This is a presentation from GlaxoSmithKline, one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008 The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry. This presentation was in the "Within the Fence" category. We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.

1. Excellence in Water Management
@
GlaxoSmithKline Consumer Healthcare Ltd
Rajahmundry
E HS V isio n
To achiev e
Site Profile Compet it ive Busi ness
advant age t hrough
Lead ership
and Exc el l enc e
in EHS
Rajahmundry
G SKCH, India
Ø Indian br anch of G lax oSmithKlin e plc U .K.
Ø Manufactur ing sites at Nabha, Rajahmu ndr y and Sonepat
A bout Rajahm undr y
Ø Commer cial pr oduction star ted in 1973 ww w.gsk.com
Ø Capa city Installed – 24 KT
Ø Pr oduct Portfolio: Hor licks, Cho co late Hor licks, Boost Cho cob last
Ø Employees ~ 1500 (In cl. co ntr actor employees)
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2. Mfg Process & Water IPO
HORLIC KS - Man ufacturin g p rocess flow diagr am
Malted Barely
Wh e t Glu te n
a
W heat F lour
IS P
Mash ing
Malt Ext ract
Raw water Mas h s e aration
p Waste water
Sa lts & Min e rals
Hu sk w ashi ng
Milk rece tion
p
Steam Weak Wort Condensat e
Milk Pas teurizat ion
W ort hol ding
CCP - 1
Milk h oldin g
Filter ed water Evaporat ion - 1 st st age
n d s tag
O ily Vit amin
(A,D ,E ),K
Milk s ta ndard iz tion
a
Condens er
Evaporat ion 2 e
SMP
Chill water F ood Trans fer for
sp read ing on trays FCS
Dry Vit amin
Hot water
Oven dryi ng ( B- Comp lex & C)
Trays s crap ping
P ART - B
CCP - 2 Grind ing
I on
r
con tamin at ion Mixing
P acking i n Drums
Water Out flow
Waste Water
• Utilities Recycl e
• Other Fu nctio ns
• Manufactur ing
Condensat e Reuse
Cond ens er water Reuse , Recycl e
Hot water Reuse , Recycl e
Gr o u n d W a t e
r f o m Bo r e
r
we l s
Rechargin g
of grou nd
Co o li n g &
Do m e s ti c P r o d u c ti o n
water
B o il er f ed
e
R a i n w a te r
E f f lu e n t
Tr e a t e n t P l n t
m a
Me t h a n e
Ga s
Us e d i n c a n t e e n f o r
f o o dp r e p a r t i n
a o
3 R (Zero Discharge) - 100% Compliance
har es t i g
v n pi
t
R e so ur ce
T r at e
e d
W at e s or e
r t d W a te r r e u s e d
f or gar eni ng
d
su b st i t u t i on
i
n l goon
a ( R e p la c in g LP G )
R e u se
R echar e of
g Fi h
s c ul ur
t e
wa t e r t o R e so ur ce
gr ound
B i o - di v er si t y
co n ser va t i on
12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.02

3. Resource Conservation Strategy
Idea Cam ps,
Sugg estion box es/JDIs
EHS Kaizens &
Plan for Pr ojec ts
Exc ellenc e
Top Down GMS – India Baselining & Bottom up
Stra teg y Benc hmar king
Innovatio n &
EHS program & Collaboratio n
pr ocedur es at sit e
Cor por at e
Functiona l & pr ogram s
Indiv idual objectives
Employee Engagement
Training & E ducation
Visual displ ays/ Controls
Idea Camp s
Competitio ns – Posters/Slog an s
Suggestion Boxes
Just Do Its
Aware ness ca mpai gn Rew ards & Recognition / Spirit Aw ards
Site Director o bserv ing the
entries i n Slogan Co mpe titi on
Rewar d to Em plo ye e
12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.03

4. Water Kaizen
Brainstormi ng sessio n
on water c ons erv ation
• Basel ining t he Curr ent p erformance.
Process follow ed • Studied cons umptio n patter n for la st 1 y ear
• Identifi ed cros s functio nal team
• Co nducted Kaize n eve nt on 21st Sep’0 6
• End hose co ntrol systems put in u se
• Replaci ng ra w water p oints wit h treate d one s
• Providi ng pu sh typ e cocks in toilets
Key Result Areas • Leak/ spil l contro l clamp s
• Rational ization of was h po ints (6 3 to 48)
– nee d base d
• 48 UDE’s Ide ntified
• Impl ement ed all Quick wi n so lution s in
Benefits 3 month s
Soluti on ide nti ficati on for
• Water consu mptio n is reduce d by 30%
the op portuni ties
pe r T OP
Community Involvement
Students witnessing a Slide from ‘Con necti ng Little
demonstration during the session Hearts’ on wate r conservation
Imbi bed EHS
concepts in 1550
young “ Ignited
Minds ”
Site Director administering oath
to Conserve Natu ral Resources
12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.04

