Foster’s India Ltd

M-99, MIDC, Waluj,

Aurangabad

FOSTER’S INDIA LTD

AURANGABAD

COMPANY PROFILE

Background:-

Foster’s Group Ltd., is a global beverage company dedicated to delivering premium branded
products to consumers in more than 156 countries around the world. Foster’s Brewing Group
became the first major international brewer to invest in India. The company completed the initial
stage of its Indian investment with the construction of a state of the art Greenfield facility in
Aurangabad, Maharashtra. Foster’s is brewed in nine countries across four continents.

Foster’s in India;-

The establishment of Foster’s India represents a landmark in the Indian beverage market. For
the first time, an international beer is being brewed in India, under world class conditions of
quality control and hygiene. The brewery has earned the prerequisite international accreditation
to brew Foster’s.

The beer brewed in India exhibits the brand’s premium characteristics, with each step in its
production rigorously controlled, One of the world’s fastest growing international beer brands,
Foster’s is ranked the 1st most recognizable beer across Asia and 5th most recognizable brand
across all product categories. It is currently available in the following markets in India; Mumbai,
Pune, Nagpur, Aurangabad, and other parts of Maharashtra, Daman & Diu, Goa, Pondicherry,
Bangalore, Hyderabad, Vizag and other places in Andhra Pradesh, Delhi, Haryana, Chandigarh,
Punjab, Jammu and Chhattisgarh.

The brand has acquired tremendous brand recall among consumers. This success can be
attributed to the Company’s strong marketing initiatives that have generated a synonymous
association between Foster’s and its Australian origin.

Foster’s synonymous with the easy going Australian lifestyle and major international sports
including Cricket, Formula One and the Olympics, offers a sense of fun, good humor and
relaxation.

Awards & Achievements :-

¾ The brand has to its credit the gold medal in the draught lager category, which was won at
the prestigious Brewing Industry International Awards, held in Britain. This only reiterates the
renowned quality of Foster’s beer worldwide.

¾ ISO 9001:2000 certification for processes and ISO 14001:1996 for environment management
systems.

¾ Foster’s has been ranked as one of the India’s Top 10 trusted Alcohol brands according to an
independent survey within three years of existence, won two awards for “Best promos of the
Year” conducted by an independent survey across various industries by a leading publishing
house.

¾ Won QAD International Case Study Award for implementation of MFG/PRO.

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 Foster’s India Ltd
M-99, MIDC, Waluj,
Aurangabad

PRODUCT PROFILE

Following products are manufactured at Foster’s Brewery, Aurangabad :-

FOSTER’S LAGER BEER : 650 ML

FOSTER’S LAGER BEER : 330 ML

FOSTER’S EXPORT PREMIUM LAGER BEER : 650 ML

FOSTER’S EXPORT PREMIUM LAGER BEER : 330 ML

AMBERRO STRONG BEER : 650 ML

AMBERRO LAGER BEER : 650 ML

AMBERRO LAGER BEER : 330 ML

Process Flow Chart: -

Attached Separately

Energy Consumption

There has been a steady decrease in the Electrical & Thermal Energy Consumption per
equivalent beer per hL due to the implementation of various energy conservation measures.

Description Unit 2001-02 2002-03 2003-04

Actual Production hL 148548 132986 163117

Electricity Lakhs kWh 27.43 24.97 25.24

consumed by the
product
Specific energy units/hL 18.47 18.78 15.47
consumption -
Electrical
Thermal energy millionkCal 6217.85 5603.26 6049.79
consumed by the
product
Thermal energy millionkCal/hL 0.0419 0.0421 0.0371
consumed by the
product

Year Electricity Thermal (Fuel)

Consumption % reduction over Consumption % reduction over
(kwh/hL beer) 2001-02 (Mkcals/hL Beer) 2001-02
2001-02 18.47 - 0.0419 -

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 Foster’s India Ltd
M-99, MIDC, Waluj,
Aurangabad

2002-03 18.78 - 0.0421 -

2003-04 15.47 19% 0.0371 13%
Electrical consumption kwh/hL beer

18.47 18.78
20 15.47
15
10
5
0
2001-02 2002-03 2003-04

Thermal Consumption Mkcals/hL beer

0.044 0.0419 0.0421
0.042
0.04
0.038 0.0371
0.036
0.034
2001-02 2002-03 2003-04

Water consumption hL/hL

10
9.57 9.6
9.5
9
8.5 8.3

8
7.5
2001-02 2002-03 2003-04

Energy Conservation Committee, Policy and Set-up :-

Foster’s India Ltd., considers fuel saving is a multi disciplinary approach. The Company’s energy
profiles consist of Electricity, Diesel, Furnace Oil & water also. Energy conservation Plan, Policy
and structure are reviewed periodically.

