCR) tyres and
Distance from Port 52.8 k.m 1.2 Million Truck / Bus Radial (TBR) tyres per annum.
Among the Most energy efficient tyre companies in the world
Land Area 102.95 Acre
(8.84Gj/Ton)
Total Built-Up Area 24 Acre 1st Indian tyre company to have certified for ISO 50001
(Energy Management)
Green Belt Area 25 Acre
1st Indian tyre company to have verified Carbon Footprint as
Expansion Area 52.95 Acre per IS-14064

6
 Product Portfolio & Key Customer
Passenger Car Radials - PCR Truck Bus Radials-TBR

PCR - Variants Size Type No of SKU

TBR - Variants Size Type No of SKU
Car Radials 12”To 18” Tubeless 63
Jeep Radials 15” To 16” Tubeless 2 Truck Bus Tube &
20” 23
Radials Tubeless
SUV Radials 16” To 18” Tubeless 51
Truck Bus
Light Truck Tube & 22.5” Tubeless 25
12” To 17” 18 Radials
Radials Tubeless

Key Customers

STATE TRANSPORT UNDERTAKEN

Tamil Nadu State Transport Corporation(TNSTC)
Kerala State Road Transport Corporation (KSRTC)
Andhra Pradesh State Road Transport Corporation (APSRTC)
7
Maharastra State Road Transport Corporation ( MSRTC)
 Salient Features of Chennai Tyre Plant
Exclusive Features
 Location Selection – Automobile Hub
 State of the Art Equipment capable of meeting future product
requirement.
 Modular designs for seamless expansion
 Highly optimized WIP material flow
 Zero Discharge Plant.
 Maximum usage of natural light and Renewable Energy.

Manpower Specialty
 Adopted Lean Management concept.
 Technically Qualified work force.
 Young Workforce 90% Age group < 30 years.
 All operatives are Diploma Engineers / Science Graduates.
 Business Partners - Outsourced services (Entire material
handling process, Utilities & House Keeping)
8
GreenCo Journey

9
CII GreenCo Award

“Greenco Gold” company in November 2014. “GreenCo Platinum” company in July 2019.

We have also achieved the distinction of becoming the “First Tyre Manufacturing
Company” to be certified under GreenCo Platinum Rating in Version 3.
 Energy Efficiency
&
Renewable Energy

11
 Plant Energy Mix
Plant Source wise Energy consumption (TJ) Plant Energy Mix in Percentage (%)
in % - for the year of 2019-20
Electrical
(Non - Thermal (Non -
70 Renewable) Renewable)
64 16% 60%
50
Percentage (% )

30 36
Thermal
10 64%

-10 Coal Electricity

Annual energy consumption (Kcal) in % FY 2019-20 Electrical

(Renewable) Thermal
20% (Renewable)
4%
 Energy Flow Diagram of the Plant
SOLAR - 4.2%
WIND – 15.9% MIXER EXTRUDER
19.5 % 13.8 % 6.1 %
DIV A
0.4 % 19.9 %
Total Electrical STOCK TYRE BUILDING
Energy 1.4 % 0.7 % 0.7 %
36% DIV B
1.4 %

1.9 % CURING FINAL FINISHING

TNEB - 15.7% 51.3 % 1.3 %
DG - 0.03 % 50.7 % DIV C
52.6 %
13.2 % COMPRESSOR & PUMPS AND FANS
Thermal Energy LIGHTING 5.3 % 20.8 %
12.9 % UTILITY
64%
26.1 %
Energy Policy
Reduce Specific
Energy Consumption
by 2-5% every year
 Energy Management Cell & Energy Manager
Corporate Energy Cell K.A. UNNI NAYAR VP (W)

S.K. SATHPATY (GM-ENGG)

T.JAYAKANTHAN B.RAMESH KUMAR M.PANDIARAJAN

(ENERGY MANAGER) (ELECTRICAL ENERGY) (THERMAL ENERGY)

MR.VASU BABU (MIXING)

MR.SIMON BABU (PROD)
MR.ANIL (EXTRUDER)
MR.NIKIL (PROD)
MR.SRIDHARAN (TECH)
ELECTRICITY MR.MANOJ (TECH) THERMAL
MR.KARTHICK (ELEC)
MR. VIJAYABASKAR (ENGG)
MR.TAMILARASAN (MECH)

MR.NARESH KUMAR MR. PRABHU (UTILITY)

MR.GOPI (PURCHASE) MR.AJAY (BOILER)

MR.SATHYA NARAYAN (ELEC) MR.RAGAVENDRA (ELEC)

MR. SURESH RAJAN (MECH) MR.RAJESHKUMAR (INST)
 Monthly Review
 Daily Review Meeting chaired by Plant Head
 Monthly Energy Review meeting chaired by Director Manufacturing
 Monthly Business Review Meeting chaired by President – India Operations
 EnMS Management Review Meeting chaired by Plant Head – Half Yearly

Specific Energy Consumption

Plant specific energy consumption of power and steam continuously monitored and gaps are reviewed and necessary
actions plans are taken in monthly energy review meeting to improve plant energy performance.

