Operational excellence initiatives in FY 2020-2021

  • Focused cost and productivity programmes resulted in substantial savings in both Capex and Opex
  • Supply chain efficiency and increased customer service levels by stepping up usage of container rake movement
  • Continuing lean six sigma and other continuous improvement programmes
  • Modernised Caustic plant to yield increased volumes and efficiencies (Mithapur)
  • Power plant and Soda Ash (Carbonating Towers) Industrial Internet of Things (IIoT) projects implemented (Mithapur)
  • Cost improvement ideas arising out of a programme facilitated by external consultant yielding continuous savings
  • Carbon capture and usage plant at combined heat and power (CHP) plant which will reduce carbon emissions by 10% or 40,000 tonnes (expected completion Q1 FY 2021-22) (UK)
  • New boiler plant at British Salt Limited with lower energy consumption and carbon emissions (UK)
  • Improvement of train safety and operations by commissioning the Trains Management System (Magadi)

Performance Materials

  • Ongoing plant upgrades to increase plant efficiencies and reliability at Silica plant, Cuddalore

Nutrition Sciences

Successfully commercialised Nellore plant alongside undertaking optimisation projects focussed on:

  • Automation: Leading to better safety, efficient operations and enhanced hygiene
  • Operation excellence: Projects undertaken enabled increase in plant throughput, while improving quality and hygiene requirements
  • Energy optimisation: Increased solar power generation capacity by 65% and reduced maximum grid power demand by 20%

Agri Sciences

  • Deployed technologies across manufacturing, R&D, human resources, supply chain and sales & distribution functions to drive automation and efficiency
  • Diversified vendor base and explored opportunities for backward integration to secure raw material supplies
  • Exploring new Seeds production locations, automation possibilities and engaging with growers for information / solutions to maximise Seed yields

Basic Chemistry Products

India

  • New CoGen Plant
  • New Vacuum Evaporated Salt Plant and associated supply chain investments
  • Expansion of Sodium Bicarbonate capacity

USA

  • Projects underway to reduce environmental load, increase safety and increase automation and digitisation

UK

  • Carbon Capture and Usage project in final stages
  • New high efficiency boiler at Salt Plant

Specialty Products

Agri Sciences

India

  • New formulation unit at Dahej (CZ)
  • Multi Purpose Plant at Dahej

Basic Chemistry Products

  • Increase salt and brine production for increased feedstock to support growth (India)
  • Undertake digitisation and automation projects for efficiency, quality and cost benefits (India)
  • Increase the use of IIoT, AI, data analytics and technology to improve manufacturing practices and business processes (India)
  • Further increase plant reliability and OEE at TCNA
  • Expand recovery of Soda Ash from waste streams (TCNA)
  • Invest further in new technologies to move towards lowering environmental footprint and increasing circularity (TCE)
  • Reconfigure supply chain network at TCML, Kenya

Specialty Products

Performance Materials

  • Enhance operational efficiency and environmental performance with further upgradation of plant and technology

 

Nutrition Sciences

  • Complete ongoing projects around operation excellence, process automation and energy reduction
  • Undertake initiatives to further agenda of efficient and responsible manufacturing

Meeting the needs of customer with white Silica

Silicone rubber companies demand pure white products due to application demand. TCL team collaborated with a potential customer. With sustained efforts, a new grade of Silica – TAVERSIL 120F – was introduced. Having optimal granulometry and being much whiter than existing products, it meets the need of the industry. We have placed it as a premium grade product. We continue to further improve the product alongside approaching similar Silicone compound manufacturers for horizontal business growth.

Agri Sciences

  • Plans underway to expand product portfolio
  • Continue with digital interventions for better access to production information, upgrading MIS and reporting dashboards, digitising Seeds production management and supply chain forecasting
  • Develop upcoming Dahej manufacturing plant at Gujarat as a Digital Smart Factory