EAR/23-24/KISEM/IITI-15/02
The subject plant is located in district of and falls under NIC Category-11. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.
General Info
Principal Product
Packaged Black and Green Tea Powders (6 Brands / 14 Blends)
Plant Area (Sq.ft)
40,000
No. of Employees
260
Production Hours
4,480
Annual Production
1,50,00,000
Annual Sales
₹5,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹47,73,000
Total Recommended Investment(one time)
₹98,60,000
Total Recommended Savings(per year)
₹16,38,801
Energy Costs Calculation
Electricity
Annual Usage
3,91,000
Unit
kWh
Unit Cost
₹10.6
Annual Cost
₹41,25,000
Solar
Annual Usage
1,64,000
Unit
kWh
Unit Cost
₹1.2
Annual Cost
₹1,91,000
Diesel
Annual Usage
4720
Unit
Ltr
Unit Cost
₹97
Annual Cost
₹4,57,000
Total Energy Costs(per year)
₹47,73,000
Observations & Recommendations
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakages are found to be high at different points of the circuit | Arrest air leakages regularly by conducting maintenance of compressed air system consisting of the plant, circuit, and fittings. | 58,238 | ₹4,54,256 | ₹80,000 | 3 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Vacuum Pump System used for conveying stock from mobile trolley to packaging machine hopper is energy intensive. | Switch from Vacuum pump system to Bucket elevator system which consumes comparatively less energy | 111186 | ₹867251 | ₹8000000 | 111 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Cyclone 2 and Tipping Hopper motor - Motor VFD is set at full speed, where VFD is not utilized for speed control | Bypass VFD and save energy lost in VFD | 990 | ₹7721 | ₹ | ||
| The conveyed length of push conveyor near packeting machine is very low | Eliminate motor driven push conveyor and change to sliding manual conveying system | 3504 | ₹27331 | ₹20000 | 9 |
ALS - Alternate Source of Power
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The present 30 kVA UPS is loaded at 33% and self consumption energy losses are high | Replace with optimum capacity 15 kVA or nearest UPS to improve loading and save energy | 2,628 | ₹20,498 | ₹30,000 | 18 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The transformer is more than 25 years aged and Daily Energy Losses are high compared to standard similar rating Transformer | Replace the existing transformer with energy efficient Transformer of optimal capacity | 7183 | ₹56029 | ₹800000 | 172 | |
| Billed MD is low compared to minimum quota of CD allotted | Surrender CD from 220 to 180 kVA and save minimum demand charges | ₹58800 | ₹50000 | 11 | ||
| System Power factor is maintained less than 0.95 | Improve Power factor to 0.99 and save penalty / incentive charges | ₹25000 | ₹50000 | 24 | ||
| Section wise energy consumption is not available due to absence of feeder sub energy meters and non functioning of certain sub meters | Install sub energy meters with remote monitoring and accounting facility for all feeders and sub feeders | ₹ | ₹800000 |
LT - Lighting
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Lights are switched ON at Tea bag packing sections and common areas during break time | Install more skylights and switch OFF unwanted lights during break time and daytime | 584 | ₹4555 | ₹ |
DG - Diesel Generator
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Specific Energy Generated (kWh/Ltr) is found low | Undergo routine maintenance and checks to improve SEC and save fuel | 14131 | ₹117360 | ₹30,000 | 4 |