Power cost
Plant power cost continuously monitored and necessary actions plans are taken in monthly energy review meeting to
improve plant energy cost performance
Energy Monitoring for Equipment
Energy Management System – Plus Breaker Control – Plant over all architecture
Advance EMS system
connected with 1013 Energy
meters and 256 Nos
Breakers
EMS plus breaker
controlling system to
control energy
System alerts the excess
energy consumption
immediately thro Auto SMS,
and E-mail helps to take
appropriate actions
immediately rather than
afterward investigation
System records Sag/swell
and transients and all
electrical parameters at the
sampling rate of 1024
samples/cycle
 Energy Monitoring for Equipment
Energy Management System – Dash Board

System alerts the

excess energy
consumption (or)
abnormality in
power quality (Low
voltage / High
Voltage / KW / Amps
/ Breaker ON/OFF )
immediately thro
Alarm / Auto SMS,
and E-mail helps to
take appropriate
actions immediately
rather than
afterward
investigation
 Energy Monitoring for Equipment
Electrical Power consumption – Continuous monitoring done daily in standard formats and the reasons for variations
analyzed
VARIABLE LOAD Canteen/MHE/Los
ETP/STP, 1.26% s, 2.72%
Mixer 38.28%
Extruder 15.91% Light, 3.01%
TBM 1.89%
Stock 1.95% AHU, 9.34%
Curing 1.73% VAM, 4.06%

SEMI FIXED LOAD FIXED LOAD, 0

Boiler 1.95%
Final Finishing,
Compressor 8.86% 3.45% Mixer, 38.28%
PCT 3.23%
HWS 0.01% HYD, 2.32%
HYD 2.32%
HWS, 0.01%
Final Finishing 3.45%
PCT, 3.23%
FIXED LOAD
VAM 4.06%
Compressor, 8.86%
AHU 9.34%
Boiler, 1.95% Extruder, 15.91%
Light 3.01%
ETP/STP 1.26% SEMI FIXED
LOAD, 0
Canteen/MHE/Lo
2.72% Curing, 1.73%
ss
Stock, 1.95% TBM, 1.89%
 Energy Monitoring for Equipment
Steam consumption - monitoring
Overall Plant Area Wise Steam Consumption MT /Day
Steam Flow monitoring – Flow meters in Percentage

0.9%

20.0%
43.4%

Utility Energy parameters monitor & 35.6%

Control - SCADA

TBR Curing PCR Curing

VAM Chiller 4Roll Calandar
 Project : High Energy Efficient Axial Fan
IDEA: High Power consuming Centrifugal Fan can be replaced with High Efficiency Axial Fan

Result: 14 Nos of units converted with investment of 1 Crore Rs., 48% of Energy Saving achieved (9 lacs
units/annum), ROI of 21 months period

21
 Project : Alternate Fuel for Boiler – Saw Dust

IDEA: Sawdust used as alternative fuel in certain proportion which can reduce the conventional fuel usage

Coal Consumption Saw dust consumption Biomass equivalent coal cons

Year reduction.
MT MT MT
2019 – 20
(Till date) 20380 1702 1420

22
 Project : Alternate Fuel for Boiler – Vegetation Waste
IDEA: Waste (Vegetation) used as alternative fuel in certain proportion which can reduce
the conventional fuel usage

Innovation Details: Vegetation waste been crushed as required size by using shredder
machine and Blend with coal in the fuel handling system and feeding to the boiler. GCV –
3800 – 4000 Kcal/Kg

Result:
Equivalent coal consumption reduction is 9 MT/month

23
 Project : Header Merging
IDEA: Steam distribution through three individual headers (HPS, MPS & LPS) in PCR Tyre Curing Process.
Individual steam headers causing more header trap losses. Header merging can be done to reduce the header
trap losses

HP Steam Header HP & MP Steam Header

MP Steam Header

Curing Press Curing Press

Result:
 9 MT / day of Steam reduction in PCR Curing (i.e. Coal Consumption – 1.7 MT/day. Cost Savings of 29.7 Lacs
/Annum)

24
Project : Cemented Coal Yard

25
 Equipment wise Efficiency Improvement
Performance evaluation of the energy intensive equipment
For Each and every Area, significant
Energy Intensive Equipment identification - Method energy use of equipments identified
ETP/STP, and prioritized
Light, 3.75%
1.29% Canteen/MHE
/Loss, 2.61%
AHU, 9.06%

Significant Energy use - Mixer Area

VAM, 4.91% 25.00
20.00

Laod (%)
15.00
Final Finishing,
3.55% Mixer, 36.89% 10.00
5.00
HYD, 2.49% 0.00
HWS, 0.01%

PCT, 3.29%

Compressor, Extruder,
8.72% 15.45% Mixer area - Equipments
Boiler, 2.06%
TBM, 2.03%
Stock, 2.11%
Curing, 1.78%
 Equipment wise Efficiency Improvement
Energy Intensive Equipment identification - method
Carbon Oil Batchoff unit Stacker Polymer
Auto loading & Charging 1% 1% Loading &
Auto chemical chemical - Auto chemical
Carbon house Charging System Charging
- 440 RMS 430 - 270 System 1% System
IOCL GPC 1% 1%

