KMB-IIT-IDR-09.11.22-04
The subject plant is located in Indore district of Madhya Pradesh and falls under NIC Category-17. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2022.
General Info
Principal Product
Offset Printing & Packaging Products
Plant Area (Sq.ft)
30,000
No. of Employees
50
Production Hours
7,200
Annual Production
50,000
Annual Sales
₹2,50,00,000
Assessment Summary
Total Energy Costs(per year)
₹2,47,34,000
Total Recommended Investment(one time)
₹31,80,400
Total Recommended Savings(per year)
₹41,71,234
Energy Costs Calculation
Electricity
Annual Usage
29,20,000
Unit
kWh
Unit Cost
₹
Annual Cost
₹2,28,87,000
LPG
Annual Usage
2368000
Unit
Tonnes
Unit Cost
₹
Annual Cost
₹1847000
Total Energy Costs(per year)
₹2,47,34,000
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 | 39,825 | ₹3,42,495 | ₹1,25,000 | 4.4 | |
| Capacity Underutilization | The compressor should be effectively operated in a manner that it should have minimum number of unloading cycles | 18,105 | ₹1,55,703 | ₹3,00,000 | 23.1 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess Power Consumption | Use energy-efficient motors | 7675 | ₹73,680 | ₹125000 | 20.4 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Old Type Fans | Use BLDC fan with equivalent velocity | 7,640 | ₹61,120 | ₹1,50,400 | 29.5 |
CHR - Chiller
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Poor Performance | Replace old chillers or compressors with new higher-efficiency models. | 44,465 | ₹3,55,720 | ₹3,00,000 | 10.1 | |
| Poor Performance | Replace old chillers or compressors with new higher-efficiency models. | 1,58,205 | ₹12,65,640 | ₹5,00,000 | 4.7 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Not economical | Replace Fuel fired process heater with equivalent energy efficient electrical heater | 1,01,972 | ₹5,91,438 | ₹5,60,000 | 11.4 | |
| Not economical | Replace Fuel fired process heater with equivalent energy efficient electrical heater | 1,21,515 | ₹7,04,787 | ₹5,60,000 | 9.5 | |
| Not economical | Replace Fuel fired process heater with equivalent energy efficient electrical heater | 1,10,094 | ₹6,38,545 | ₹5,60,000 | 10.5 |