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Environmental Responsibility and Safety first Culture  

Even though the world today is divided by boundaries that separate us into different nations and regions, we all are a part of the same natural environment. Nature is a shared resource which provides us with all that we need to lead a happy and fulfilling life on this planet. Any kind of harm done to it affects all the inhabitants of this planet, directly or indirectly. In such a scenario, it becomes imperative for us as global citizens to do our part towards protecting Mother Nature. At Glenmark, we endeavor to continually identify and implement initiatives to reduce our environmental footprint across our operations. This is yet another important way in which we strive to fulfil our mission of enriching lives of our employees, our neighborhoods, the global community and the future generations.

Introduction 

While the immediate benefit of our environmental initiatives is better environmental quality for our employees and those living in the immediate vicinity of our plants, the global nature of our atmosphere also means that some of the environmental benefits go beyond our local communities. For example, decreased used of virgin natural resources and nonrenewable energy sources ensures that there is more left behind in the nature for use of future generations. We endeavor to continually take initiatives broadly pertaining to the following areas: decreasing water footprint, reducing our emissions, increasing the energy efficiency of our operations, and efficient waste management. Another aligned aspect is our commitment to provide a safe working environment to all our employees, which apart from meeting the moral and legal obligations, also leads to enhanced productivity and workplace satisfaction.

Social-Environment impact meter FY 2015-16 

  • Water Conservation
    215
    Million Liters Saved
  • Amounts to annual drinking water requirement of more than 1,17,000 PEOPLE in rural India
  • Electricity Conservation
    5,300
    Megawatt-Hours Saved
  • Can light up more than 55,000 RURAL HOUSEHOLDS for one year
  • Waste Management
    110
    Metric Tonnes Co-Processed
  • Resulted in reduction of more than 122 TONNES of carbon emissions
  • Fuel Consevation
    2,771
    Kilo Liters Saved
  • Equivalent to more than 18,000 TREES planted

Water and Wastewater Management 

While water covers about 71% of the earth's surface, only a miniscule percentage of it is in the form of freshwater, and is available for direct use for human activities. As the global population and industrial use of water increases, the sources of fresh water come under stress, thereby reducing its per capita availability. The problem is even more severe in India, where rapid urbanization and population growth is juxtaposed against dwindling sources of water. We recognize the gravity of this problem and are committed to doing our bit by reducing our water usage and improving water use efficiency.

We have taken a number of initiatives to reduce the amount of freshwater drawn and wastewater discharged by our facilities. We have imbibed the principle of 3R’s (Reduce, Reuse, Recycle), which has helped us reduce our specific water consumption year after year.

In order to reduce the stress on natural sources of water, we have built rain water harvesting structures at our facilities in Goa, Taloja and Mahape, and set up groundwater recharging systems at Indore, Nalagarh and Baddi.

We have adopted a new high pressure water cleaning system that reduces the water consumption for equipment cleaning by more than 40%. By shifting to plate heat exchanger for the generation of hot water and by capturing the steam condensate, we have been able to reduce the water required for the process by 20%.

Over the years, we have continuously improved our processes to reduce the wastewater being generated at our facilities. The fact that our specific wastewater generation has been reducing every year is a testimony to our success and commitment. In line with the 3 R’s principle, we consider the wastewater generated during our processes to be a valuable resource and make efforts to utilize it effectively.

Specific Wastewater

(kl/kg)

  •    
  • FY 2012-13 0.022
  • FY 2013-14 0.018
  • FY 2014-15 0.015
  • FY 2015-16 0.014
TOTAL REDUCTION TOTAL REDUCTION 0.008 kl/kg
We recycle about 98% of the wastewater generated at our facilities. Collectively, all these initiatives have helped us save more than 215 million liters of water during the reporting year.

