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 Ropar, 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


Total Energy Costs(per year)


Observations & Recommendations
BL - Blower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
A variation in power consumption is observed in larger and smaller blowers in the OE machines compared with the same type of blowers in similar OE machines.Do periodic maintenance to arrest all the leakages from the machine. Remove the waste periodically or use an automation system to remove the waste periodically from the OE machine.5,77,800₹43,33,500₹5,00,0001.4
FN - Fans
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
More than the required static pressure is given to the carding machine.Adjust the speed of the fan in VXL machine with the vfd drive so as to get the required pressure at the extreme end of the duct without damper.1,14,408₹8,58,060₹50,0000.7
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Four to Seven machines are connected with the same rotary for waste recovery and the rotary is observed as running at constant speed even when a few machines are in off condition.Automation should be provided to close the main duct of idle machines and at the same time control the rotary speed based on static pressure.6,03,501₹45,26,264₹6,00,0001.6
Energy-inefficient and re-winded motors are used in the machinesConventional motors can be considered for replacement with energy efficient IE4 motors.1,03,167₹7,73,750₹43,84,00068
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Overall air leakage was observed to be very highArrest air leakages regularly83,082₹6,23,118₹10,0000.2
In Screw Compressor 5 (40 HP), the unloading time is highOperate this screw compressor with a VFD Drive.51,961₹3,89,707₹3,00,0009.2
Compressed air at 7 bar is used for cleaning application in all over the plant.Use dedicated compressors for cleaning applications with separate airlines and reset the cut-out pressure of the compressor to 3 bar for cleaning application.1,22,774₹9,20,808₹2,00,0002.6
HF - Humidification Plant
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Efficiency of Humidifiers is observed to be very low.Do periodic maintenance of the humidifier.3,02,280₹22,67,099₹4,00,0002.1
The airflow rate through all the humidifiers is observed to be very high.Optimise the air flow rate based on humidity requirements at the department by balancing supply and return air.
TR - Transformer
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Two Off-circuit tap changer (OCTC) Transformers of 1250 kVA and 3000 kVA capacity with an HV range of 9900 to 11550 Volts are installed in the plantIt is recommended to replace the existing transformer with 5 star rated On-load tap changer (OLTC) transformer with more position and wider range.2,26,359₹16,97,689₹60,00,00031.8
To stabilise the voltage two servo transformers are installed at the secondary of both the transformersIt is recommended to replace the existing transformer with 5 star rated On-load tap changer (OLTC) transformer with more position and wider range.75,967₹5,69,754