H & R Johnson India Limited
Company Profile
H & R Johnson (India) LTD, manufacturer of the premium brand of wall, floor, porcelain, vitrified
and industrial tiles, is a pioneer in the tile industry in India.
H & R Johnson (India) LTD is also India’s largest tile manufacturer with a capacity of 332720
TPA. and technologically the most modern tile company in India. H & R Johnson (India) LTD is a
member of Johnson International U.K., which has a leading presence in all the continents of the
globe. With a leading presence all over the globe for 100 years, the ‘Johnson’ brand has earned
the trust of over four generations with its philosophy of “Leadership through Innovation”. The
company has four manufacturing plants which are in Pen (Maharashtra), Dewas (M.P.), Karaikal
(Pondichery) and Kunigal (Karnataka). The company also has joint venture companies in Andhra
and Gujarat for manufacturing of ceramic and vitrified tiles.
In our quest for total quality, all our plants have received the prestigious ISO 9001, ISO 14001
and ISO 18001 certificates. The plant at Pen is technologically one of the most modern in the
world, producing world-class quality tiles.
Beside its internationally preferred brand Marbonite, an alternative to Italian Marble, the company
has introduced India’s first joint-free glazed porcelain tiles. Branded as Porselano, these tiles are
available in natural marble designs and in popular sizes. Unlike conventional ceramic tiles, the
joints between tiles would be virtually invisible and are almost paper thin joints. The company has
also launched heavy duty tiles for use in heavy industries and pavements and is marked under
the brand name – Endura.
Process Flow Chart
EE EE & TE EE & TE
Batching Milling & Spray Drying Pressing & Drying
EE EE
Glaze Dipping Line for Screen Making
EE Preparation Decoration/Glazing
EE & TE Tunnel Dryer for Drying
EE & TE
Firing in Kiln
Rectification for other
Polishing for unglazed EE & TE glazed products like
EE & TE vitrified products (MB) MP, MC & GP
Selection & Sorting
EE
Packing EE
Energy Conservation Commitment, Policy and Set
Storage
EE: Electrical Energy Despatch
TE: Thermal Energy
H & R Johnson (India) Limited, considers energy savings as a multidisciplinary approach and it is
one of the core responsibility to the nation and also globally. The company’s energy profile
consists of electricity’ fuel i.e. NG, LPG, PROPANE, LDO, C9, HSD, FO, coal, soyabin, rice husk,
groundnut shell and other utilities like water, air, etc. A dedicated energy management
department is established for the implementation of energy conservation projects. Budget
provisions are made exclusively for such activity. Energy conservation plans, policy and structure
are reviewed periodically.
Our Energy Management Department is ISO: 9001-2000 certified.
National Technology Day & National Energy Conservation Day is celebrated every year to
emphasis on energy conservation and other modern technologies for the betterment of the
processes and products. Periodic energy audits are carried out department wise in all the plants
as per audit calendar. Regular training to inculcate energy conservation awareness and upgrade
the knowledge among the plant people is organized regularly in all the units. For our efforts in the
field of energy conservation, we have been awarded Natural Gas Conservation award by GAIL
for the year 2004-2005.
Energy Management Policy
We shall constantly strive to provide quality products and services to meet & exceed customer’s
expectations.
Continual improvement, commitment, accountability and teamwork shall be our guiding principles.
Energy Management Objectives
1. To optimize and reduce energy consumption in specified and identified operational areas.
2. Undertake Energy Conservation projects in all potential areas.
Energy Consumption
Energy consumption trends for thermal and electrical energy, for the last three years have been
shown.
Energy Consumption
Description Unit 2003-2004 2004-2004 2005-2006
Production MT 229888 241965 254195
Electrical Energy Lacs Kwh 596 569 576
Consumption per
annum Lacs Rs. 2423 2227 2509
Specific Energy
Consumption : Kwh/Ton 259 235 227
Electrical
Mkcals 358872 373911 357656
Thermal Consumption
per annum
Lacs Rs. 5002 5748 6557
Specific Energy
Mkcals/ton 1.56 1.55 1.41
Consumption : Thermal
Energy Consumption in
terms of % % 35% 26% 19%
manufacturing cost
* The specific energy consumption has been calculated with respect to the equivalent weight of
tile as energy consumption changes with the thickness and size of the tile.
