IIT Madras

IIT Hyderabad

IIT Bombay

IIT Indore

IIT Gandhinagar

IIT Guwahati

IIT Ropar

Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras


The subject plant is located in district of and falls under NIC Category-13. This assessment was carried out by the IEAC Center, IIT Bombay, during the course of the year 2023.

General Info

Principal Product


Plant Area (Sq.ft)


No. of Employees


Production Hours


Annual Production

Annual Sales

Assessment Summary

Total Energy Costs(per year)


Total Recommended Investment(one time)


Total Recommended Savings(per year)


Energy Costs Calculation

Annual Usage




Unit Cost


Annual Cost



Annual Usage




Unit Cost


Annual Cost


Total Energy Costs(per year)


Observations & Recommendations
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Excess air is too high around 250 %. Allowable excess air is 70 % MaximumInstall Oxygen analyser and give feedback to existing FD and ID fan VFD.52,560₹5,51,880₹3,00,0006.5
PRV used to decrease the pressure from 10 bar to 5 bar.Install steam expander which can generate electricity of 19.57 kW/hr for 1 Ton steam from 10 to 5 bar.1,71,433₹8,10,879₹14,00,00020.7
Temperature in boiler walls in certain area are high.Insulate the walls37,150₹3,90,075₹50,0001.5
Many steam line insulations are not proper.Complete steam line insulation to reduce heat loss in the line7,687₹80,714₹10,0001.5
Steam trap is not working in good conditionConnect the pipeline to water tank730₹7,665₹5,0007.8
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
High Unloading hours for certain compressorsInstall VFD for unloaded compressors73,809₹3,49,117₹1,00,0003.44
Leakage cfm is high in many loom machinesArrest leakages in Loom machine33,271₹1,57,371₹10,0000.8
Pressure setting in looms is high around 5.5 bar. Recommended for cotton is 4.8 to max 5 bar and for polyester 5 to 5.2 barAdjust regulator so that 0.2-0.4 bar pressure can be decreased which will give minimum 3 cfm savings per machine.2,47,534₹11,70,837
Many compressor suction filters are chokedRecommended to maintain filters periodically
HF - Humidification Plant
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Supply cfm is less than Return cfmInstall VFD in return fan and optimize the speed according to the supply cfm.2,61,836₹12,38,486₹2,50,0002.4
Return ducts of Looms are choked. It should be cleanedIt should be optimized by including VFD in Supply and Return fans23,565₹1,11,464₹1,00,00010.8