TSS
270 F 19%

440 M
K310

Mixer and
270 M K430-1 aux
76%

K430-2 For all equipments significant energy

use of components identified and
prioritized
 Offsetting through Renewable Energy Sources
15.2 MW Installation Capacity Dried Leaves ,Wooden waste with Coal

Total Off-site Renewable Energy Generation = 39 %

6 MW Installation Capacity Saw dust mix with Coal (5%)

Total On-site Renewable Energy Generation = 10 %

28
 Green Energy Substitution
Electrical Thermal

120.0% Green Power Non Renewable Green Fuel Non Renewable

100% 0.0% 5.0% 8.0%
100.0%
0.1% 90%
15.7%
80%
80.0% 44.2% 48.0%

Consumption (in %)
70%
66.6%
Consumption (in

60.0% 60%
50%
95% 92%
40.0% 40% 100%
%)

30%
20.0% 99.9% 84.3% 52.0% 20%
55.8% 33.4%
10%
0.0% 0%
2015 2016 2017 2018 2019 2017 2018 2019

29
 IIOT Deliverables which strengthen Energy
Implementation of IIOT

Enhanced FIFO Realtime Data Exchange

Bi-Directional End-to-End Centralized Item Mgmt.
Traceability Genealogy

Activity based Energy

Mistake Proofing Monitoring

Improved Time to
Market
Condition Based
Monitoring

30
CII National Energy Leader

JK-Tyre Chennai Tyre Plant awarded as “National Energy Leader for consistent 3 years as
Excellent Energy Efficient Unit” from CII - National Energy Management Award
 CEM Award Excellence in Energy Management(2019)

JK-Tyre Chennai Tyre Plant has been

awarded as a “Excellence in Energy
Management” by Clean Energy Ministerial -
Vancouver, Canada in May 2019. We have
also achieved the distinction of becoming
the “First Company in India” to be awarded
under Excellence in Energy Management at
Global Level.

The Clean Energy Ministerial (CEM) is a high-level global forum to promote policies and programs that advance the
deployment clean energy technology
Water Conservation

33
 Water Source & Fresh Water Usage
Overall Fresh water usage

WTP Rejects
14%

Cooling tower
Make up
20%
Boiler Make up
41%

Source of Raw Water – SIPCOT (Lake water) Domestic Water

pH – 7 to 7.5 25%
TDS – 380 to 450 ppm
Total Hardness – 120 ppm
Chloride – 100 ppm
Silica - 15 ppm
Turbidity – 8 NTU
Fresh Water Usage – Fixed & Variable Consumption

Fixed Consumption

Service Water
24.77 %
Drinking Water

Variable Consumption

Boiler Make up 41.55%

Cooling Tower Makeup 19.70%

WTP Rejects 13.98%

Water Policy

Reduce Specific
Water
Consumption
by 2-5% every
year
Water Manager & Accountability
Plant Head
K.A.Unni Nayar Head-Utility
M. Pandiarajan

Head- Engg
S.K. Satpathy
K. Arvind
Water Manager

ETP, STP & WTP Beyond the

Domestic Water Process Water
Operations Fence

Drinking & Service Water System Boiler Make up Cooling Tower & Extruder Recycling and reuse Augmentation & Recharging
System
CFT – Domestic : CFT – Process : CFT – Treatment Plant : CFT – Beyond the Fence
HR – Manikandan Utility – Manager Utility – Manager Admin – Manager
Canteen & Cooking – Fusion GSH – Facility Manager GSH – Facility Manager Project – Manager
Food – Site In charge Civil – Maintenance In charge Civil – Maintenance In Civil – Manager
Utility – Prabhu Curing – Process In charge charge NGO – Hand In Hand
Civil - Maintenance In charge Extruder – Process In charge Eco care – Site In charge
GSH – Facility Manager Mixer – Process In charge
Water coolers – In charge Mechanical – Maintenance In
charge
Water Balance Diagram

Overall Water Mix Process Water – 84%

Cooling tower Evaporation

WTP Rejects 43 %
10%
loss
Cooling tower Blow down
Cooling tower Boiler Make up 5%
Blowdown loss 27% loss
5%
Boiler make up 27 %
Domestic Water
15% WTP Rejects 10 %

Cooling tower Domestic Water – 16%

Evaporation loss
43%
Service Water 12.6%

Drinking Water 3.4%

Water Balance Diagram
WATER BALANCE CTP MARCH "19

INPUT FROM INPUT FROM OTHER

SIPCOT 15510 KL SOURCES 0 KL SPECIFIC WATER CONSUMPTION
15510 KL PRODUCTION TBR 5188.50 MT
WATER TREATMENT PLANT PRODUCTION PCR 2567.13 MT
CONSUMPTION 12737 KL TOTAL PRODUCTION 7755.63 MT
OVER ALL WATER CONSUMPTION 12737 KL
828 KL TO CLARIFIER SP.WATER CONSUMPTION 1.642 Ltr/Kg