Year Electricity Thermal
Specific Specific
Energy % Reduction Energy % Reduction
Consumption over 2003-2004 Consumption over 2003-2004
(Kwh/ton) (Mkcal/ton)
2003-2004 259 1.5611
2004-2005 235 9.32 1.5453 1.01
2005-2006 227 12.60 1.4070 9.87
Specific Electrical Consumption
270 259
255
Kwh/Ton
235
240
227
225
210
2003-2004 2004-2005 2005-2006
Financial Year
Specific Fuel Consumption
1.6 1.56 1.55
MKcal/Ton
1.5
1.41
1.4
1.3
2003-2004 2004-2005 2005-2006
Financial Year
Energy Conservation Achievements
During the year 2003 to 2006, H & R Johnson (India) Limited has implemented energy savings
projects through engineering initiatives, team leader suggestions, auditor’s proposals. Many cost
reduction measures being adopted by the company’s management resulting into a total annual
savings (2005 – 2006) of Lacs Rs. 451 Lacs.
Major Projects implemented during 2005-06 are listed below:
1) Wood based charcoal gassifier in dewas for Kiln
Annual LPG consumption @ 1485 tons
@ Rs. 30 per kg @330 day/year
Rs.445 Lacs
Cost of equivalent fuel (wood based charcoal)
@ 3712 Tons/year @ Rs. 7 per Kg @330 day/year
Rs. 273 Lacs
Total Annual Savings is Rs 172 Lacs
# Wood based charcoal is procured from sustainable sources.
2) Indirect hot air generator for vertical dryer in Pen
Annual LPG consumption 1088 tons & NG
consumption 53845 scm
@ Rs. 29 per kg and Rs.4.86 per scm respectively
@330 day/year
Rs.318 lacs
Cost of equivalent fuel (coal)
@ 3630 Tons/year @ Rs. 4.32 per Kg @330 day/year
Rs. 165 Lacs
Total Annual Savings is Rs 153 Lacs
3) Replacement of batch type smelter by continuous smelter Karaikal (Phase One)
Before replacement
Production: 12 tpd
NG Consumption: 8842 scmd
After replacement
Production: 15 tpd
NG Consumption: 2842 scmd
Annual saving of NG @ Rs.5 per scmd and 330 days operation per year = Rs.99 lacs
4) Modification of kiln burners at Karaikal
Fuel consumption before replacement of burners = 5070 scmd
Fuel consumption after replacement of burners = 4563 scmd
Annual saving of NG @ Rs.5 per scmd and 350 days operation per year = Rs.8.87 lacs
5) Supply side air management system in compressors at Pen
Daily consumption without the supply
side air management system (units) 12000 Kwh
Daily consumption with the supply side
air management system (units) 11400 Kwh
Annual savings @ Rs.4 per Kwh @ 350 days
per year = Rs. 8.4 lacs
6) Different activities under the water management
Daily Water consumption before
implementation of the project = 48.00 KL
Daily Water consumption before implementation of the
project = 2.52 KL
Annual saving of water @ Rs.50 per KL
and 350 days operation per year = Rs.7.96 lacs
7) Lighting load energy saver for Kunigal plant
Daily consumption without lighting load energy saver system (units) 560 Kwh
Daily consumption with the supply side air management system (units) 464 Kwh
Annual savings @ Rs.5.5 per Kwh @ 365 days per year = Rs. 2.0 lacs
Major Projects implemented during 2004-05 are listed below:
1. Co-generation (Pen plant)
The process of manufacturing ceramic tiles requires substantial thermal energy in spray
dryers where dry powder is produced from ceramic slurry. For operating three of our spray
dryers the total heat requirement is 12.07 Mkcal / hr. We have installed a gas turbine (Co-
generation system) of 5 MW capacities where the exhaust of the turbine is directly being
used inside the spray dryers.
