Established in 1966
Sales: US$ 555 million
Global manufacturing presence: India, China, UK and Germany
Comprising of 12 manufacturing plants
First Indian company to get ISO 9000
Location
Products Manufactured
No. of Employees
408
Annual Sales -
(2014-15)
93.50%
Milestones of KPM
2012
TN Govt.
GREEN
Award
2008
TPM
Special
Award
2001
ISO 14001
2006
SHE Award
1998
TPM
Excellence
Award
1981
Start of
Production
2013
Greenco
Gold
1990
ISO 9002
Factory Location
Krishnapuram
40-60 cm. annual
rainfall
Stream segregation
Sources of effluent
Metal
finishing
Zinc
plating
Acid/
alkali
wash
Domestic
(canteen, toilet)
Zinc
phospahting
Zinc wash
ETP
GreenCo Summit 2015
Coil
phosphating
Chrome
wash
STP
Early Days
190 KL / Day
IETP
190 KL / Day
220 KL /day
B/O
Water
Process
30 KL / day
Domestic
usage
220 KL /
day
Sewage
Treatment
30 KL
day
Dischar
ge to
ground
Recycle Stage 1 RO I
Reuse
175KL
250 KL / day
IETP
RO I stage
250 KL / day
Process
B/O
Water
Domestic
usage
125 KL /
day
Sl No Item
RO
Reject
50 KL / day
KL/Day
STP
40 KL / day
1 Consumption
300
2 Bought out
125
42
3 Bore water
4 Recovery
175
58
5 Recycled
300 100
6 Discharge
50
17
Discharge
to ground
High
Dissolved
solids
75 KL / day
Solar
pond
IETP
Ultra
Filteration
360
KL
RO 2 stages
400 KL / day
Process
B/O
Water
Domestic
usage
100 KL /
day
Sl
Item
No
50 KL / day
STP
KL/Day %
50 KL / day
1 Consumption
450
2 Bought out
125
28
3 Bore water
4 Recovery
360
80
5 Recycled
400
89
6 Discharge
50
11
Discharge
to ground
High
Dissolved
solids
RO
Reject
40 KL / day
Solar
pond
MVR fan
Vacuum
pump
58 0C
Feed
Heat
exchanger
Condensate
Out
Condensate
pump
Concentrate
pump
To crystalliser
section
Recirculation
pump
Condensate
tank
From RO 360 KL
/ day
RO plant
100 KL /day
Permeate
RO reject
40 KL / day
Treated
sewage
MVR
Reject
70 KL / day
Sl
No
Item
1 Consumption
2 Bought out
3 Bore water
4 Recovery
5 Recycle
6 Discharge
KL/ day
470
10
0
460
470
0
Solar
Pond
2
0
98
100
0
10 KL / day
Water
Vapour
Feed
Vapour
Vapour
Vapour
Steam
Vapour
Waste Heat
Concentrate
Primary Condensate
Condensate
MVR
UNIT
RO
6 KL / day
100 KL / day
Crystallizer
Permeate
Permeate
10 KL / day
MVR
Reject
Sl No Item
KL/ day %
1 Consumption
470
2 Bought out
10 2
3 Bore water
0 0
4
Recovery
466 99
5
Recycle
470 100
6
Discharge
0 0
2000
Kg
Slurry
Solar Pond
Water Management
Journey Towards 100% Recycling
Ultra Filtration
Effluent Treatment
Plant
Reverse Osmosis
% Reocvery
100
80
60
40
20
0
Series1
Recovery
Befor
e RO
RO I
UF/
RO II
MVR
MVR/
Crys
57
80
98
99
Crystallizer
Mechanical Vapour
Recompressor
Water Conservation
12 % reduction in water consumed in last 3 years
through various projects Industrial use
20 % reduction in water consumed in last 3 years in
domestic use
Rain water harvesting improved water table and
quality
Challenges
Challenges (contd..)