5. Monitoring & Review system
Repor ting
Water
Consumption
Format for monitoring
Spec ifi c water consumption
Format for monitoring
Absolute water
consumption
20 06 20 07 2 00 8 20 08 ac tual s 20 09 20 10 Tra ff ic
KPI UO M
a ct ua ls ac tual s Ta rge t Target Targe t Light
Month YTD
2008
S ite 2007 Target Q3 2008 P lan 2008 FC
Month YTD
List of Water Conservation Projects
Investment Water Savings Annual Saving
Project/JDI (m3/day)
Rs. in ‘000 (Rs.)
Floor cleaning ma chine
Floor cleaning ma chine 660 20 9782
Tray cleaning mach ine 365 55 26900
Optimization of water pressure - 100 105668
Improving con densate reco very 75 30 14673
Use of Cooling Tower water for va cuum - 130 60262
pump sealing
Auto flush for toilets at Admin blo ck 12 2 978
Use of nozzles for drum washing - 5 4891
Treated Water for flushing of toilet 3 3 1467
End of hose control
Treated water for coal wetting 5 5 4891
Modification of flushing at Amen ity 5 20 9782
blocks
Introduction of self closing taps 1 5 4891
12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.05

6. Initiatives : Floor Cleaning machine (2006)
Before
Wastage of w ater arising fr om conventional floor
cleaning is eliminated thr ough use of Flo or Cleaning
m achine
Investment : 6.6 Lakhs
Water savings per annum : 7300 m 3
After
Mech an ize d C le an in g usi ng Fl oo r
Cle an in g ma chi ne
Initiatives : Mechanization of Tray cleaning
(2007)
After
Befor e
Manual clea ning of foo d tr ays w as r eplaced
w ith mechanized cleaning
Investment : Rs. 3.65 Lakhs
Water savings per annum : 20000 m 3
12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.06

7. Initiatives : Optimization of Water pressure
• Redu ction of Water pr essur e : 1.5 to 0.9 Kgs/Sq cm
• Use of Var iable Fr equency Drive
Investment : Nil 1.5 Kg / cm2
Water savings per annum : 36500 m 3
0.9 Kg / cm2
Initiatives : Improving Condensate Recovery
Impr ovement of Conde nsate r ecover y : 61.7 to 75 %
Resu lt : Red uction in DM w ater consumption by 28.7 Cu. M / Day
Investment : Rs. 0.75 Lakhs
Befor e implementation : 84.3 m3/day
After implementation : 55 m3/day
Water savings per annum : 10700 m3
12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.07

8. Initiatives : Cooling Water for seal cooling
of Vacuum pumps
Cooling Tow er wa ter was r eused for seal c ooling of Vac uum
pum ps in plac e of F resh water
Inv estment : Insig nif icant
Befor e im plement at ion : 130m 3 /day
After im plem entation : Nil (As C ooling Tow er
wat er is r eused)
Wat er sav ings per annum : 474 50 m 3
Fresh water l ine disco nnec ted
and c on necte d with Co oli ng water
Initiatives : Auto flush for toilet
Every drop count s …
Small change …
Sustained improvement
12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.08

9. Initiatives : Sprinkler & Drip Irrigation
Sprinkler i n use Drip irriga tio n o n-si te
Performance delivered
38% reduction
In 3 yrs sp an
25 21.1
17.3
20 15.5
KL per Ton
13
15
10
5
0
2004 2005 2006 2007
Speci fi c Water co nsum ption
12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.09

10. Performance delivered
45% reduction
277 In 3 yrs sp an
300 255
250
Lit. per Day
172 152
200
150
100
50
0
2004 2005 2006 2007
Per capit a Wat er consumption
Waste Water Treatment - Process
KITCHEN
Bio-gas Do me Not in use
(50 Cu.M)
Process Canteen / Do m estic
Aerati on Tank – II (1013 KL)
Fat Trap Eq. Tank UASBR Aerati on Clarifier
Tank - I
(25 KL) (200 KL) (287 KL) (271 KL)
(510 KL)
Treat ed Wa ter to
Green Bel t
12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.010

11. Waste Water Treatment - Facility
Supply to Cant een
Bio-gas Collection
Equalisation Tank UASBR (Anero bic Dig estion) Bio-gas Collecti on Dom e
Green Bel t
Treat ed Wa ter S tora ge Pon d Clarifier Aerati on Tank (A ero bic Sys tem)
Rain Water Harvesting
Objective :
GSKCH , Ra jahmundr y uses bor e w ell w ater for its oper ation. In or der
to avoid adverse effect of the oper ations on the w ater table,
implemented Rain w ater har vesting.
Rai n Wate r Co ll ecti on Rai n Wate r Ha rvest in g
12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.011

12. Waste Water Generation
22% reduction
9.4 In 3 yrs sp an
10
8.1
9 7.7 7.5
KL per Ton
8
7
6
5
4
2004 2005 2006 2007
Laurels
External
National Energy Cons erv ation Direc tor of Fac tories Award’ 05
APPC B Award 2004
FAPCCI Award -2008
Award 2005 for “OHSA S 18001”
Internal
CEO’s Award 2005 – First Place CEO’s Award 2005 - Vanguard CEO’s Award 2007 – Special
Award pres ented by JIM in Aug’ 06 commendation Awards
honor for U SE Methane- Aug’ 06
12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.012

13. Way forward…
Installation of s ub me ters at ide ntifie d areas
Conducting Water balance regularl y
Year on year stretche d tar gets
Innov ativ e suggestions / ideas fr om em ployees
20 %
20 %
Reductio n
Reductio n
by 2010
by 2010
12/9/2008 2:40:06 PM cc_20082 Heary PPT- 2498 JC CEHS-2.013