WTP RO REJECTS 1190 KL ,

UF REJECT 1160 KL & PLANT CONSUMPTION
UF BACK WASH 828 KL 10387 KL STP TREATED WATER 590 KL
FOR GARDENING &
SLUDGE LOSSES
TO SERVICE 1160 KL
SERVICE WATER (3213KL)
1248 KL 1190 KL 2053 KL WASHING 2439 KL
DRINKING 774 KL 2206 STP KL A
A 1248 KL

ETP 3930 KL
SAND BLASTING
150 KL & PAINT
LUBRICATION
STP TREATED WATER 113 KL
STP TREATED FOR FOR ASH QUENCHNG
28 KL CHILLER MAKE UP NEW STP
COMMISSIONING
ACTIVITIES
255 KL
BOILER MAKE UP
5772 KL Water taken for new
STP trial and given to
127 KL 124 KL BOILER BD gardening
SOLAR PANEL
HOT WATER & CLEANING
EJECTOR SYSTEM 3153 KL
RECOVERY 3153 KL 2384 KL
COOLING TOWER
MAKE UP (9331 KL)
3794 KL

EJECTOR CT & VAM CT BD 540 KL

POWER PACK CT BD & HW PIT 828 KL
1492 KL 1368 KL
Water Metering at Critical Locations

UF PRODUCT FLOW METER IN WTP CONDENSTAE FLOW METER IN ETP REJECT FLOW METER IN ETP

DOUBLE STAGE RO FLOW METER IN

RO PRODUCT FLOW METER ETP
Project :STP Treated water recycling for process

80 % of STP TREATED WATER STP TREATED WATER USED

RECYCLED THROUGH RO FOR COOLING TOWER MAKE UP
STP PRETREATMENT

20 % recycled & utilized for drip

irrigation & Land scapping

41
Project: Nitrogen System for Tyre Curing
Fresh water make
up of 65 KLD saved.
24 % decrease in
Boiler make up

HOT WATER SYSTEM FOR CURING NITROGEN SYSTEM FOR CURING

Internal Cure media has been changed from Hot Water to Nitrogen. Thereby eliminating the Hot Water
Usage. Daily steam utilization for hot water system is eliminated & Water used for boiler make up is
reduced.

42
Water Efficient Landscaping & Irrigation Practices

25 acres of Green Belt

Area is maintained
through drip irrigation
& sprinkler system

Highly efficient irrigation systems incorporating the following features:

 Segregation of plant species based on watering needs
 Drip & Sprinkler irrigation
 Pressure regulating valve

14000 plants & 3 Lac sqft of green belt area..

 Implementation of Rainwater harvesting Structure
 JK Tyre has provision to harvest 100% of the roof & non roof run off water. The total run off volume of
the site is around 10000 m3.
 The run off water is harvested through RWH Pond and Percolation pits strategically located at various
places across the site.
 Implementation of Rainwater harvesting Structure

Onsite RWH Pond Percolation Pit in Drains – 30 Pits

Harvesting Capacity of Percolation & storage systems on site:

1. Storage capacity of onsite Pond = 4055 m3

2. Percolation Capacity of Natural Unlined pond = 4204 m3
3. Percolation Pits in Drains = 2580 m3

Total Harvesting Capacity of Percolation & storage system =10,839 m3

Substitution of Process Fresh Water with Harvested rain water

Harvested Water
used for Cooling
Tower Make up –
Average 30KL/day
in monsoon

Harvested Water Harvested Water under goes Pre Treated Water used as
Pre Treatment Cooling Tower make up

Harvested Water used as make up Water in Process Cooling Tower after Pre Treatment
Augmentation of Ground Water beyond the fence

47
Augmentation of Ground Water beyond the fence

48
 CII – National Award Excellence in Water Management (2019)

JK-Tyre Chennai Tyre Plant awarded as

“Excellence in Water
Management” from CII – 13th
National Award for Excellence in Water
Management 2019
Green House Gases

