The making of a green factory is no pipe dream here

Do pipes and fittings that go behind the walls in bathrooms make you think of renewable energy? Hardly, you might say.

But changing that perception is the HSIL (formerly Hindustan Sanitaryware Industries Ltd) factory at Ishnapur village in Medak district of Telangana.

The facility, which makes plastics-based UPVC pipes and fittings, has won “Platinum rating” from the Indian Green Building Council, in a ‘first-of-its-kind’ certification.

For those wanting a little bit of history, this diversified building products company is known for its Hindware range. Incorporated as Hindustan Twyfords Ltd in 1960 by the Somany family in collaboration with Twyfords Limited of the UK, to introduce vitreous China ceramic sanitaryware in India, the stock exchange-listed company later became HSIL.

Not a ray of light lost

Telling the green story with pride, Rajesh Pajnoo, President, HSIL, explains, “The manufacturing facility, operational this year, is compliant with green building norms of IGBC and is capable of providing higher yield over the prevailing industry benchmarks.”

This is the first such facility in the country to achieve this rating in the PVC products-based industry and the 32nd across various industries in the country.

“This would not have been possible but for planning various measures right from the factory design stage,” he says, emphasising that from at least 9 a m to 5 p m, the factory area does not need any lighting — that shows how innovatively it has been designed to use natural light.

The factory, set up earlier this year with investment of ₹160 crore, could have seen 5-7 per cent of incremental higher cost in its quest to adopt green building measures. “But the best part of this is, the payback time is short and the employees take pride in working in such an environment,” he says.

The facility, which makes the Truflo range of products, has an installed capacity of 30,000 tonnes per annum for CPVC (chlorinated poly venyl chloride-based thermoplastic) pipes and fittings for potable hot and cold water applications, which have been made from NSF certified Durastream CPVC compound of Sekisui of Japan, UPVC (unplasticised poly venyl chloride) pipes and fittings, SWR Pipes and fittings for soil waste and rainwater systems.

In a nutshell, the factory is energy, water, process and waste-management efficient.

What eco-friendly measures did the company adopt, to achieve this? These include use of energy-efficient IE3 motors for all the production equipment; every unit consumed in the factory is monitored, measured and controlled through Energy Management System with multi-function metres, efficient compressors, chillers, cooling towers and pumps.

Water at different temperatures is used for the various processes for energy efficiency and for better quality product and the entire process waste is collected and re-used.

Fully automated process

The company has completely automated its processes — from raw material to finished product — and the material compounding is done through a system that ensures consistent mixing of ingredients while preparing batches through a supervisory control and data acquisition (SCADA) system. This ensures the work is automated without any manual intervention.

The pipes are weighed online, for the first time in the industry, which ensures that the promised quality is delivered.

What would he want to highlight about the facility? Pajnoo says, “Apart from advanced machinery used for better productivity and consistent quality, advanced testing equipment is being used for product testing and measurement.”

Besides capturing more than 90 per cent daylight, the entire lighting system is LED-powered. It has efficient fans installed for fresh air and motors for processes.

Apart from ensuring asbestos-free environs in the entire factory, the facility uses low volatile compound-based paints and adhesives, which are workmen-friendly.

To cap it all, a 1 MW solar plant takes care of the non-process power requirement of the factory. All this won it Platinum rating.

That’s not all, says Pajnoo. The plant uses drip irrigation for landscaping, has 100 per cent rainwater harvesting covering both roof and non-roof area.

The facility ensures zero water discharge and 100 per cent water treatment is ensured with 40 kld capacity unit.

‘Reuse, recycle’ is mantra

Apart from using 100 per cent CFC (chloro fluro carbons) free HVAC (heating, ventilation and air-conditioning) equipment, low thermal conductivity is ensured through toughened glass. The roof insulation is with poly carbonated sheet.

To promote employee welfare, cardio-vascular gym, sports facility, break-out spaces and amphi theatre have been set up. Electric charging facility has been created to encourage use of battery-operated vehicles.

There is 100 per cent waste segregation to effect maximum reuse of materials within the site. The biodegradable waste is taken care of through vermi composting beds. The entire construction waste generated in the factory is reused or recycled, sums up Pajnoo.