Dr. Reddy's Laboratories Ltd. is India's premier pharmaceutical company, committed to providing affordable and accessible medications worldwide. The company is at the forefront of discovering, developing, and commercializing innovative medicines that address unmet medical needs. As a vertically integrated entity with a global presence spanning over 100 countries, Dr. Reddy's stands as one of the leading generic pharmaceutical companies in terms of revenue. The company is unwavering in its dedication to delivering affordable healthcare solutions globally, transcending geographical and socio-economic barriers.
The CTO Unit-3 manufacturing plant, situated in Hyderabad, India, where energy management methods were initiated, spans 12 acres with an employee strength exceeding 600. The electrical power is procured from the State Electricity Board, and the installed capacity of the captive power plant is capable of delivering 2150 KVA. The monthly energy consumption, amounting to 500,000 kWh, is drawn from the Electricity Board supply.
Elmeasure's Energy Management Solution was deployed, enabling meticulous monitoring of Power Factor in every section of the manufacturing area. Despite the installation of Capacitor Banks, certain locations experienced a Power Factor dropping below 0.9 Lag. Through diligent analysis, the root cause was identified, and the issue was rectified by relocating the capacitor banks. The solution not only facilitated real-time monitoring but also allowed for the determination of energy consumption on a section-wise or department-wise basis. Additionally, detailed reports were generated, providing insights into energy usage on a shift-wise and day-wise basis.
When Reddy's Lab implemented the Energy Management System (EMS), they uncovered a 4% loss occurring between the incoming transformer and the distribution panel. Additionally, they identified voltage fluctuations ranging from 20 to 30 Volts originating from the transformer. Addressing this issue, they replaced the existing transformer with an On-Load Tap Changer (OLTC) transformer, successfully reducing the voltage fluctuation to a more stable range of 3 to 4 Volts. Consequently, the losses, initially at 4%, were significantly reduced to 1.2%.