IIT Madras

IIT Hyderabad

IIT Bombay

IIT Indore

IIT Gandhinagar

IIT Guwahati

IIT Ropar

Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras


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

General Info

Principal Product


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


Total Energy Costs(per year)


Observations & Recommendations
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Un-necessary superheating of metal is observed due to the faster heating rate. (During the final stage of melting, the temperature of molten metal rises at a rate of 7°C per minute)Manually adjust the power of furnace during the final stage of melting.3,55,395₹24,87,768₹1,00,0000.5
Scrap is loaded without weighing and thus the furnace is over loaded to adjust the composition by trial and error methodProper weighing mechanism should be incorporated to avoid the overloading of furnace and reduce the testing time.
Radiation loss from the furnace during idle timeFurnace cover can be used during idle time58,342₹408,394₹1000002.9
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Screw compressor unloading time is highThe screw compressor can be operated with VFD drive and reciprocating compressors can keep as standby.51,230₹358,607₹100,0003.3
Overall air leakages are highArrest air leakages regularly in the compressed air lines30,012₹210,086₹10,0000.6
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Overflow of water in the cooling tower is observedVFD technology can be used to regulate the water flow in pump with respect to the requirement45,687₹3,19,811₹50,0001.9
FN - Fans
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Mould cooling fans where operated 24 hrsProper positioning of either fan or mould can reduce the operating hours25,200₹176,400₹100000.7
CPF - Capacitor & Power Factor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Three faulty and three derated capacitors foundReplace the faulty capacitors28,148₹1,97,038₹210001.3