C-1, MIDC, Lohara, Yavatmal – 445 001 (MS)

Plant Details

Location Raymond UCO Situated in Vidharbha ,Yavatmal

Maharashtra.
Maharashtra Industrial Development Corporation (MIDC)
Manufacturing Denim Fabric
Commissioning 1996
of Plant
Capacity Fabric( Denim) – 420 Lac Mtr.

Plot Area of 557311 Sq. Mts.

Plant Industrial Utilization - 200631.96 Sq. Mtr.
Residential - 55731.10
Green Belt - 70853 Sq. Mtr.
Roads - 30094.94
Utility Power - 128.53 Lacs Kwh per annum
Consumption Water - 15300 Lacs Ltrs per annum
Man Power Employed Staff - 415 , Workers - 1110

Accolades An ISO 9001:2000 Certified Company. ; SA – 8000 ; GOTS

Raymond UCO Denim Private Limited

Raymond Group is a front runner in the Indian textiles market. Denim plant of Yavatmal is single largest
Denim fabric producer in India. Raymond Denim is well recognized in India and created a favorable image in
international market.
The plant is located in Yavatmal (Maharashtra) and manufacturing one of the best Quality ring Denim fabric. In
the year 2007-08, 337.94 Lac linear meter fabric was produced and sales turn over was 400.08 Corers.
M/s Raymond UCO (Denim Pvt. Ltd) has adopted latest modern technology with Energy Efficient Technique
from the beginning. For example we have fitted all the tube fittings with electronic ballast, all the lighting was
supplied with low voltage, street lights were with timers, Variable frequency drives were used in almost all the
application & automation was used to great extent.
We strive continuously to reduce our specific energy consumption by a well established system in place for
monitoring, and finding innovative techniques for adopting Energy Efficient Equipment and machineries.
The following figures itself explain that, how we are rationally uses the energy-
In the year of 2007-08 we have increased the connected load by – 41.42 % still we have reduced the Energy Cost
by – 1.8%.This was achieved by maintaining the specific power (Kwh/Mtr) and Thermal (Kcal/Mtr)
consumption equal to or less than last two years.

We believe energy conservation as the way of life and thus for the year 2008-09 we have planed a huge
investment towards it. The Projects planed would cost Rs.170Lac with a lucrative return of Rs.197 Lac/annum.
Most of the plans (Almost 70%) are under either erection or commissioning.
Our aim is to become a role model to all the Denim manufacturing units in terms of Quality, Quantity and
Efficient Utilization of ENERGY.
Looking to our commitment for continual improvement and preparedness for investment towards energy
conservation, we strongly believe that we are the most eligible participant for this prestigious award.

C-1, MIDC, Lohara, Yavatmal – 445 001 (MS)

Energy Management Policy

We at Raymond UCO Denim Private Limited. Yavatmal, involve in the production of High
quality Denim Fabric and Yarn, are dedicated to Conserve Energy for the self, National and global
interest without affecting our product quality.

We strive continuously to –

Reduce specific energy consumption of the plant.

Use renewable energy sources wherever possible.
Rationalize the consumption of fossil fuels.
Implement the innovative techniques to reduce energy consumption.
Comply with the Energy Legislation and other regulations.
Spread and implement the information of energy conservation techniques in
organization.
Educate the people / student on the benefit of energy conservation.
Reduce the specific energy consumption of our plant by 1% for next 5 years
i.e. up to 2013

Suketu Shah

Chief Manufacturing Officer

Quality Policy

We are committed to delight

and service the most discerning
customers of
Denim Garment Brands
all over the world.
We endeavor to achieve this
by consistent quality
and timely delivery of Specialty Denims.

E. S. Sankar
Chief Operating Officer ( INDIA )
Environmental Policy

To build and sustain an organization which is totally committed to

Conserve and protect the environment through
Prevention of Pollution
*
Continual Improvement in environmental performance
*
Compliance with all environmental legislation and regulations
Applicable to plant operations
*
Our motto
*
To give a
CLEANER & GREENER
Environment to the posterity

Suketu Shah
Chief Manufacturing Officer
 Methodology adopted for energy
conservation

1. Energy Conservation Cell

2. Small Group Activity of departments
3. Awareness & Training
4. Continuous Monitoring
5. Bench Marking
6. Energy audit ( Internal & External)
7. Adoption of new ideas through various inputs.
1. Energy Conservation Cell

Encon Cell Structure

Plant Head

DGM Engineering

Mechanical Elect/ Inst

Power Plant Engg. Engg. Manager Energy Conservation Civil Engg

ENCON Cell

Small Groups

Engineering Spinning Weaving Dyeing Processing

1. Energy Conservation Cell

Management of Energy Conservation

Programs

Constitution Of Energy Conservation Cell:

A full fledge group of 9 members has been formed which includes one or
two member from each department and headed by Energy Manager. This
group known as Energy Conservation Cell (ECC), meets once in every
month to review progress on matter of Energy Conservation measures
implementation and follow-up.
Technical Committee:
Technical committee is formed which comprises of Engineers from all
Faculties viz., Mechanical, Electrical, Electronics and Textile, headed by
DGM Engineering. This committee evaluates suggestions and
recommendations of Energy Conservation Cell for its technical and
financial aspects. Than a proposal is prepared and submitted to top
management for its approval.
1. Energy Conservation Cell

Functions Of Energy Conservation Cell

• To ensure Involvement of top level Management to workman for
the cause of Energy Conservation
• To create Awareness among all employees regarding Energy Conservation
• To obtain Approval from top management for implementation of
vital suggestions
• Organizing Periodic Meetings to brainstorm along with workmen and
evaluate feasibility of suggestions received from employees
• Workout of Savings achieved after implementation of saving projects
• Data Compilation and send it to corporate office
• Close Monitoring and follow-up of Energy Conservation Activities
2. Small Group Activity of departments

Small Group Activity

• A small group is formed in each Dept.

• Idea is to get direct input from the users

• Ownership of the ideas and Energy conservation

• Spreading the importance of Energy Conservation

3. Awareness and training

Energy Conservation - Awareness

•Displayof Slogans and Banners at various locations in mills

premises for promotion of Energy Conservation amongst the
employees

•Formation of small Group Activities and Task Force cell at

department level to ensure involvement of Workmen in Energy
Conservation Activities

•Conduct the workshop on energy Efficient Motors and invited

delegates from out side Industries

•Continues motivation to all members through reorganization and

reward.
3. Awareness and training

Energy Conservation - Awareness

Displays at Various Locations

3. Awareness and training

Energy Conservation - Awareness

Displays at Various Locations

3. Awareness and training

Energy Conservation - Awareness

Program Conducted in Raymond UCO Denim Private Limited

3. Awareness and training

Energy Conservation - Awareness

Training program attended by Cell Member

These programs are the part of Employ Motion and Awareness

No Of
Sr. No. Program name & Details Organized by Participant Duration
1 Workshop on International copper
Energy Efficient Promotion Council of
Motors India & Raymond 20 1 Day
UCO, Yavatmal

2 3L Workshop for BEE India

Textiles Sector 1 1 Day
4. Continuous Monitoring

Absolute Energy Savings Vs Investment

for Energy Conservation
60 54.52 Savings Lakhs
50
42.17 Invest. Lakhs
38.79
40
Lakh Rs.

30
21.5
17.41
20

10
2.65
0
2005-06 2006-07 2007-08
Year
Year 2005-06 2006-07 2007-08

Savings in Rs. Lakhs 42.17 38.79 54.52

Investment in Rs. Lakhs 2.65 21.5 17.41

4. Continuous Monitoring

Absolute Energy Savings in Electrical Units

14 12.05 Savings in
12 Lakh KWH
10 8.62
Lakh KWH

7.97
8
6
4
2
0
2005-06 2006-07 2007-08
Year

Year 2005-06 2006-07 2007-08

Energy saved in Lacs KWH 12.05 8.62 7.97
4. Continuous Monitoring

Specific Energy Consumption

2.50
2.22
Kwh/Mtr

2.10
Kwh/Mtr
2.00

1.50
2006-07 2007-08

Year
2006-07 2007-08 % Change
Year
(a) (b) (a-b/a)*100
Specific Energy Consumption in KWH/ Mtr 2.10 2.22 -5.7

Connected Load 13401.26 18952.26 -41.42

Value added products 58% 73% -25.86
4. Continuous Monitoring

Specific Water Consumption

60 53.4
Ltr/Mtr
46.5 45.2
45
Kwh/Mtr

30

15

0
2005-06 2006-07 2007-08

Year

Year 2005-06 2006-07 2007-08

Ltrs / Mtr 53.4 46.5 45.27
Innovative Technologies Employed

Natural Draft Cooling Tower

Cooling Water Recovery Pump

Waste Heat Recovery Boiler at

FO Generator Power Plant.