Awareness programme & competition on Energy Saving being organized during Safety Week
Celebration (4th March to 11th March) every year. Employees been motivated to participate in
Poster, Slogan & Quiz competition on saving. Various awareness posters on energy saving are
displayed in the Brewery.

Energy Management Policy :-

Energy Management Policy is part of Foster’s Quality, Environment & Safety Policy which is
produced below:-

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 Foster’s India Ltd
M-99, MIDC, Waluj,
Aurangabad

Title: Quality, Safety and Environment policy of Foster’s India Ltd

Quality, Safety and Environment

POLICY

We, at Foster’s India Limited, Aurangabad are committed for making consistent Quality

product and services by meeting the needs & expectations of our customers and also

ensuring our commitment towards environmental protection, occupation health and safety.

We achieve this by:

• Producing safe quality beer consistently through hygienic, clean environment,

the best use of system, competent people & advance technology at the

reasonable and the competitive cost.

• Ensure a culture of responsibility and accountability by involving all employees

in an environment of continuous improvement & learning.

• Set objectives towards zero harm or injury by maintaining a safe & eco-friendly

working environment.

• Developing and improving mutually beneficial suppliers relationship.

• Comply with all statutory and regulatory requirements related to quality,

Environment, occupational health and safety.

• Prevent pollution and Conserve natural resources through optimum utilization

of the same and also continue our efforts to minimize the volume of waste generated.

• Ensure food safety during all the stages of manufacturing.

• Adopt and Adhere to international management system based on ISO 9001,

ISO 14001, OHSAS 18001 and also the guidelines of HACCP.

Place: Aurangabad Mr. Ravi Kant Handa

Date: 1st October 2003. G M (Operations)

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 Foster’s India Ltd
M-99, MIDC, Waluj,
Aurangabad

Energy Conservation Cell Structure :-

General Manager
(Operations)

Manager - Mfg.
(EC Chief )

Sr. Executive
(EC Supervisor)

EC – Core Member EC – Core Member EC – Core Member

Energy Conservation Achievements :-

During the period 1999-2004, Foster’s India Ltd., has implemented various energy initiatives
through employees suggestions, Kaizen, Open Forum meeting , cross sharing of good
experiences across the Foster’s Group & other Industries and Self realization concept on HSE
(Health, Safety & Environment).

With the above, we have experienced the following successes: -

¾ Water to beer consumption ratio (hL/hL) has come down from 13.62 in year 1999 to 8.3 in
year 2004
¾ Electricity consumption in units per hL, has come down from 22.75 in year to 15.6 in year
2004.
¾ Fuel consumption ration Lit/hL of beer has come down from 5.89 in year 1999 to 4.46 in year
2004.

Major Projects implemented during the year 2003-04 are listed below: -

Energy Conservation Projects

1. Energy Conservation by Installation of 15KW Air compressor for off peak load
requirement instead of using 37KW

Energy consumption per year without this compressor= 324120 units Refer CD picture
Energy consumption after installation = 235170 units No. 761
Total savings = 88950 units
Total savings = Rs. 4.00 Lac

2. Installation of Automatic Power Factor controller and re-arrangement of capacitors

Average power factor per annum before installation = 0.975 Refer CD picture
No. 776

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 Foster’s India Ltd
M-99, MIDC, Waluj,
Aurangabad

Power factor from March 03 to August 04 (6 months) = UNITY

Savings from September 03 to August 04 = Rs. 3.22 Lac

3. Use of emergency lighting in non-production hours

Potential savings in Lighting load during

non-production hours = 21.5 KW
Load on emergency lighting = 1.5 KW
Savings by use of emergency lighting = 20 KW per hour
Savings per annum = Rs. 2.63 Lac

4. Installation of wind ventilators

Potential savings by avoiding the use of

Electrical ventilation = 180 units per day
Savings due to installation per annum = Rs. 2.43 Lac

