KMB-IIT-MAD-27.04.23-05
The subject plant is located in district of and falls under NIC Category-13121. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2023.
General Info
Principal Product
Garments
Plant Area (Sq.ft)
9,000
No. of Employees
75
Production Hours
3,000
Annual Production
30,00,000
Annual Sales
₹6,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹75,64,839
Total Recommended Investment(one time)
₹6,70,000
Total Recommended Savings(per year)
₹17,29,525
Energy Costs Calculation
Electricity
Annual Usage
8,64,553
Unit
kWh
Unit Cost
₹8.75
Annual Cost
₹75,64,839
Total Energy Costs(per year)
₹75,64,839
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 | 30 | ₹3,93,750 | ₹50,000 | 1.5 | |
| 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. | 15000 | ₹ | ₹0 | ||
| Capacity Underutilization | 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. | 66,500 | ₹5,81,875 | ₹100000 | 2.1 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Heater is in continuous ON condition | Install automation in heaters | 20000 | ₹1,75,000 | ₹100000 | 6.9 | |
| No condensate recovery | Maximize Condensate Return | 13600 | ₹1,19,000 | ₹100000 | 10.1 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Old Type Fans | Use BLDC fan with same velocity | 10,560 | ₹92,400 | ₹220000 | 28.6 |
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 | 42,000 | ₹3,67,500 | ₹100000 | 3.3 |