We have installed wastewater recovery systems at our plants in Dahej, Ankleshwar, Aurangabad and Mohol, which has brought down our fresh water requirement. Our state-of-the-art systems employ technologies like Reverse Osmosis (RO), Multiple Effect Evaporator (MEE) and Agitated Thin Film Drier (ATFD). The recovered water is used for flushing, gardening, boilers and cooling towers. Currently we are in the process of installing these technologies at our Kurkumbh plant and have established it as a norm for all our future plants.

Case Study 

Started in: 18 JULY 2015

Rationale / Desired Change: To implement the innovative idea of using water generated in AHUs due to condensation, which was earlier considered as waste. This was expected to reduce the fresh water consumption and wastewater generation.

Description: As part of our water conservation project, condensate water from 30 AHUs and a few split air conditioner units is collected in an underground water tank specially constructed for this purpose. The collected water is then pumped to the cooling tower to fulfil its fresh water requirements. To automate its working, the underground tank is provided with a level sensor that prevents any overflow.

Outcome: Everyday around 3.5 kl water having a temperature of 24°C is prevented from flowing to the Effluent Treatment Plant (ETP). The low temperature of condensate water has also helped improve the cooling tower’s performance.

Energy Efficiency at Glenmark 

The direct correlation between increasing use of fossil fuels and global climate change has been well established by the scientific community. In such a scenario, it is vital for industries throughout the world to optimize their fuel consumption and tread the path of sustainable development.

As part of our environmental responsibility, we continually identify opportunities for adopting a less carbon intensive path as we grow as a company. This is being done by adopting a two pronged strategy. First, we have begun to diversify our energy mix by including low or no carbon emitting sources such as biodiesel, solar and hydro power. Second, we continually upgrade our equipment and processes to the latest energy efficient systems, thereby bringing down our specific energy requirement.

More than 10% of our electricity demand in the reporting year was met by electricity from renewable sources like solar and hydro power. After successfully introducing the biodiesel based boiler at our Nashik plant, we extended this project to our Mohol and Kurkumbh plants, thereby substituting a total of 435.4 kl of High Speed Diesel (HSD) with biodiesel.

More than 3.6% of our electricity demand in the reporting year was met by electricity from renewable sources like solar and hydro power


Rooftop solar plant at our Mahape R&D Center

Following are some of the other initiatives undertaken by us for decreasing our energy intensity:

  • Replacement of conventional CFL by more energy efficient LED lighting
  • Upgradation of chilled water generation unit by installation of electrically driven screw chiller instead of steam operated vapor absorption heat pump, resulting in saving of 3,60,000 SCM natural gas per year
  • Installation of motion sensors and timers for lights, energy efficient Heating, Ventilation and Air Conditioning (HVAC) systems, enhanced heat recovery systems and new automatic power factor control panels that maintain the power factor at 1, which has decreased our electricity demand
  • Efficient running of DG sets and boilers, which resulted in saving of 2,771 kl of HSD in the reporting year
  • Installation of new energy efficient surface aerators in place of old aerators for the ETP at Ankleshwar, which reduced the power consumption of the aeration tank by 40%. This upgradation has resulted in saving of 80357 kWh of electricity in the reporting year
ENERGY ASSESSMENT TOOL:
Innovative solution at Baddi Plant

THE ONLINE ENERGY ASSESSMENT tool is the first step in our structured approach to improve the energy efficiency of our plants. It is an online portal that leverages the power of digital technology to help us identify equipment, lighting and ventilation systems which consume the maximum electricity. This enables us in identifying areas/opportunities that can be explored for further improvements to reduce our energy consumption.

The online tool operates by recording per hour electricity consumption of the various equipment, along with their daily running times. It then calculates the total energy consumption of these equipment block wise, which is reconciled with the actual meter reading for each block at the plant. By focusing our efforts on the equipment that consume the maximum energy, we will be able to increase the efficiency of our plants. This will be achieved by either bringing operational control in these equipment or by replacing them with newer and more efficient equipment, lighting and ventilation system.

All the above efforts for lowering our energy use and enhancing the energy efficiency at our plants have led to decreased amount of greenhouse gases being emitted into the atmosphere, thereby contributing to the global efforts to prevent climate change.