Total Investment : Rs. 14 crores
Rated power generation capacity: 5 MW
Average power generation at site condition: 4.3 MW
Turbine Input (NG) 1550 SCM / hr
The average heat 8 Mkcal / hr
Generated
Annual expected savings is Rs. 582 Lacs GAS
TURBINE: 5 MW
Note: The system is intermittedly operated at part load due to un-availability of NG in
adequate quantity. Project was initiated on the basis of policy decision of GAIL to
supply NG by early 2005 but it is delayed. Now the required quantity of gas supply is
expected by end 2006.
2. Hot air generator (for spray dryer of Kunigal Plant)
Annual FO consumption 1923 KL
@ Rs. 15.34 per litre @330 day/year
Rs. 295 Lacs
HOT AIR GENERATOR
Cost of equivalent fuel (ground nut shell) @ 5641 Tons/year @
Rs. 2.1 per Kg @330 day/year
Rs. 118 Lacs
Total Annual Savings is Rs 177 Lacs
3. Lighting Load Energy Savings System
(Pen Plant)
Daily consumption without the
savings system (units) 2840 Kwh
Daily consumption with the
savings system (units) 2194 Kwh
Annual savings is Rs. 8.5 Lacs
LIGHTING ENERGY SAVER
4. Flat Belts Installation replacing V Belts
(Kunigal Plant)
Power consumption of all drives
with V belts 1555 Kwh/day
Power consumption of all drives
with Flat belts 1317 Kwh/day
Annual savings is Rs. 4.76 Lacs
FLAT BELTS IN COMPRESSOR
5. Control Air System for Compressors
(Kunigal Plant)
Without ControlAir
Power Consumption per day 1251 Kwh
With ControlAir
Power consumption per day 1080 Kwh
Total Annual savings is Rs. 3.44 Lacs
CONTROL AIR
SYSTEM
6. Cooling Tower Fan Controller
(Dewas Plant)
Total running hrs of cooling
Tower motors before installation of
Controllers 24 hrs/day
Total running hrs of cooling
Tower motors after installation of
Controllers 16.8 hrs/day
Total running load of all the cooling
Tower fan motors 5 Kw
Annual savings is Rs. 0.58 Lacs
COOLING TOWER FAN
CONTROLLER
Major Projects implemented during 2003-04 are listed below:
1. Conversion of LDO fired Hot air generator to fluidized bed Hot air Generator (for spray
dryer of Dewas plant)
Annual LDO consumption @ 4320 Ltrs/day
@ Rs. 21 per litre @350 day/year
Rs. 317 Lacs
Cost of equivalent fuel (lignite/ground nut shell) @ 12167 Kg/day
@ Rs. 1.5 per Kg @350 day/year
Rs. 64 Lacs
Total Annual Savings is Rs. 253 Lacs
2. ControlAir System for Compressors
(Pen & Dewas Plant)
Without ControlAir
Power Consumption per day 8526 Kwh
With ControlAir
Power consumption per day 7384 Kwh
Total Annual savings is Rs.16.67 Lacs
CONTROL AIR SYSTEM
3. Reducing the heat losses through exhaust gases i.e. fuel consumption from the vertical
dryers (5 Nos.) by optimizing the opening of cold air suction damper
Annual consumption of fuels
before implementation 15422 MKcal
Annual consumption of fuels
after implementation 12686 MKcal
Annual savings after by reducing the
heat loss through exhaust gas 2736 MKcal
Fuel used 100% NG
Cold air opening in vertical dryer
Annual savings is Rs. 16 Lacs
4. Flat Belts Installation replacing V Belts
(Pen Plant)
Power consumption of all drives
with V belts 5299 Kwh/day
Power consumption of all drives
with Flat belts 4630 Kwh/day
Annual savings is Rs. 9.97 Lacs
Flat belts in dust extraction motor
5. Variable Speed Drive Installation in Ball Mill Main Motor (Pen Plant)
Power consumption per batch of
Grinding without VSD 1250 Kwh
Power consumption per batch of
Grinding without VSD 1000 Kwh
Energy savings 20 %
No. of batches in 2 days 3
Annual savings is Rs. 4.93 Lacs VFD in Ball Mill
Other projects implemented during 2003-2006 are:
Installation of automatic power factor correction unit. Annual savings achieved is 66
lacs.