5. Use of small pumps in refrigeration for Glycol and cooling tower during off-peak load

Glycol 2 pumps Cooling tower pump

Old Installation capacity 30KW 37KW
New small pump installation 15KW 7.5KW
Savings of 15KW for 10 hrs in a day Rs. 4.92 Lac Rs. 4.84 Lac

6. Re-engineering in Glycol distribution

Savings out of modification is elimination of secondary glycol pump usage during

average load = 30 KW No picture
Total savings = Rs. 2.43 Lac available

7. Installation of condensate recovery system for brewhouse and use of flash steam

Condensate recovered from the system = 3513000 litres = 12254 litres of Furnace Oil
Flash steam recovered from the system = 612 kg of steam
Total savings in 5 months = Rs. 3.03 Lac

8. Use of fuel additives & magnets on fire and water side on boiler

Boiler Efficiency improvement by 3 - 4% = Rs.4.00 Lac

From 81% to 85%

9. Installation of auto controlled water pre-heating system

Average feed water temperature from 68% to 88%

has raised by 180C - 200C thereby Reducing the annual
FO consumption by 3% = Rs. 3.00 Lac

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 Foster’s India Ltd
M-99, MIDC, Waluj,
Aurangabad

10. Installation of CO2 evaporator

Before installation, FO consumption for this = 100 Ltrs / day

After installation, FO consumption for this = 0.29 millionkcal
And also a electricity savings of = 0.29 lakhskwh
Total savings = Rs. 2.60 Lac

Other Projects implemented during 2003-04

1. Installation of measuring and monitoring instruments to analyse the opportunities for

energy conservation.
2. Use of glycol based air cooling system instead of traditional air conditioners in office and
laboratory.
3. Use of energy efficient blowers for aeration and stirring instead of traditional gear box
driven stirrers
4. Use of high capacity tanks for cold water storage in order to avoid start and stop cycle
losses
5. Construction of underground water tank to conserve the refrigeration energy since the
temperature of water store in under ground tanks is less than the overhead tank
6. Routine maintenance of all energy savings equipment.
7. Kaizen movement to conserve energy.
8. Training of people and awareness generation on energy conservation.
9. Automation in refrigeration plant utilizing every opportunity out of manual operation.
10. Maintenance of cooling tower for conservation of energy.
11. Use of MIDC water pressure for domestic purposes and filling the overhead tanks.
12. Utilising one pump for filter water and soft water generation.
13. Installation of additional valves on steam distribution lines to isolate the steam supply
whenever required.
14. Re-visiting the SOP’s of processes and equipments to reduce the waste generation
15. Collection of hot water generated in brewhouse for use in boiler thereby reducing the cold
fresh water make up quantity.
16. Increasing the overall equipment efficiency conserve energy.
17. Conversion of forklift operation from mechanical to electronic to conserve the energy
required for frequent charging.
18. Electronic controls for switching off motors by way of level, temperature, time and
pressure signals

Energy Conservation Plan and Targets

Energy Conservation Measure (Planned) Anticipated Approx. Project
savings in investment commencement
Energy (Rs. Lakhs) & Completion
(Rs.Lakhs) year
Use of effimax 4000 system on boiler to limit 1.50 / annum 6.00 2005-2006
excess air by monitoring oxygen levels in stack
and automatically controlled the inlet air, and
also analyse the steam consumption pattern,
and monitor the Steam to fuel ratio on line
Generation of electricity from methane gas in 5.00 / annum 30.00 2006-07
ETP
Replacement of existing compressor based 8.00 / annum 45.00 2006-07

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 Foster’s India Ltd
M-99, MIDC, Waluj,
Aurangabad

system to vapour absorption based refrigerated

system for refrigeration
Replacement of mercury vapour lamps by tube 1.00 / annum 5.00 2005-06
lights with electronic choke
Separation of refrigeration system for cold 1.10 / annum 3.00 2004-05
water generation
Installation of new bottle washer for conserving 100.00/annum 250.00 2004-05
energy for bottle washing
Replacement of aeration stirrers by energy 1.00/ annum 5.00 2004-05
efficient blowers
Installation of conserve air on compressor 0.50/annum 2.00 2004-05
Use of energy efficient pumps for transfer of 1.00 / annum 5.00 2004-05
product
Installation of AC drives on KC6 compressors 2.00/ annum 15.00 2005-06
Converting the manual processes to auto 2.00 / annum 10.00 2004-05
Installation of 20MT CO2 storage tank to 6.00 / annum 40.00 2004-05
recover 100% in house generated CO2
Installation of AC dives on packaging 1.50/ annum 10.00 2005-06
conveyors
Installation of wind ventilators in other areas of NIL 10.00 2005-08
Plant
Hot water generation from ammonia 0.75 / annum 6.00 2005-06
compressor discharge for use in pasteuriser

All other initiatives like Kaizens, suggestion schemes, Engineering initiatives, open forum, self-
realization concept etc. will continue. By adopting the above energy conservation, Foster’s will be
able to achieve the best target by the year 2005-06.