Waste Management 

Our approach is to reduce the amount of waste generated at our facilities and adopt environmentally sound disposal practices for the waste, while meeting all applicable regulatory requirements. An important part of our waste handling process is segregating the different waste streams, which makes recycling and disposal easier and more efficient. We have separate collection, storage and disposal processes for domestic waste, e-waste, biomedical waste and hazardous waste at all our facilities.

Segregation at source is the first essential step for safe handling of hazardous waste. The hazardous waste generated at our facilities is collected separately and sent to Common Hazardous Waste Treatment Storage and Disposal Facilities (CHWTSDF) for safe disposal.

A novel practice that we have adopted since FY 2014-15 is to send expired and off-specification medicines to a cement factory for co-processing. These are completely burnt at an extremely high temperature inside the cement kilns, which extracts their intrinsic energy while rendering them harmless. The ash generated in this process becomes a part of the cement. This reduces the amount of fuel and other raw material required for cement production, while simultaneously reducing the amount of hazardous waste being sent to the common facilities for disposal. In the reporting year, 110 MT of hazardous waste generated by our facilities was co-processed.

As a responsible organization that values human health and safety, we ensure that the bio-medical waste generated at our facilities is disposed safely at an authorized disposal facility. In order to educate our employees, we display the procedure of handling and storage of bio-medical waste through posters.

In the reporting year, 110 MT of hazardous waste generated by our facilities was co-processed.

Separate hazardous waste storage area at our Goa facility

Reducing the amount of waste that goes to a landfill is another area where we strive to decrease our environmental footprint. Our canteen and garden waste undergoes vermi-composting, wherein organic waste gets converted to rich manure, which is used for in-house gardening. What started out as a pilot at our Ankleshwar plant three years ago, has now been adopted by seven other facilities. We aim to adopt this initiative across all our facilities in the near future. At Glenmark, we make conscious efforts to reduce the quantity of electronic components that are discarded. To this end, we encourage refurbishment of old equipment which increases its life and reduces the demand of virgin materials. We also ensure that all our discarded electronic components are recycled safely. This is done by handing over the used electronic components to authorized recyclers, who extract valuable materials from such discards in an environmentally sound manner. In the reporting year, we disposed 1,914 kg of e-waste generated at our facilities.


In the reporting year, we disposed 1,914 kg of
e-waste generated at our facilities.

We select packaging configuration for our new products in a way that allows minimizing the quantity of packaging material required, without compromising its functionality and regulatory requirements related to the product. This leads to lesser packaging material requirement during commercial manufacturing.

Case Study 

Started In: 20 JULY 2015

RATIONALE / DESIRED CHANGE: Use of Alum and Lime for primary chemical treatment in ETP generated huge quantities of chemical sludge. There was a need to reduce this hazardous waste as it increased the environmental burden and cost for the company

Description: Alum and Lime were replaced by Poly Aluminum Chloride and Caustic which are 100% soluble and help to lower chemical consumption through optimum chemical reactivity. The advantages of these coagulants include effectiveness over wide ranges of pH and raw effluent temperatures, zero chemical residue and lower chloride or sulfate residues. This resulted in lower final water TDS and lower sludge generation. A further reduction of the sludge weight was achieved with the help of sludge dewatering units, Filter Press & Decanter.

Outcome: Reduced chemical consumption and sludge generation at the ETP.

Solvent Recovery 

In line with the 3R's principle, we have adopted new methods to make our processes efficient, which includes setting up state of the art solvent recovery plants. This has resulted in lesser burden on the natural environment.

The new products that are being developed use direct blending-compression method and water granulation method that avoid the use of organic solvents in the formulation. Analytical methods have been developed that require less hazardous solvents. Organic solvent consumption has been reduced by using special analytical methodology that employs High Performance Liquid Chromatography (HPLC) column.

