IIT Madras

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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-25. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.

General Info

Principal Product

Copper and Copper alloys components

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 fittings.9,791₹94,968₹18,0003
Unloading time is high due to varying pressure demandExisting screw compressor could be retrofitted with a VFD drive and optimize power consumption according to actual pressure demand24570₹238329₹200,00011
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Specific Energy Consumption of the Bright Annealing Furnaces were found to be high at 0.136 kWh/kg of the product and Specific Energy Cost is Rs.1.31/kg, due to low loadingOptimize the loading of furnace by increasing the loading per batch and reduce specific energy consumption near to 0.088 kWh/kg and specific energy cost to Rs.0.85/kg64512₹625766₹1000002
DG - Diesel Generator
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Specific Fuel Consumption is found very high than standard limitsUndergo routine maintenance, oil and oil filter change, coolant change, air filter cleaning or changing, diesel pump and injection tuning, overall lubing, overall checkup etc.108₹56848₹30,0007
DM - Demand Management
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Bright Annealing Furnaces are operated in ON/OFF control modeInstall a Thyristor based Power Converter with suitable controller for smooth ramp power modulation and integrate with the available PID Controllers and reduce Maximum Demand by 29 kVA and save demand charges₹153310₹50,0004
LT - Lighting
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Some Down Lights are switched ON unnecessarily in the daytime even though enough daylight is available (Bright annealing furnace area)Switch OFF the unwanted lights3000₹23700₹15,0008
HVC - Heating Ventilation & Cooling
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Conventional Ceiling fans are usedReplace with Energy Efficient BLDC Ceiling fans1944₹16558₹19,20014
Conventional Wall fans are used in the Office SpacesReplace with Energy Efficient BLDC Wall fans3600₹32440₹64,00024
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Inefficient Pump in the Cooling Tower CircuitReplace CT Pump without affecting water flow rate, which will maintain the Range temperature of the CT23407₹225410₹100,0006
Multiple Pump used in Single Circuit and same well is used for hot and cold waterProvide only one pump in the CT circuit before Heat Exchanger. By pass hot well and release hot water directly to inlet of CT
Inefficient Pump in the Cooling CircuitProvide proper size of pump in the circuit
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 98 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy90000₹711000₹375000064