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

General Info

Principal Product

Press and Fabrication (Welding Assembly)

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
CPF - Capacitor & Power Factor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
All APFC are contactor type and one capacitor Y phase was found disconnectedAPFC operating mechanism should be corrected with thyristor based
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Many Pressing machines are idle for most of the timeInstall VFD for big machines1,41,271₹15,53,981₹8,80,0006.8
Pulleys are broken.Don’t over tight the belts. If slippage is more replace with cogged belts
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Too much leakage in compressed air line.Arrest Leakage frequently1,25,654₹13,82,194₹10,0000.1
All compressors are normal screw type compressorsOne of the compressor should be provided with VFD so as to meet the variable loads41,949₹4,61,439₹1,50,0003.9
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Water flow is bypass to maintain the flow inside the plantInstall VFD and optimize the flow in such a way that the pressure/flow in plant is maintained11,130₹1,22,435₹1,20,00011.8
Cooling Tower has no sprinkling.Sprinkling will increase the range of cooling tower and hence save energy
ALS - Alternate Source of Power
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Soiling, degrading of glass surface which may result in moisture ingress.Install water drainer clip