50
 GHG Emission Inventorisation
Carbon foot print of any entity is the measure of Setting GHG Operational Boundaries Emission Sources:
the Green House Gas (GHG) emitted due to the Emission Sources Scope of Emission
activities of that entity. Diesel for internal material transport
• All Plant (decentralized level) GHG Diesel for generators
Inventorisation Boiler coal
• Rolling up the inventory to Corporate Level HSD (High speed diesel)
Company vehicle‐Diesel
Direct Emission (scope 1)
Identification of GHG Company vehicle‐Petrol
Sources and Sinks LPG consumption ( GH)
Selection of Quantification Release of refrigerant
Methodology Use of Acetylene
Weight of CO2 released from fire extinguishers
Selection and collection of
GHG Activity Data Overall purchase of Electricity Energy Indirect Emission (scope 2)
Material Logistics (Raw Material & FG
Selection of GHG Emission
Factor Transportation)
Business Travel Other Indirect Emission
(Scope 3)
Calculation of GHG Employee Commute
Emission and Removal Waste Disposal
 GHG Emission Inventorisation
Annual GHG Inventorisation sheet (2019-20) EXAMPLE
NAME OF THE PLANT JK TYRE & INDUSTRIES LTD - CHENNAI 2018 -19
S.R Description Unit APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR Total
General Information
A Production MT 7070.41 7917.26 7936.23 7821.39 7680.94 8455.17 8225.69 7780.377 8360.72 5896.59 6456.59 7762.3 91363.67
Tree Plantation 0
B B.1 Current Year Nos 0 0 0 0 0 28 41 107 72 0 47 0 295
B.2 Cumulative 295
Projects Implemented with Saving in eCO2t
C C.1 Current Year Nos 0
C.2 Cummulative 0
SCOPE 1
Fuel for Boiler MT
Coal Consumption MT 2539 2799 2526 2410 2308 2489 2384 2540 2730 1925 1862 2366 28879
1.1
Coal net calorific value kcal/kg 3938 4032 4155 4042 4082 4093 4059 3936 3945 4129 4210 4183 4067
1
Charcoal Consumption MT 0 0 0 0 0 3030 1000 0 0 500 200 0 4730
1.2
Charcoal net calorific value kcal/kg 0
1.3 Biomass-Briquette (Separate Accounting) MT 0 32.74 205.04 271.29 265.87 171.1 135.65 122.13 148.91 73 41.16 87.21 472.04
Diesel (Stationary)
2.1 Genset (Including GH+Hydrant) 0 2277 1223 3070 4063 3132 388 489 219 3464 1104 627 20056
2 Ltr
2.2 Dip Unit 0
2.3 Boiler-Startup 313 0 0 262 0 473 0 1072 0 362 0 0 2482
Diesel (Movable)
3.1 Company Operated vehicle 715 725 695 745 830 720 700 690 730 911 700 695 8856
3.2 Diesel for Forklift 4448 4426 4090 4010 2612 2353 2624 2164 2911 2691 1941 3697 37967
3.3 Tractor/Truck Transportation 0
3 3.4 Tractor-Boiler (Ash handling) Ltr 0
3.5 Coal Handling-JCB 569 619 971 1243 897 368 715 744 769 367 551 735 8548
3.6 Company Operated Ambulances 0
3.7 Security Related Activities 0
3.8 Horticulture Related Activities 0
Petrol (Movable)
4.1 Company Operated Vehicles (Ambulance & Bike) 15.56 31.85 21.73 10.01 26.25 22.07 45.38 24.96 37.24 39.72 30.00 20.00 324.77
4 Ltr
4.2 Security Related Activities 0
4.3 Horticulture related activities 0
GHG Policy

Reduce Specific
greenhouse gas
emission by 2-
5% every year
 Carbon Neutral Approach
Spreadsheet calculation demonstrating emission Offset values
fuel emission GHG Emission-
fuel Density Emission (t CO2 e Tons
S.N. Description Unit CTP Total Consumptio NCV (TJ/Gg) factor (t
(kg/m3) CO2) Scope 1 Emission 47998
n (kg) CO2/TJ)
General Information Scope 2 Emission 34283
A Production MT 91363.07022 91363
B Tree Plantation Nos Scope 3 Emission 9124
Coal Consumption MT 28883 28883.5 28883480.0 17.01 96.1 47216 Renewable Energy 31972
1.1
1 Coal net calorific value kcal/kg 4068 4067.9 This is Average calorific value
1.2 Charcoal Consumption MT 4.03 4.0 4030.0 29.5 112.0 13.3
Total 123377
Diesel (Stationary) Renewable Energy (Carbon Offset) 31972
2 2.1 Genset (Including GH+Hydrant) Ltr 20056 20056.0 820 16445.9 43.0 74.1 52.4 Biomass as Alternate Fuel (Green Fuel) 1410
2.3 Boiler-Startup 2482 2482.0 820 2035.2 43.0 74.1 6.5 Carbon Offset due to Tree Plantation 248
Diesel (Movable)
3.1 Company Operated vehicle 8856 8856 820 7261.9 43.0 74.1 23.1
Total 33631
3 Ltr
3.2 Diesel for Forklift 37967 37967 820 31132.9 43.0 74.1 99.2 27.3
3.5 Coal Handling-JCB 8548 8548 820 7009.4 43.0 74.1 22.3
Petrol (Movable)
4 Ltr
4.1 Company Operated Vehicles 324.77 325 720 233.8 44.3 69.3 0.7
5 Fire Extinguishers - CO2
Air Conditioners – Refrigerants
kg 521.5 522 521.5 0.5
27.3 %
6 kg
6.1 Type 1 (R22) 310.7 311 310.7 1810 offset/sequestrati
562.4
LPG Consumption
7
7.2 Canteen,Pantry & Guest house
kg
410 410 409.5 47.3 63.1 on with respect to
1.2
3
11 Welding - Acetylene m 114.5 115 4043 0.1100 0.4overall emission
SCOPE 2
Emission factor (kg CO2/kWh) Emission (t
Same for all Grid (NEWNE & S) CO2)
Purchased Elecriticy from Grid kWh 41808701 41808701 0.82 34283.1
Renewable Energy kWh 38990018 38990018 0.82 31971.8
 GHG verification & Public Disclosure
1st Indian tyre company to have verified Carbon Footprint as per IS-14064

