EAR/22-23/KISEM-13/IITR-02
The subject plant is located in district of and falls under NIC Category-22. This assessment was carried out by the IEAC Center, IIT Ropar, during the course of the year 2022.
General Info
Principal Product
Plastic products
Plant Area (Sq.ft)
1,00,000
No. of Employees
350
Production Hours
7,200
Annual Production
Annual Sales
₹5,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹1,05,74,190
Total Recommended Investment(one time)
₹2,70,000
Total Recommended Savings(per year)
₹12,10,063
Energy Costs Calculation
Electricity
Annual Usage
8,75,400
Unit
kWh
Unit Cost
₹7
Annual Cost
₹61,27,800
HSD
Annual Usage
48180
Unit
Ltr
Unit Cost
₹84.25
Annual Cost
₹40,59,165
LPG
Annual Usage
3705
Unit
kg
Unit Cost
₹104.5
Annual Cost
₹3,87,225
Total Energy Costs(per year)
₹1,05,74,190
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High surface temperature on Extrusion machines and Moulding Machines | Provide proper thermal insulation is to all Extrusion machines and Moulding Machines | 54,375 | ₹3,80,625 | ₹40,000 | 1.3 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakages are high | Arrest air leakages regularly | 38,984 | ₹2,72,885 | ₹20,000 | 0.9 | |
| Screw compressor unloading time is high | Existing screw compressor can be operated with VFD drive | 36,537 | ₹2,55,756 | ₹1,50,000 | 7 |
CHR - Chiller
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| SEC of the chiller is very high | Do periodic chiller maintenance | 17,013 | ₹1,19,095 | ₹50,000 | 5 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Capacitor bank is derated | Install sufficient capacitors to improve the power factor | ₹1,81,702 | ₹10,000 | 0.7 |