EAR/23-24/KISEM/IITR-06
The subject plant is located in Patauda district of Haryana and falls under NIC Category-22209. This assessment was carried out by the IEAC Center, IIT Ropar, during the course of the year 2023.
General Info
Principal Product
Plastics Spool Manufacturing
Plant Area (Sq.ft)
3,00,000
No. of Employees
300
Production Hours
7,200
Annual Production
Annual Sales
₹50,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹3,72,07,152
Total Recommended Investment(one time)
₹69,60,800
Total Recommended Savings(per year)
₹44,55,354
Energy Costs Calculation
Electricity
Annual Usage
39,63,953
Unit
kWh
Unit Cost
₹8.4
Annual Cost
₹3,32,60,562
Diesel
Annual Usage
43,851
Unit
Ltr
Unit Cost
₹90
Annual Cost
₹39,46,590
Total Energy Costs(per year)
₹3,72,07,152
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High surface temperature is observed on the barrel and heater section near to material loading hopper in all the Injection moulding Machines (47 Nos.) | Provide proper thermal insulation is to the heater section in all Injection moulding Machines | 57,865 | ₹4,62,919 | ₹1,50,000 | 3.9 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Multiple air leakage points were observed | Arrest all air leakages regularly in the compressed air lines. | 31,615 | ₹2,52,920 | ₹25,000 | 1.2 | |
| Screw compressor unloading time is high | The screw compressor can be operated with VFD drive | 29,120 | ₹2,32,960 | ₹75,000 | 3.9 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| It is observed that the cooling tower installed for the plant is of oversized | Operate only one compartment (cell) of the cooling tower (150 TR) for the existing plant load (79.37 TR) | 47,061 | ₹376,488 | ₹10,000 | 0.3 | |
| The process water circulation pump (30 kW) efficiency is 36.6% as the flow is regulated by throttling. | VFD drive can be used for flow regulation | 44,234 | ₹3,53,875 | ₹1,60,000 | 5.4 | |
| Hot water flow rate through cooling tower is observed as very high. For balancing both hot and cold water flow, both hot and cold well are interconnected, thus hot and cold water mix | Both hot and cold-water flow rate should be balanced and VFD drive can be used to regulate the flow. Also, separate both hot and cold well to avoid mixing of both hot and cold water | 75,704 | ₹6,05,632 | ₹1,00,000 | 2 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 44 number of conventional wall mounted fans of 180 Watts were used in the plant. | Conventional energy inefficient fans can be replaced with energy efficient BLDC fans of 100 Watts | 19,008 | ₹1,52,064 | ₹1,62,800 | 13 | |
| 45 number of conventional pedestal fans of 180 Watts were used in the plant. | Conventional energy inefficient fans can be replaced with energy efficient BLDC fans of 100 Watts | 19,440 | ₹1,55,520 | ₹1,71,000 | 13 | |
| 20 number of conventional pedestal and wall mounted fans of 100 Watts were used in the plant | Conventional energy inefficient fans can be replaced with energy efficient BLDC fans of 35 Watts | 9,360 | ₹74,880 | ₹76,000 | 12 | |
| 7 number of conventional pedestal fans of 150 Watts were used in the plant. | Conventional energy inefficient fans can be replaced with energy efficient BLDC fans of 100 Watts | 1,512 | ₹12,096 | ₹21,000 | 21 |
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Contract demand with DISCOM is unutilised. | Surrender 400 kVA of unutilised excess demand as the billing is based on 100% of the contract demand | ₹7,92,000 | ₹10,000 | 0.2 |
ALS - Alternate Source of Power
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| An off-grid 900 kWp solar plant without storage is installed and during the peak solar production plant demand is less than solar production. | It is recommended to convert 115 kWp plant capacity to off grid mode with battery storage | 123,000 | ₹984,000 | ₹6,000,000 | 73.2 |