Innovation and Savings
Packaging Material Optimization 2024
At Mega, we implemented Packaging Optimization Design for Strip Packaging in 2024 by optimizing the strip design with a new efficient machine with Non fill detection Inspection.
This improvement led to 23.85% reduction in foil usage
| Material | Dimension (cm2) | Reduction | |
|---|---|---|---|
| Old Design | New Design | ||
| Foil | 149.5 | 113.85 | 23.85% |
- This initiative Saved 16,650 kg of foil annually, minimizing material waste.
- This had resulted in estimated CO2 reduction of 53,363 kgs annually.
Optimizing Shrink Film Thickness
At our Mega, we Optimized the specification of Shrink film from 15-micron to 12-micron.
- This change resulted in an annual shrink film reduction up to20%of our annual consumption.
- This initiative resulted in reducing the estimated CO2 Emissions by 792 kgs annually.
Packaging material Reduction Initiative 2024
At Mega, we optimized packaging by reducing excess cardboard and plastic usage by reducing carton volume from 668 cm3 to 499 cm3.
- This improvement 25.39% in Reduction of Carton Board.
- Total of 13,320 kg of carton Board consumption reduced.
- This initiative estimated to reduce CO2 Emissions by 16,330 kgs annually.
| Material | Dimension (cm2) | Reduction | |
|---|---|---|---|
| Old Design | New Design | ||
| Box (W x L x H) | 668.7 | 499.06 | 25% |
Hazardous Waste Reduction – Filter Optimization 2024
At Mega Factory, we optimized our filters replacement process by shifting from a fixed time schedule to a condition-based approach based on usage.
- This resulted in 66.67% increase in lifespan of Filters.
- This initiative reduces an estimated CO2 emissions of 287 kgs of CO2.
Hazardous Waste Reduction – Bangpu 2024
At Mega, we optimized Batch sizes which resulted in Reduction of Analysis per Million Tablets.
- This resulted in 38% reduction of in hazardous waste.
Optimizing Energy: Dehumidifier efficiency enhancement 2024
In 2024, at Mega, we optimized steam pressure to enhance latent heat by 2.28% and improved the usage of dehumidifiers, leading to energy savings. This initiative saved 184.58 MMBTU of energy, contributing to a reduction of CO2 emissions by 10,933 kg annually.
Cooling tower efficiency Enhancement 2024
At Mega, we completed an upgrade to our Cooling Tower by replacing the existing 1,300-ton unit with two unit of 2,300-ton to have flexibility to operate at lower loads.
This change resulted in a 14% increase in leading to a reduction of CO2 emissions by 106,928 kg annually.
| Type | Energy saving/year (kWh) | CO2 saving (kgs) |
|---|---|---|
| Electricity | 26,732 | 106,928 |
Enhancing Efficiency and Usage of Water 2024
At Mega, we focussed on water conservation by installing 106 high-efficiency water nozzles and sensors for Hand washing stations across all manufacturing areas.
This initiative reduced 66% of Water usage at handwashing stations leading to an annual savings of approximately 242,700 litres of water and at plant level resulted in 15% reduction of water per million capsules produced along with other water initiatives.
Before
After
Water Resource Optimization 2024
At Mega, we optimized our usage of purified water by Using Hot water for initial cleaning and Purified water for Final Cleaning.
Key Benefits:
- This resulted in reduction of Purified water usage by 50%.
- This helped in energy reduction and contributed to Estimated CO2 reduction of 172,490 Kgs.
Water Conservation and Water Reuse – Mega 2024
At Mega, we diverted concentrated water from the Reverse Osmosis (RO) system for gardening, factory cleaning, and hand washing.
This led to an annual water savings of 1,387 m3.
Water Conservation and Reuse – Mega 2024
At Mega, we have implemented a water reuse initiative by utilizing 50% of the treated wastewater from the WWTP (Wastewater Treatment Plant) for garden irrigation.
- This initiative has successfully saved 604 m3 of water annually.
Innovation and Savings : Waste 2023
Improved roller in feed sealing station has resulted in a reduction of waste by 2.88% thus resulting in a net saving of 581 kgs of waste per annum.
Improvement of carton design lead to reduction of 834 kgs of waste per annum
Innovation and Savings : Electricity 2023
Innovations to make this planet cleaner and safer
Innovations to make this planet cleaner and safer : Mega Lifesciences has invested Thai baht 1.5 million to achieve efficiencies in electrical usage of chillers in the Thailand manufacturing plant resulting in net savings of 337 tons of Co2 emissions and Thai Baht 2.5 million per annum.
Motion and time sensor switches have been installed in the Thailand manufacturing plant resulting in net savings of 29 tons of Co2 emissions by investing Thai Baht 100,000.
MEGA Myanmar 2023
- 500 KVA generator installed and in operation from 13 oct 2022
- Initial estimation shows consumption of diesel reduction by 23.7%
- 66 liters per hour for 1000 KVA generator
- 52 liters per hour for 500 KVA generator
- Daily estimated CO2 reduction is 3,189 kgs
- Annual estimated CO2 reduction is 1,164 Tons
- Investment: $75,000
- ROI: 7.4 months
