KMB-IIT-MAD-08.05.23-07
The subject plant is located in district of and falls under NIC Category-13131. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2023.
General Info
Principal Product
Socks
Plant Area (Sq.ft)
10,000
No. of Employees
Production Hours
7,200
Annual Production
39,00,000
Annual Sales
₹78,40,00,000
Assessment Summary
Total Energy Costs(per year)
₹11,97,06,984
Total Recommended Investment(one time)
₹9,00,000
Total Recommended Savings(per year)
₹49,83,922
Energy Costs Calculation
Electricity
Annual Usage
97,91,544
Unit
kWh
Unit Cost
₹11
Annual Cost
₹10,77,06,984
Wood
Annual Usage
30,00,000
Unit
kg
Unit Cost
₹4
Annual Cost
₹1,20,00,000
Total Energy Costs(per year)
₹11,97,06,984
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Condensate recovery is very less | Maximize Condensate Return | 15,217 | ₹60,868 | ₹30,000 | 5.9 | |
| High Feed water TDS | Test and Treat Boiler Water on a Continuing Basis | 126783 | ₹5,07,132 | ₹150000 | 3.5 | |
| Poor Thermal Insulation | Locate and Repair Defective Insulation on All Heating Plant Equipment and Piping | 15,217 | ₹60,868 | ₹20,000 | 3.9 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 2,69,914 | ₹29,69,054 | ₹2,00,000 | 0.8 | |
| Higher than the machine required pressure | 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. | 87297 | ₹ | ₹0 |
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 | 126000 | ₹13,86,000 | ₹500000 | 4.3 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Motor speed | Use adjustable frequency drive or multiple speed motors on existing system | 54000 | ₹ | ₹0 |