KMB-IIT-MAD-15.09.22-11
The subject plant is located in Shanthapuram district of Tamil Nadu and falls under NIC Category-27. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2022.
General Info
Principal Product
Watch case for Titan watches
Plant Area (Sq.ft)
30,000
No. of Employees
50
Production Hours
7,200
Annual Production
50,000
Annual Sales
₹25,00,000
Assessment Summary
Total Energy Costs(per year)
₹13,69,854
Total Recommended Investment(one time)
₹1,94,500
Total Recommended Savings(per year)
₹2,91,558
Energy Costs Calculation
Electricity
Annual Usage
1,75,690
Unit
kWh
Unit Cost
₹7.5
Annual Cost
₹13,69,854
Total Energy Costs(per year)
₹13,69,854
Observations & Recommendations
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Fair Power Factor | Replace the de-rated capacitors with new capacitors | 5,065 | ₹37,988 | ₹5,000 | 1.6 | |
| Insufficient Capacitor Rating | Add new capacitors as per the requirement | 5,065 | ₹37,988 | ₹5,000 | 1.6 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Medium Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 983 | ₹7,373 | ₹10,000 | 16.3 | |
| Capacity Underutilization | The compressor should be effectively operated in a manner that it should have minimum number of unloading cycles | 13,217 | ₹99,128 | ₹50,000 | 6.1 |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Blower 1 - Belt Driven | Use low-slip or flat belts or directly couple fan with motor | 3,845 | ₹28,838 | ₹35,000 | 14.6 | |
| Blower 2 - Belt Driven | Use low-slip or flat belts or directly couple fan with motor | 3,757 | ₹28,178 | ₹35,000 | 14.9 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Old Type Fans | Use BLDC fan with equivalent velocity | 2,132 | ₹15,990 | ₹45,500 | 34.1 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Heater 2 - Poor Maintenance of Heater Transformer | Periodically check for heater transformer performance and replace if necessary | 1,560 | ₹11,700 | ₹3,000 | 3.1 | |
| Heater 3 - Poor Maintenance of Heater Transformer | Periodically check for heater transformer performance and replace if necessary | 1,640 | ₹12,300 | ₹3,000 | 2.9 | |
| Heater 4 - Poor Maintenance of Heater Transformer | Periodically check for heater transformer performance and replace if necessary | 1,610 | ₹12,075 | ₹3,000 | 3.0 |