KMB-IIT-GUW-230814-06
The subject plant is located in Guwahati district of Assam and falls under NIC Category-20. This assessment was carried out by the IEAC Center, IIT Guwahati, during the course of the year 2023.
General Info
Principal Product
Hair Dye, Liquid Detergent
Plant Area (Sq.ft)
30,000
No. of Employees
50
Production Hours
7,200
Annual Production
Annual Sales
₹10,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹1,23,74,333
Total Recommended Investment(one time)
₹12,35,000
Total Recommended Savings(per year)
₹47,55,555
Energy Costs Calculation
Electricity
Annual Usage
14,17,680
Unit
kWh
Unit Cost
₹8.7
Annual Cost
₹1,23,74,333
Total Energy Costs(per year)
₹1,23,74,333
Observations & Recommendations
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Maximum Demand that has been reached in the previous year is 264 kVA while the sanctioned demand is 619 kVA | Surrender the excess demand of 300 kVA | ₹12,96,000 | ₹ |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Only 87 kVAR connected in 140 kVAR APFC panel | Replace the derated capacitor | ₹ | ₹15000 | |||
| PF correction is based on feedback from single phase only | Install three phase sensing to bring PF to unity. | ₹ | ₹ |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Transformer current harmonics is slightly higher than the IEEE Standard | Install Harmonics filter to avoid distortion in harmonics | ₹ | ₹7,00,000 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Plant overall Air leakage is high (140 cfm) | Arrest all the identified air leakages | 1,93,363 | ₹17,40,267 | ₹50,000 | 0.3 | |
| Compressor 2 & 4 pressure setting is very high ( 7.5 bar) | Reduce the pressure setting of compressor 2 & 4 to 6 - 6.5 bar | 23,884 | ₹2,14,956 | ₹ | ||
| Unloading time of Non VFD compressor is high (5 hrs per day) and the current set pressure of the Non VFD compressor is low compared to the other VFD compressor | Set the pressure setting of Non VFD compressor at maximum value that need to be achieved | 10,395 | ₹93,555 | ₹50,000 | 6.4 | |
| The unloading time of Nitrogen compressor is high – 9 hours per day | Install VFD to minimize the unloading losses | 18,144 | ₹1,63,296 | ₹50,000 | 3.7 |
AHU - Air Handling Unit
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| In the AHU for Creme section, there is no significant temperature difference at the suction side (37°C) and delivery side (36.5°C) because Air dryer is present near suction side of AHU | Replace the AHU with 20 BLDC fans. Relocate the air dryer away from the suction side of AHU. | 45,936 | ₹4,13,424 | ₹50,000 | 1.5 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The effectiveness of the cooling tower is 40% | Proper maintenance should be done regularly | 6,336 | ₹57,024 | ₹1,00,000 | 21 | |
| In cooling tower, the fills are chocked and the water distribution is uneven. | Proper maintenance should be done regularly | ₹ | ₹ |
CHR - Chiller
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| In both the chiller, the actual kW/TR (2.52) is higher than the designed kW/TR | Proper maintenance should be done at regular basis at chiller section | 69,128 | ₹6,22,152 | ₹1,00,000 | 1.9 | |
| In chiller, the evaporator tube and condenser fills has been chocked | Proper maintenance should be done at regular basis at chiller section | ₹ | ₹ |
LT - Lighting
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Nearly, 57 LED lights were turned on during the day time where there is enough source of natural light | Turn OFF the LED lights during day time | 3,385 | ₹30,465 | ₹ |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Totally, there are 48 conventional ceiling fan in the plant running for 24 hours and power consumption by each fan is 70 W | Replace the conventional ceiling fan with BLDC fans which consumes only 30 W | 13,824 | ₹1,24,416 | ₹1,20,000 | 11.6 |