IIT Madras

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Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras


The subject plant is located in Ujjain district of Madhya Pradesh and falls under NIC Category-24319. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.

General Info

Principal Product

Auto Casting Products Manufacturer

Plant Area (Sq.ft)


No. of Employees


Production Hours


Annual Production


Annual Sales


Assessment Summary

Total Energy Costs(per year)


Total Recommended Investment(one time)


Total Recommended Savings(per year)


Energy Costs Calculation

Annual Usage




Unit Cost


Annual Cost



Annual Usage




Unit Cost


Annual Cost


Total Energy Costs(per year)


Observations & Recommendations
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Overall air leakages are found to be high at different points of the circuitArrest air leakages regularly by conducting maintenance of compressed air system consisting of the plant, circuit and fittings173230₹1212608₹300001
Compressor - 1 (A) is fully loaded throughout the day but in Compressor - 3 (C) unloading time is high compared to loading timeOptimize loading of Compressor by Operate Compressor - 1 (A) as slave and Compressor-2 (B) as a master by installing VFD and Keep Compressor -3 (C) as standby106596₹746172₹2000004
For cleaning and low-pressure applications, high rated compressor used. The requirement for low pressure is 2 bar, but the compressor used 8 bar set pressure.Provide appropriate size of compressor for low pressure applications. Use 2 to 2.5 bar dedicated compressor for low pressure applications.28627₹200390₹250002
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Specific Energy Consumption of the Induction Furnaces at 600 kg were found 0.67 kWh/kg of melting and Specific Energy Cost is Rs.4.7/kg, due to high stock loadingOptimize the loading of furnaces to the design capacity of 500 kg/batch and reduce specific energy consumption near to 0.562 kWh/kg and specific energy cost to Rs.3.9/kg670965₹4696756
Specific Energy Consumption of the Induction Furnaces were found high at 0.562 kWh/kg of melting and Specific Energy Cost is Rs.3.9/kg, due to inefficient conventional SCR based Power Converter with Pulse firing schemeReplace the existing SCR / Diode based Power Converter Unit with Modern IGBT based Power Converter with Vector Controlled PWM Firing scheme and reduce specific energy consumption near to 0.515 kWh/kg and specific energy cost to Rs.3.6/kg294939₹2064570₹10000006
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
In the existing stage cooling tower fan operate 24X7 and L/G ratio is highInstalled VFD for better optimization of cooling tower fan. Operate fan according to approach temperature and improve L/G ratio9936₹69552₹400007
In the existing condition, hot and cold well used in the circuit. The hot well used for the furnace coil water circuit and the cold well used in the cooling tower circuitBypass the hot well and cold well from the existing circuit. Provide close loop circuit to use of potential head produced by the pump. The return water line of the furnace coil will be directly connected to the suction side of the pump instead of to drop the water in hot well. In cooling tower, the sump exit line will be directly connected to the suction side of the pump instead of water flow to the cold well. Provide make up water arrangement directly to the sump side of the cooling tower8424₹8424₹5000072
FN - Fans
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Ceiling fans used in the plant and office areas are inefficient conventional typeReplace 44 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC ceiling fans7128₹58696₹14080029
ALS - Alternate Source of Power
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Electricity is consumed from utility grid alone and there is no source of renewable energy in the plantInstall a Rooftop 392 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy470400₹3292800₹1960000072