KMB-IIT-MAD-08.13.23-04
The subject plant is located in district of and falls under NIC Category-13111. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2023.
General Info
Principal Product
Fabrics
Plant Area (Sq.ft)
13,000
No. of Employees
200
Production Hours
8,400
Annual Production
26,80,000
Annual Sales
₹23,45,00,000
Assessment Summary
Total Energy Costs(per year)
₹8,30,12,816
Total Recommended Investment(one time)
₹27,09,000
Total Recommended Savings(per year)
₹1,05,58,275
Energy Costs Calculation
Electricity
Annual Usage
94,87,179
Unit
kWh
Unit Cost
₹8.75
Annual Cost
₹8,30,12,816
Total Energy Costs(per year)
₹8,30,12,816
Observations & Recommendations
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 2,10,000 | ₹18,37,500 | ₹1,00,000 | 0.7 | |
| High Cut-off Pressure Setting | Reduce air compressor discharge pressure to the lowest acceptable setting.((Reduction of 1 kglcm2 air pressure (8 kg/cm2 to 7 kg/cm2 ) would result in 9% input power savings. | 35000 | ₹3,06,250 | ₹300000 | 11.8 |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Duct Leak | Eliminate ductwork leaks. | 280000 | ₹24,50,000 | ₹299000 | 1.5 | |
| High Pressure Drop | Clean screens and filters regularly. | ₹0 | ₹10000 | Infinity |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Converging Comber is used | Use smooth, well-rounded air inlet ducts or cones for air intakes. | 52500 | ₹4,59,375 | ₹200000 | 5.2 |
HF - Humidification Plant
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Improper maintenance | Exhaust filters must be cleaned at least once a day and in case of louver & eliminator sheet, the cleaning should be done based on the drop in air volume in the department | 184800 | ₹16,17,000 | ₹100000 | 0.7 | |
| Supply cfm is lower | The air supply must be 5% more than the air exhaust and this is to be maintained in all the departments | 0 | ₹ | ₹0 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Poor Ventilation | Provide proper ventilation(Motor life will be halved for every 10°C rise) | 76860 | ₹6,72,525 | ₹200000 | 3.6 | |
| High cylinder speed | Use adjustable frequency drive or multiple speed motors on existing system | ₹ | ₹ |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Poor Ventilation | Provide proper ventilation(Motor life will be halved for every 10°C rise) | 367500 | ₹32,15,625 | ₹1500000 | 5.6 |