Environment & Safety :-

Foster’s India Ltd., is committed to the protection of the environment by Prevention & Pollution
and continual improvement in the Environmental Performance. The Company has successfully
worked on Environmental Management System (ISO 14001) & Occupational Health, Safety
Assessment Series (OHSAS 18001) and bagged both the certification in June 2003 & Feb 2004
respectively from ICS India. We have clearly focused on the following: -

• Conservation of natural resources like water, energy & fuel

• Effective Pollution Prevention
• Effective waste management
• Good Health of each employee
• Zero injury

The above has been implemented with the use of research and technological innovation, bringing
out & implementing all good ideas, supporting the overall process with effective leadership,
sharing & learning from others & keeping the commitment to the overall concept through long
terms policies & systems.

100% usage of Treated Effluent for complete landscaping & providing green cover to 11 acres
land in the factory premises, resulting in zero usage of raw water from MIDC & also zero
discharge of treated effluent with a complete pipeline distribution network with a capital
investment of more than Rs. 9 lacs.

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 Foster’s India Ltd
M-99, MIDC, Waluj,
Aurangabad

Industrial Safety is an essential & integral part of every operation at Foster’s India Ltd., FIL is
having its complete 16 sets of standards on HSE in combination with OHSAS 18001. FIL has
received letter of appreciation from TERI, New Delhi. FIL also participated in awards by various
institutes like CII, FICCI. “Zero Harm or injury” is the main object behind it.

Following activities are introduced to achieve zero harm or injury :-

• Monthly safety committee Meeting

• Monthly safety audit to locate unsafe conditions, acts
• Well defined system on Accident reporting & investigation
• Self realisation concept on Safety
• Safety Week celebration
• Periodic Mock Drills
• Training on Safety to all employees like Fire Demo, First Aid, HSE etc.,
• Work permit system etc
• Kaizens

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 Foster’s India Ltd.,
M-99, MIDC, Waluj,
Aurangabad
Project – Energy Conservation by Installation of 15KW Air compressor for off peak load
requirement instead of using 37KW

Background of the Project: - Production fluctuation on account of Seasonality

Observations made: The need for pressurized air varies depending upon the production cycles.
The volume of air required during non-production hours was less than 50%.

Technical & Financial analysis made: Installation of a small compressor during this non-
production hours could conserve energy.

Impact of implementation: Opportunity resulted in savings of 22KW per hour in non-production

hours resulting to the savings of Rs. 4.00 Lac

Project – Installation of Automatic Power Factor controller and re-arrangement of

capacitors

Background of the Project: - Scope to reduce the energy losses, grab the opportunity of discounts
in MSEB bills.

Observations made: Power factor was always stable on production days. During non-production
hours the PF dropped to 0.97 and capacitors switching cycles were more.

Technical & Financial analysis made: Installed the PF meter, which enabled the PF to raise to
0.99, however the PF during non-production hours was difficult to sustain, which further was
rectified by selecting the rating and re-locating the capacitors in the Plant.

Impact of implementation: We have achieved unity factor for last 6 months and annual savings
are Rs. 3.22 Lac

Project – Use of emergency lighting in non-production hours

Background of the Project: - There was a need of emergency lights in the Plant premises during
night time.

Observations made: Energy conservation gave a thought to select CFL as emergency lights.
Further the idea to use them during non-production hours clicked another energy conservation
project.

Technical & Financial analysis made: Since there are minimal manpower in the plant, during non
production hours, the lighting requirement was also minimal. There was a scope to switch off
20KW lighting load.

Impact of implementation: Savings to the tune of Rs. 2.63 Lacs per annum achieved in addition to
additional emergency lighting requirement.

Project – Installation of wind ventilators

Background of the Project: - The process areas needs air circulation throughout the day in order
to provide better working environment.

