EAR/23-24/KISEM/IITR-04
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 2023.
General Info
Principal Product
Plastic Components Manufacturing
Plant Area (Sq.ft)
3,00,000
No. of Employees
150
Production Hours
7,200
Annual Production
Annual Sales
₹10,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹3,17,62,528
Total Recommended Investment(one time)
₹6,56,200
Total Recommended Savings(per year)
₹33,62,168
Energy Costs Calculation
Electricity
Annual Usage
33,70,170
Unit
kWh
Unit Cost
₹7.9
Annual Cost
₹2,68,08,748
Diesel
Annual Usage
55,042
Unit
kWh
Unit Cost
₹90
Annual Cost
₹49,53,780
Total Energy Costs(per year)
₹3,17,62,528
Observations & Recommendations
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Contract demand with DISCOM is unutilised | Surrender 450 kVA of unutilised excess demand | ₹18,57,600 | ₹10,000 | 0.1 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| De- rated capacitor bank found in the APFC panel & smaller step size capacitors are not installed in APFC | Replace all de-rated capacitor banks and install smaller step size capacitors in APFC (5,7.5,10 kVAR) | 15,325 | ₹1,37,232 | ₹10000 | 0.9 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakages are high | Arrest air leakages regularly | 23,040 | ₹2,07,360 | ₹25000 | 1.4 | |
| Energy savings settings in the vfd drive is not properly maintained | Energy savings settings in the vfd drive should be modified to minimise the energy loss during least air demand in the plant | 14,400 | ₹1,29,600 | ₹10,000 | 0.9 | |
| Existing pipeline for compressed air system is very small in size (half inch) so the cut-out pressure in main compressor is set at 8 bar | Major air line should be replaced with at least 1.5- inch diameter pipe to reduce the pressure drop in line and then reduce the cut-out pressure in main compressor to 7 bar | 4,032 | ₹36,288 | ₹1,00,000 | 33.1 | |
| Reciprocating compressor used for IBM blow moulding machine (200 T) is operated with a cut out pressure of 31 bar, but the maximum pressure requirement in the machine is 21 bar | Cut out pressure in the reciprocating compressor can be reduced to 25 bar and it can be completely utilised for blowing application in IBM moulding machine. The air from main screw compressor can be utilised to cater the low pressure air demand in the same machine. | 202 | ₹1,814 | ₹5,000 | 33.1 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Cooling tower pump is having on and off control but the associated fan is not controlled | Both fan and pump should control simultaneously | 4,625 | ₹41,627 | ₹20000 | 5.8 | |
| Energy inefficient fan is used in the cooling tower | Fan can be replaced with energy efficient FRP fan | ₹ | ₹ | |||
| Two pumps are operated to circulate cold water to the plant during peak and off-peak demand. | One pump can be switched off during offpeak demand hours (Sundays) for cold water | 14,665 | ₹1,31,985 | ₹ |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Conventional energy inefficient fan is used in the air washer | Conventional energy inefficient fan be replaced with energy efficient EC fan. | 7,920 | ₹71,280 | ₹80,000 | 13.5 | |
| 21 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 | 10,080 | ₹90,720 | ₹88,200 | 11.7 | |
| 35 number of conventional pedestal and wall mounted fans of 100 Watts were used in the plan | Conventional energy inefficient fans can be replaced with energy efficient BLDC fans of 35 Watts | 17,010 | ₹1,53,090 | ₹133,000 | 10.4 | |
| 25 number of conventional pedestal fans of 70 Watts were used in the plant. | Conventional energy inefficient fans can be replaced with energy efficient BLDC fans of 35 Watts | 4,050 | ₹36,450 | ₹75,000 | 24.7 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High surface temperature on the barrel and heater section near to material loading hopper in all the Injection moulding Machines (40 Nos.) | Provide proper thermal insulation is to the heater section in all Injection moulding Machines | 51,902 | ₹4,67,122 | ₹1,00,000 | 2.6 |