KMB-IIT-MAD-22.12.22-16
The subject plant is located in district of and falls under NIC Category-22209. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2022.
General Info
Principal Product
Plastic container
Plant Area (Sq.ft)
12,000
No. of Employees
40
Production Hours
7,200
Annual Production
1,88,00,000
Annual Sales
₹56,40,00,000
Assessment Summary
Total Energy Costs(per year)
₹3,77,95,450
Total Recommended Investment(one time)
₹23,90,000
Total Recommended Savings(per year)
₹34,21,649
Energy Costs Calculation
Electricity
Annual Usage
49,08,500
Unit
kWh
Unit Cost
₹7.7
Annual Cost
₹3,77,95,450
Total Energy Costs(per year)
₹3,77,95,450
Observations & Recommendations
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Current Harmonics | Install Harmonic Filters | 31,080 | ₹2,39,316 | ₹15,00,000 | 75.2 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 241800 | ₹18,61,860 | ₹150000 | 1.0 | |
| Capacity Underutilization | The actual plant CFM load should be calculated accurately and there should be one compressor meeting the base air load by running at full load and the other for meeting peak/fluctuating loads by operating it with a VFD; | 65,520 | ₹5,04,504 | ₹125000 | 3.0 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Poor Thermal Insulation | Locate and Repair Defective Insulation on All Heating Plant Equipment and Piping | 17770 | ₹1,36,829 | ₹200000 | 17.5 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Most of the time, it is found to be running idle | Use adjustable frequency drive or multiple speed motors on existing system | 45,000 | ₹3,46,500 | ₹375000 | 13.0 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess Power Consumption | Modify pumping to minimize throttling. | 43,200 | ₹3,32,640 | ₹40,000 | 1.4 |