Observations made: There was a need for installing air handling units, which would have
increased the electrical load by around 50KW. The idea of using energy conservation devices
forced us to use wind ventilators.

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 Foster’s India Ltd.,
M-99, MIDC, Waluj,
Aurangabad
Technical & Financial analysis made: Although wind ventilators are costly, we decided to go with
its installation in phases in order to conserve energy.

Impact of implementation: Energy conservation. Savings of Rs. 2.43 Lac

Project – Use of small pumps in refrigeration for Glycol and cooling tower during off-peak
load

Background of the Project: - The refrigeration load varies depending upon the beer to be
produced, which is a batch process.

Observations made: The refrigeration load is more during beer manufacturing process and
reduces to 30% during non- manufacturing period.

Technical & Financial analysis made: The volume of chilled glycol supply reduces to 30% than
that during the peak hours. This was an opportunity for conservation of energy. We therefore
installed two small pumps for this purpose.

Impact of implementation: Energy saving without impacting the process parameters to the extent
of Rs.4.84 Lac

Project – Re-engineering in Glycol distribution

Background of the Project: - During non-production hours, due to reduction in refrigeration loads,
the amount of glycol required was less.

Observations made: We were using more volumes of glycol, which was a waste of energy. Hence
we decided to change the glycol distribution and did glycol circulation through one single tank.

Technical & Financial analysis made: The modification in pipe line distribution was negligible cost
as compared to the energy conservation from it.

Impact of implementation: Energy savings to the tune of Rs. 2.43 Lac

Project – Installation of condensate recovery system for brewhouse and use of flash steam

Background of the Project: - Energy conservation to reduce FO consumption

Observations made: The steam requirement is highest during brewing hours. This caused the use
of more make up quantities of cold feed water.

Technical & Financial analysis made: There was a drop in efficiency of boiler on account of cold
water addition, which reduced the feed water temperature. There was an opportunity to re-collect
the condensate during the peak hours, which was at a temperature of 90 C and feed it back to
boiler.

Impact of implementation: It has reduced the cold feed water requirement and maintains the feed
water temperature during peak hours resulting in energy and savings to the tune of Rs. 3.03 Lac

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 Foster’s India Ltd.,
M-99, MIDC, Waluj,
Aurangabad
Project – Use of fuel additives & magnets on fire and waterside on boiler

Background of the Project: - In-Consistent Boiler efficiency

Observations made: We observed that the boiler needs to be tuned with every lot of FO received
to maintain the combustion efficiencies. The scaling on the boiler tubes and shell resulted in
reduction in heat transfer leading to more FO consumption.

Technical & Financial analysis made: The use of additives and fire side magnets helped us to
improve the atomization thus resulting in improved combustion efficiencies, reduction in excess
air and reduction in soot formation and maintain the stack temperatures for a longer period. The
waterside magnets helped us to avoid scaling on waterside.

Impact of implementation: Self-maintenance of heat transfer surface and consistency in

maintaining boiler efficiency in a narrow bandwidth resulting in energy savings of Rs. 4.00 Lac

Project – Installation of auto controlled feed water pre-heating system

Background of the Project: - Improve S/F ratio in boiler.

Observations made: Average feed water temp. was not being maintained on account of
fluctuation in steam demand, feed water level in the tank and manual control on feed water
heating. There was an opportunity to increase the efficiency by 3%.

Technical & Financial analysis made: Installed water level controller and auto steam controller to
heat the feed water in order to maintain it between 85 to 950 C.

Impact of implementation: Rise in feed water temperature resulted in reduction in FO

consumption by around 2.5 to 3% and savings to the tune of Rs.3.00 Lac.

Project - Installation of CO2 evaporator

Background of the Project: - Heat recovery from liquid CO2 to reduce the energy consumption in
refrigeration.

Observations made: On order to convert liquid CO2 to vapour, we were using steam. Liquid CO2
is available at a temp. of –25 deg. C. We were using steam at 130 deg. C. There was an
opportunity to use glycol and recover the cold energy from CO2 without using steam for this
conversion.

Technical & Financial analysis made: There was a dual purpose of conserving energy. A) Used
cold energy to chill glycol, which is done in refrigeration plant. B) Eliminate the use of FO.

Impact of implementation: Reduction in FO for this purpose, and heat recovery from CO2 thereby
reducing the refrigeration load resulting savings to the tune of Rs. 2.60 Lac