Public Disclosure through Sustainability

Report & GHG Annual Report

55
Waste Management

56
Waste Management Policy
 Waste Collection ,Segregation ,internal transport & Handling, storage
and disposal mechanism
Hazardous Wastes Generation Treatment after ELC Recycle/Reuse Disposal
Used Oil Mixer 1. Sent to hazardous waste storage Recycled Sent to authorized recycler for reuse.
area
ETP Sludge ETP Operation 2. Quantity Entered in log Co Processed Sent to TNPCB authorized vendor
3. Kept in identified location.
Non-Hazardous Wastes Generation Treatment Recycle/Reuse Disposal
Maintenance
Metal scrap Reused to make MS parts.
Activity
1.Sent to scrap yard area.
Rubber Process Activities Reused for Rubber Parts Sent to authorized recycler for reuse.
2.Kept in identified location.
Reused for making cardboard
Cardboard & Paper Office Work
& paper bags.
1. Sent to IT dept. 2. Item noted in Sent to TNPCB authorized vendor for
e-Wastes Recycled
IT & EEI log & kept in a separate container. recycling.
Buy Back Policy. Sent back to Battery
Battery Kept in identified location Recycled
Manufacturer
Quantity Entered in log
Food Waste Canteen Used as Manure Used for Horiticulture
Kept in identified location
1. Sent to scrap yard area 2. Quantity
Reused for making Tarpaulin
Polythene Process Entered in log.3. Kept in identified Sent to authorized recycler for reuse.
and Poly ropes
location.
 Waste Collection ,Segregation ,internal transport & Handling, storage
and disposal mechanism
Waste Collection and Segregation
Metal Scrap Paper Compound E-waste Polythene

Tag from All 1.Building

RAW Material 1.Banbury All Process
Generation process 2.Super Assembly
Stores 2.Extruder Equipments
machine 3.Cutters

Collection

Segeration NA

Internal Transport to Scrap Movement to

Value Yard vendor
 Non Hazardous Waste Management
Elimination of Rubber Spew generation in Tyre Curing:

Redesigning of our Mould venting system by Sprint Vent Technology and there by eliminating the Extra
rubber/ Vents

Conventional vent - Tyre Spring vent - Tyre

Spring vent Mould

Result: 20-30 grams/Tyre rubber is saved

Horizontal Deployment: Deployed horizontally to all other moulds (65 % Existing mould modified) and
incorporated in our new mould design
 Non Hazardous Waste Management

Racks made from scrap steel

Ramps & supports

made from scrap steel

Operations/Maintenance Activities:
For operations, there is a strong policy of
conservation, reusing, recycling, and
composting everything
Non Hazardous Waste Management

Food Digester 100 % Food

Waste generated
is converted into
Manures
 Non Hazardous Waste Management
Alternate use of Boiler Fly Ash as Raw Material in Brick Manufacturing Process (TNPCB Approved Agency)
• Disposal: 100% Fly Ash Generated is Disposed to Fly Ash Brick Vendor through Closed container Vehicle
• Green Environment: Fly Ash Bricks are Environment Friendly

100 % Fly Ash

disposed to
Recycler
Fly Ash Brick
Zero Waste to Landfill

Used Oil 100% Recycled Zero Landfill

Hazardous Waste
ETP Sludge Co Processing - Plan

Non Hazardous
Sent to Recycler Zero Landfill
Waste
Non-Hazardous Wastes Recycle/Reuse
Metal scrap Reused to make MS parts.
Rubber Reused for Rubber Parts like Mats, Toys etc
Cardboard & Paper Reused for making cardboard & paper bags.
e-Wastes Sent to Authorized recycler
Buy Back Policy. Sent back to Battery
Battery
Manufacturer
Food Waste Used as Manure
Polythene Reused for making Tarpaulin and Poly ropes
Material Conservation

65
% Raw Material distribution in a Tyre
Chemicals Steel Cord
S.No Raw Material %
4% 5%
1 Rubber 52%

Oil 2 Carbon (23%) + Silica (10%) 33 %

6%
3 Process Oil 6%
4 Reinforcement Material 5%
5 Chemicals 4%
Rubber
Filler 52%
S.No Raw Material %
33%
Contributes to
1 Rubber 52% Major Consumption
in Tyre
Carbon (23%)
2 33 % Manufacturing
+ Silica (10%)

Rubber Carbon Oil Chemicals Steel Cord

 Percentage reduction in Specific Raw Material consumption

 REDUCTION IN AROMATIC OIL CONSUMPTION:

Aromatic oil, having high poly cyclic carbon content is 100% reduction
of Aromatic Oil
replaced with Low PCA oil and NAPHTHENIC OIL reducing the
hazardous impact to the environment

 REDUCTION IN CHEMICAL SPILLAGE IN MIXING AREA:

EVA and LDPE bags are used for weighing the chemicals and
used as such while mixing for compounds. ZERO % Spillage.
 Specific Reduction in Consumables