Use of Wind Energy

Innovative Technologies Employed

Air Booster Pump

Caustic Recovery Plant

Automatic Steam Control Valve

Waste Heat Recovery Plate

7. Adoption of new ideas through various inputs

Measures taken for Encon: 07-08

Heat Recovery Plate

Location of Installation : Caustic

Recovery Plant

No. of Installation : 1

Advantages : Saved Thermal Energy

: 3888 Lac Kcal/
Annum

TOTAL Investment Rs. 2 Lac. : Saving Rs. 5.38 Lac/Year

7. Adoption of new ideas through various inputs

Measures taken for Encon: 07-08

Automatic Steam Control Valve

Location of Installation : Rope Dyeing, Desizer and

Finishing

No. of Installation :5

Advantages : Saved Thermal Energy

: 7776 Lac Kcal/ Annum

TOTAL Investment Rs. 2.1 Lac. Saving Rs.9.62 Lac/Year

7. Adoption of new ideas through various inputs

Innovative Technologies Employed

First Time in Textiles Industries

Location of Installation : Master Dyeing Machine
No. of Installation :1
Advantages : Saved 11 KW Electrical Energy by
stopping compressor.

Saving - 0.81 Lac Kwh/ Annum

TOTAL Investment Rs.0.35Lac. Saving Rs.3.80 Lac/Annum

Principal Of Working –
It takes the compress air of 6/ 7 Kg /cm2.
And compresses it further up to12Kg.
With the help of inbuilt pneumatic booster pump.
7. Adoption of new ideas through various inputs

Measures taken for Encon: 07-08

Pulley change

It was observed that 90 kw compressor motor was having minimum loading cycle, and
was taking 130Amp,on load and 56 Amp on Unload. The Driver Pulley was of 30 Inch.
Observation
This Pulley was replaced with 36 inches Pulley. Which result in increase in loading
time with less current.
Before After
Power consumption Kwh/Day 888 775.2
Power consumption Kwh/year 306360 267444
Power saving Kwh / year 38916
Saving Rs. ( lac/ Year ) 1.95
7. Adoption of new ideas through various inputs

Measures taken for Encon: 07-08

VFD at Boiler FD Fan

The ID fan No.3 having 30 kw motor was running on star delta starter. VFD was
Observation incorporated for it (ABB Make) and it was observed that nearly 50% power was
saved.
Before After

Power consumption Kwh / Day 470 334

Power consumption Kwh /year 162150 115230
Power saving Kwh/ year 46920

Saving Rs. ( lac/ Year ) 2.35

7. Adoption of new ideas through various inputs

Measures taken for Encon: 07-08

VFD At CT Fan

The CT fan having 22 kw motor was running on star delta starter. VFD was
Observation incorporated for it ( ABB Make) and it was observed that nearly 65% power was
saved.
Before After

Power consumption Kwh/Day 384 160.8

Power consumption Kwh /year 132480 55476

Power saving Kwh / year 77004

Saving Rs. ( lac/ Year ) 3.85
7. Adoption of new ideas through various inputs

Measures taken for Encon: 07-08

VFD At Boiler ID Fan

VFD of ABB make was introduced for 37 kw ID fan motor at Boiler No.1 and
Observation
it was observed that 26% power was saved

Before After

Power consumption/Day 686 432

Power consumption /year 226380 142560
Power saving / year 83820

Saving Rs. ( lac/ Year ) 4.19

Use of Renewable Energy Sources

1. Solar Energy

Location of Installation : Solar Water Heaters at Mill Guest House.

No. of Installation : 08
Capacity : 500 lit/day
Advantages : Saved electrical energy 4000KWH/Year
Replaced 8 no. of electrical geysers of 2 KWh. Hot water available for 24 hours for 250 days/year.
Saving on maintenance cost of geysers.
Safe operation than Electrical geysers.
KWH Saved =8* 2*250 = 4000KWH/ Year
Use of Renewable Energy Sources

2. Wind Energy

Location of Installation : Turbo Ventilators at roof

of Dyeing &Process house
No. of Air Changes : 12
No. of Installation : 60
Advantages : Saved electrical energy 2.14 Lac KWH/annum
Replaced 20 no. of 1.5 KW electrical exhaust fans.
Inside room temperature decrease.
Illumination level increase due to natural light through transparent PVC sheet
Driven by wind power, no electricity required Maintenance free
Use of Renewable Energy Sources

3. Use Of Natural Sun Light

Location of Installation : Transparent PVC sheet at Process,

dyeing and finishing roof.
No. of Installation : 50
Advantages : Illumination level increased
Maintenance free.
Saved Electrical Energy 11520/ Year
No of T/L stopped = 96
Light OFF for day time for 250 Days/ year.
KWH saved / Year = 80x96x6x250 = 11520 KWH/ Year
Management of Energy Conservation
Programs

Finance Availability :

Projects having recommendation of Energy Conservation Cell and are

having investment Up to Rs. 5.0 Lacs are approved by CMO At Plant Level
itself

Projects having investment more than Rs. 5.0 Lacs are send for approval to
corporate office, Thane for Capital Expenditure Budgeting
Save Energy
Save Future !

Thank You…!