Timers installed in three press motors of 45 Kw to stop the idle running of them.
Annual savings achieved is 14850 kwh i.e. Rs. 62370
Timers installed in the six stirrers of the slurry tanks to ON/OFF the motors of 15 Kw
each, after preset time. Annual savings achieved is 10395 kwh i.e. Rs. 43659
Timers installed in the 30 Kw four ball mill motors to stop the mill motors running after
the specified time. Annual savings achieved is 12473 kwh i.e. Rs. 52390
Centralised air conditioning system for the complete tool room is replaced by localised
air conditioning systems at the required places. Annual savings obtained are Rs. 6
Lacs.
Covering of hot air ducts of the spray dryers by ceramic blankets to reduce the heat
losses. Annual savings achieved is 33 Mkcal i.e. Rs. 51000
Switching off lights, fans, ACs, by individuals wherever offices are not occupied.
Annual savings achieved is 23809 kWh i.e. Rs. 100000
Installation of voltage stabilizer for our plant distribution. This has made has reduced
the frequent damages of cards and other electronic component.
Energy Conservation Plans and Targets
Project
Anticipated Anticipated Approximate
Energy Conservation Commencement
Savings in Savings Investment
Measures (Planned) and Completion
Energy/year INRL/year (Lacs Rs./Year)
year
No direct
Coal Gassifier for roller savings in
hearth kilns.-- Kunigal energy – 440 200 2006
fuel switch
project
No direct
savings in
Coal gassifier for spray dryer
energy—fuel 1500 600 2007
in Pen
switch
project
Continuous smelter (Phase 46,332
244 500 2006
two) in Karaikal Mkcal
No direct
savings in
Indirect hot air generator in
energy—fuel 170 65 2006
Dewas
switch
project
No direct
Biomass based indirect hot savings in
air generators for vertical energy—fuel 184 65 2006
dryers – Kunigal switch
project
Replacement of electrically
14,60,000
heated LPG vaporizer with 30 10 2006
kWh
fuel fired hot water generator
Biomass based power 79,20,000
79 600 2007
generation – Kunigal kWh
Variable Speed Drives in 23, 80, 95
10 8 2006
Fans and Blowers kWh
Carrying LNG to site by 16,25,000
65 65 2007
virtual pipeline – Pen kwh
Kiln heat recovery and
10,40,760
utilization of the same in 42 35 2007
Kwh
rectification & polishing lines.
Heat recovery in kilns for 8643
256 184 2007
combustion air preheating Mkcal/hr
Compressed air management
60000 kwh 200000 200000 2006
system in Karaikal
All other initiatives like suggestion schemes, training programs, and engineering initiatives will
continue. By adopting the above energy conservation measures, H & R Johnson (India) Limited
will be able to achieve the set target of reduction of 1% energy bills.
Environment and Safety
H & R Johnson (India) Limited is committed to the protection of the environment by Prevention of
Pollution and continual improvement in Environmental performance. The company has got the
certification of ISO 14001. The company works continuously as per the Environmental Policy for:
Minimisation of generation of waste.
Conservation of resources.
Recycling and re-use of waste
The company has installed Effluent Treatment Plant (ETP) in all its plants for processing of solid
waste and water generated in the plant for reuse in the process.
For safety, health & environment (SHE) we have formed a task force which comprised of people
from every department.
Our company is OSHAS 18001 certified.