CONSUMABLES CONSUMPTION IN % Consumable % Usage

Bladder 37.8
Paint Lube 21.4
3% 2%
6% Bladder Poly-Liner 17.5
Sleeve 11.6
Paint Lube Stitcher 6
12% Gloves 3.2
38% Poly-Liner
Barcode 2.5
Sleeve
Stitcher
Consumables % Reduction
18% Gloves
Bladder 35%
Barcode Paint-Lube 73.33%
Poly-Liner 25%
21%
 Specific Reduction in Consumables

Reduction in Consumables by improving bladder’s life cycle

OLD Bladder Life Cycle of New Bladder life cycle of

240 325

35 % reduction in Bladder
Consumption
Specific Reduction in Consumables

Reduction in Mould Lube Consumption

MONO-LUBE
TO
Application
33 % REDUCTION
Application: MULTI-LUBE
1:3 GTs
Every GT

Fly loss reduction

Nozzle dia from 1mm to 0.5 26 % REDUCTION

Consumption Reduction from 30gm/tyre to 8 gm/tyre

 Specific Reduction in Consumables

Change in Liner material from

DICKSON to BERATEX increase its
durability by 25 %

Increase life by
25%

DICKSON BERATEX

Green tackiness Product Wrinkle Moisture Colour Printing

Application Durability Staining
retension release resistance absorption options YYMM

PCR/TBR Good Good Yes Yes No Zero% 7 colours Yes

SideWall,
Good Good Yes Yes No Absorbs Nil No
Sh.pad Liners
Reduction in Packaging Materials

100 % of Domestic Supply without Poly

Wrapping - No Packing

85 % of Domestic Supply without Straps

(Tubeless Tyres)

Export Packing with Packing Materials

Contributes 7 % of our overall Warehouse
Production
Green Supply Chain
 Identification of Critical Suppliers/Vendors
• All are Large Scale Industry
Vendors to CTP • Supplying to all over PAN India
192 Nos • Many Vendors are Monopoly like SKI
Carbon, Reliance, Bekaert, TATA Steel,
Misc. Items- Non Nocil, Acmechem etc.
Critical -13 Nos
Import Pan India Large - 48 Nos
119 Nos 73 Nos
RM Production –
Critical – 60 Nos Medium – 2 Nos

• All are Large Scale Industry Small – 10 No

• Supplying to all over the World Scope for
• Many Vendors are Monopoly Improvement

Criteria considered for Supplier Selection:

1. Environmental Impact and also Critical
2. SME – Where there is lot of scope for
improvement
Green Supply chain Cell
Mr. K A Unni Nayar
Vice President Works

VP Materials Green Supply chain Manager

Mr. Ashish Pandey Mr. Anand Somani
Central Purchase GM Commercial

Technical Raw Material Purchase – Stores & Spares Dispatch FGS –

Mr. Sridharan & Mr Sasi Mr. Ernaveeran Mr.Gopinath Mr.Sebastian, Mr.Akhil Das
Kumar

Production Engineering Quality Assurance

Mr. Vasubabu, Mr Anil, Mr. Suresh Rajan & Mr Mr. Chacko & Mr
Mr Nikhil & Mr Simon Jayakanthan Dinesh Kumar

Quality Assurance
Mr. Suresh

HSE Department
Mr. Karthikeyan &
Mr. Arvind
Implementation of Green Procurement Guideline
 All the Procurement activities are through SAP
 For all Raw Materials, Green initiatives like packing standards
Logistics Requirements etc., form part of Specifications issued
to suppliers and specification forms an integral part of the
Purchase contract.
 Requirement of energy efficiency gets reflected in all Purchase
documents.
 Taking measures in Energy management system by being
reactive , innovative and cost effective including procurement
of energy efficient products & services.
 As a Responsible company, we are started procuring from
suppliers near to our manufacturing plants in South. Eg. :-
Carbon Black, Zinc Oxide, Bead wire, Reclaim rubber, Stearic
Acid Which was earlier supplied from North.

No Hazardous / Toxic Materials :

We are not using any toxics and hazardous materials in our plant
Implementation of Green Procurement Guideline
Chemicals Steel Cord
S.No Raw Material Green Procurement Guideline
4% 5%
100% - Recyclable Packaging Material – Good
Oil 1 Rubber
6% pack, Open Truck
100% - Jumbo bags – To improve Logistics
2 Carbon) + Silica
Efficiency
Rubber 100% - Low PCA Oil (Env Friendly )& Receiving in
Carbon 52% 3 Process Oil
33%
Tankers in place of barrels (Logistics Efficiency)
4 Steel Cord 100% - Reusable Packaging Material

Rubber Carbon Oil Chemicals Steel Cord S.No Material Green Procurement Guideline
100% Procurement of BEE Star rated products
1 Energy Products
(Motors, AC’s , LED etc)
S.No Material Green Procurement Guideline
House Keeping
100 % Procurement Eco Friendly chemicals and
1 Chemicals &
Low VOC Paints
Paints
Implementation of Green Procurement Guideline

Rubber -Reusable Packaging Bead Wire - Reusable Packaging Silica -Jumbo Bags in place of
Material – Good pack Material – Spools Paper bags
Purchase of Green Certified Products of Material

Eco Friendly Silica in place of Carbon Black (Petro based)

