KMB-IIT-MAD-10.11.22-13
The subject plant is located in Kakkalur district of Tamil Nadu and falls under NIC Category-24319. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2022.
General Info
Principal Product
Electroless Nickel & Acid Zinc Plating
Plant Area (Sq.ft)
30,000
No. of Employees
50
Production Hours
7,200
Annual Production
50,000
Annual Sales
₹50,00,000
Assessment Summary
Total Energy Costs(per year)
₹26,88,429
Total Recommended Investment(one time)
₹15,00,000
Total Recommended Savings(per year)
₹7,11,473
Energy Costs Calculation
Electricity
Annual Usage
3,75,440
Unit
kWh
Unit Cost
₹7
Annual Cost
₹26,88,429
Total Energy Costs(per year)
₹26,88,429
Observations & Recommendations
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Capacitor Not Available | Add new capacitors as per the requirement | 27,819 | ₹1,94,733 | ₹25,000 | 1.5 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Air Leakage Quantity | Eliminate leaks in inert gas and compressed air lines/ valves | 2,450 | ₹17,150 | ₹5,000 | 3.5 | |
| Low Volumetric Efficiency | Establish a compressor efficiency-maintenance program with periodic maintenance schedule | 3,672 | ₹25,704 | ₹10,000 | 4.7 |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Belt Driven | Use low-slip or flat belts or directly couple fan with motor | 2,918 | ₹20,426 | ₹25,000 | 14.7 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess Power Consumption | Replace induction based electrical heaters with equivalent capacity of Heat Pump | 13,858 | ₹97,006 | ₹5,50,000 | 68.0 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess Power Consumption | Replace old Diode type rectifier with IGBT type energy efficient rectifier | 29,466 | ₹2,06,262 | ₹8,00,000 | 46.5 |
CHR - Chiller
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess Water Flow | Keep the Chilled Water Supply Temperature as Low as Possible | 14,112 | ₹98,784 | ₹25,000 | 3.0 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Rewinded Motors | Replace rewound motors with energy efficient motors | 4,680 | ₹32,760 | ₹40,000 | 14.7 | |
| Rewinded Motors | Replace rewound motors with energy efficient motors | 2,664 | ₹18,648 | ₹20,000 | 12.9 |