Solvent recovery plants have been set up at our API facilities in Ankleshwar, Dahej and Aurangabad. These plants recover and recycle the spent solvent, which is used only after multiple quality checks. This reduces the demand for fresh solvent and in turn, the demand for fresh raw materials required to manufacture the solvent. The rest of the spent solvent, which we do not recycle in-house, is sold as a by-product to the Pollution Control Board authorized parties. This ensures that the toxic solvents do not cause any harm to the environment.

In the reporting year, we recovered and recycled more than 72% of the spent solvent, amounting to more than 4300 kl.

Safety 

Statistics from the international labour organization show that, globally, 153 workers have a work-related accident every 15 seconds. Every day, 6,300 people die as a result of occupational accidents or work-related diseases that amount to more than 2.3 million deaths per year. Each year, an estimated 4 percent of the global Gross Domestic Product is lost due to poor occupational safety and health practices.

At Glenmark, we are fully committed to the well-being of all our employees and attach the highest level of importance to workplace health and safety. It is our firm belief that a safe working environment also improves productivity and contributes in creating a stress free atmosphere. In line with our Environmental, Health and Safety (EHS) and Occupational Health and Safety (OHS) policies, our focus is on minimizing occupational injury, preventing ill health and risks to our employees at the workplace.

We invest in safety infrastructure and strive to create a ‘Safety First’ culture across our operations. We have implemented a Safety Management System as per international standards. For all our operations across the organization, we have adopted the Globally Harmonized System (GHS) by the International Labour Organization (ILO) which follows a standardized 16 point Safety Data Sheet (SDS).

We have made considerable progress in our safety performance, and continue to raise the bar every year. We believe safety is a collective responsibility and every employee is equally responsible for creating a safe working environment. Employees are made aware of the safety practices to be followed at the workplace right at the time of joining the organization, and are imparted regular trainings to upgrade their knowledge on safe working practices. In the reporting year, more than 36,000 man-hours of safety training was provided to our employees.

REPORTABLE INCIDENTS PER MILLION MAN-HOURS WORKED

  •    
  • FY 14 0.22
  • FY 15 0.21
  • FY 16 0.12
TOTAL REDUCTION0.10
We invest in safety infrastructure and strive to create a ‘Safety First’ culture across our operations.

Employees being trained to use firefighting equipment as part of safety training

Safety Initiatives

  • Safety Programs

    Following a detailed analysis of the safety performance at our plants for the past three years, we initiated various programs to enhance the safety culture at the plants. These safety programs pertaining to contractor safety, chemical safety, working at height safety and lock out tag out system. These programs are designed and implemented using a step wise approach, which includes initial assessment, action planning, implementation of actions planned and final assessment for achieving highest efficacy.

  • Personal Protective Equipment (PPE)

    These ensure safety of our employees at the workplace. A new initiative in the reporting year includes introduction of anti-static clean room safety shoes at our Taloja R&D center. These clean room shoes provide our employees with protection from heat, chemicals and falling objects, while eliminating slip and trip hazards. In addition, the adoption of this initiative reduces the usage of plastic shoe covers, which in turn reduces the waste generated at the site.

  • Toolbox Talks

    These open talks conducted at the department level, encourage discussions about the status of safety practices in the facilities.

  • Mock Drills

    Periodic mock drills are conducted at all our facilities to ensure preparedness for emergency situations.

All occupational health and safety incidents/accidents are reported as per the corporate standard operating procedure. Lost Time Injuries Frequency Rate (LTIFR) (per 2,00,000 man-hours) for the last three years (2013- 2016) is reported to be 0.46 on a combined basis for formulation and API facilities. The LTIFR is lower than the incident rates noted in the average incident rate for pharmaceuticals and medicine manufacturing (employment size of 1000+) i.e. 1.3 for 2014 as reported by Bureau of Labor Statistics, USA. All injuries were duly investigated to identify root causes and corrective actions implemented.

Case Study 

NEAR MISS

What is a Near Miss? A Near Miss is an unplanned event that did not result in injury, illness, or damage – but had the potential to do so.