100 % replacement of Aromatic Oil with LOW PCA Oil

REACH
Registration
Evaluation
Authorization/Restriction
……………….of Chemical Substances
 Purchase of Green Certified Products of Material

Air conditioner with high star rating to reduce

the consumption of electric power.
 Purchase of Green Certified Products of Material

High Energy Efficiency Motor

Eco friendly, Biodegradable & Recyclable Plastic covers used for

packing.
 Purchase of Green Certified Products of Material
Used as Room Used for Rest Room
Used as floor cleaner Freshener Sanitary Cleaning

S.NO House Keeping Area 100 % Procurement

Chemicals
Eco Friendly House Used for Glass
1 TASKI R1 Rest Room Floors
keeping chemicals Cleaning
2 TASKI R2 All Floors and Low VOC Paints
3 TASKI R3 Glass Cleaning
4 TASKI R4 Wood Polishing
5 TASKI R5 Toilet Room Freshener
6 TASKI R6 Urinal Stain Remover
7 TASKI R7 Hard Floor Cleaner
8 TASKI R9 Toilet Cleaning
9 SPIRAL HD Metal Floor and Stained Floor
 Supply Chain Efficiency Improvement
% Reduction
S.No Raw Material in MT Cumm % Before After

Loose packing in Trucks and

67.71% of Raw Material
1 Natural Rubber 2233.7 2233.71 29.60% Wooden Pallets stored directly in Metal 100%
Packaging through
Gandola
Reusable Bins, Loose
Reusable Bins like Good pack
2 Synthetic
93.31% Rubber 1255.7
of Raw Material 3489.43 46.24% Wooden Pallets packing or GPS 100%
Packaging through
3 Bead Wire
Sustainable packing 314.9 3804.30 50.41%
Reusable Packaging Material Reusable Packaging Material 100 %
4 Steel Tyre Cord 1287.1 5091.43 67.47%

5 Reclaim/Crumb Rubber 18.1 5109.52 67.71% Loose packing in Trucks and stored directly in Metal Gandola 100%
1 Ton Jumbo Bags or Paper
6 Carbon Black 1654.0 6763.47 89.63%
bags
1 Ton Jumbo bag only 100%

Fabric Roll + Dipped 80.3 %Empty

Overall
Shells reduction in Domestic
return back to the Incoming supplier for reuse
7 122.6 6886.06 91.25% 30%
Fabric Raw material
Working withPackaging
Import supplier for reuse

8 Silica 155.5 7041.56 93.31% 25 Kg Paper bag 400 Kg Jumbo Bag 93%
Working with Supplier for usage of Biodegradable or
9 Chemicals 504.7 7546.21 100.00%
Reusable Packaging Material
 Supply Chain Efficiency Improvement
Natural Rubber & Synthetic Rubber:
4819 Nos of empty
S.No Raw Material Before After % Reduction bins send back to
Loose packing in Trucks and stored directly respective vendors
1 Natural Rubber Wooden Pallets
in Metal Gandola
100% on 2018 -19

2 Synthetic Rubber Wooden Pallets Reusable Bins like Good pack or GPS 100%

X
NR stored in Metal SR stored in Good packs –
Eliminated Wooden Pallets Gandola Reusable bins
 Supply Chain Efficiency Improvement
Steel Tyre Cord and Bead Wire:
S.No Raw Material Before After % Reduction

1 Bead Wire Reusable

Packaging Reusable Packaging Material 100 %
2 Steel Tyre Cord Material

 3R (Reduce, Reuse and Recycle):-

We are receiving bead wire in steel pallets in
place of wooden packing. We have eliminated
82.4 MT of wood per year (20 kgs of wood X
4120 MT of bead wire). We are returning the
cartons & spools of steel tyre cord to the vendor.
We have eliminated 264 MT of wood per year
(20 kgs of wood X 13195 MT of STC)
Bead Wire Steel Tyre Cord
 Supply Chain Efficiency Improvement - Logistics
 Huge Savings in KMS run & Fuel was achieved due to standardization of container Height
from 8’~8.5’ to 9’ due to which we were able to load 11~22 TBR tyres extra in each
vehicle.
 In 17-18 we saved 341,000 KMS resulting to savings of 85KL fuel and 222.9 MT of CO2
 In 18-19 we saved 387,000 KMS resulting to saving of 97KL fuel and 252.6 MT of CO2
 Supply Chain Efficiency Improvement - Logistics
 We had initiated in PCR, Coins type stuffing to Lacing type stuffing for increasing load capacity and
reduce trucks & fuel.
 In 17-18 we saved 385,000 KMS resulting to savings of 96KL fuel and 251.5 MT of CO2
 In 18-19 we saved 315,000 KMS resulting to saving of 79KL fuel and 205.7 MT of CO2
Green Infrastructure &
Ecology
Green Building

INDIA’S FIRST AND ONLY PLATINUM RATED TYRE FACTORY

Green Building
Green Building
Green Building
Sports & Games to promote physical, Mental and Emotional Well being

SPIKE - VOLLEYBALL JK - MARATHON JK – PREMIER LEAGUE

JK FOG –INDOOR GAMES JK – PREMIER LEAGUE JK FOG –INDOOR GAMES

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