Stated In: 2 DECEMBER 2015 RATIONALE / DESIRED CHANGE: Encourage the employees to report incidences of near miss and build a proactive safety culture. This helps to take a preventive measure to reduce the number of accidents.

Discription: A simple process to report near miss incidences was put in place to encourage the employees to report all such incidences. Each member of the plant’s EHS team was given a target to report a minimum of three near miss incidences every week, which were used as examples for other employees. Employee awareness campaigns were conducted with the help of posters, e-mailers and engagement activities. Also, messages from the Chairman & Managing Director, Director - Corporate Affairs and President - Operations highlighting the importance of near miss reporting were shared with the employees.

Outcome: Employees became more aware about the benefits of reporting near miss incidences and there was a sharp increase in the number of such incidences being reported. In 3 months, the number of near miss incidences reported per month increased from CASE STUDY NEAR MISS 119 to 464

Safety Matrix

To keep track of plant safety performance, we have introduced a safety matrix at all our plants. The parameters tracked in the safety matrix are Reportable Accident Rate, Recorded Incident Rate, Incident Severity Rate, Near Miss/Enrolled Employees and Training Man-Hours/Enrolled Employees. The safety matrix displays the plant’s performance in each parameter for Month-To-Date (MTD), Year-To-Date (YTD) and the last financial year. There is also a target set for each parameter against which the plant’s performance is measured. This simple tool has proved to be very effective in monitoring and comparing the safety performance across plants.

EHS Management System

Our EHS management system follows ISO 14001:2004 (Environmental Management System) and OHSAS 18001:2007 (Occupational Health and Safety Management System) standards. Based on the Plan Do Check Act (PDCA) cycle, our EHS management system ensures that a step wise approach is followed in any given scenario while acting as an effective process improvement guide.

Eleven of our facilities are currently ISO 14001:2004 certified and one is OHSAS 18001:2007 certified.

Two additional facilities are currently undergoing the certification process for OHSAS 18001:2007.

Safety Week and Environment Week celebration

In order to raise awareness about the importance of environment and safety, we celebrated the World Environment Week and National Safety Week across all our facilities. The environmental celebrations included tree plantation drives, mass awareness drives, essay writing and poster making competitions. We also centrally organized employee engagement activities on the intranet including, quiz, slogan writing, photography and green idea contests. Leaflets recognizing innovative green initiatives were distributed during the week across facilities.

During the National Safety Week, we focused on the Near Miss campaign across all our facilities. Further, we organized a competition amongst our facilities to report the highest number of near miss incidents.

Towards Safer Roads

As part of the National Safety Week celebrations at our Mohol plant, helmets were distributed to all the employees who rode two wheelers. The employees proactively collected funds to implement this initiative, with an aim to promote road safety among their colleagues.

Environment & Safety Performance*

Energy
Electricity saved through energy efficiency initiatives
12,034 MWh
Renewable energy used
12,034 MWh
Reduction in specific HSD consumption
12,034 MWh
HSD substituted by Biodiesel
12,034 MWh

Reduction of 26,547 MT of carbon emissions

Water
Potential of groundwater recharge systems
205 ML
Reduction in specific freshwater consumption
28%
Wastewater recycled
98%
HSD substituted by Biodiesel
12,034 MWh

Quantity of freshwater saved equivalent to annual drinking water requirement of 1,17,000 people in rural India

Environment Health & Safety
ISO 14001:2004 certified
11 plants
OHSAS 18001:2007 certified
01 plant
EHS training conducted
36,000 hours
Online Environment Management System
03 plants

50% reduction in reportable incidents

Waste
Hazardous waste co-processed
308 MT
E-waste sent to authorized recyclers
6,995 kg

Reduction of 343 MT of Carbon emissions

Solvent Recovery
Hazardous waste co-processed
308 MT

17 ML of spent solvent saved from being discarded

Tree Plantation
E-waste sent to authorized recyclers
6,995 kg

1445 MT of sequestration potential

*Base Year FY 12-13