EAR/23-24/KISEM/IITI-01/01
The subject plant is located in Indore district of Madhya Pradesh and falls under NIC Category-29301. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.
General Info
Principal Product
Rubber based Auto parts, Resin Seals and Spacer Rings Manufacturer
Plant Area (Sq.ft)
6,325
No. of Employees
19
Production Hours
7,200
Annual Production
9,00,000
Annual Sales
₹30,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹14,27,000
Total Recommended Investment(one time)
₹28,84,700
Total Recommended Savings(per year)
₹5,55,934
Energy Costs Calculation
Electricity
Annual Usage
1,60,000
Unit
kWh
Unit Cost
₹8.9
Annual Cost
₹14,27,000
Total Energy Costs(per year)
₹14,27,000
Observations & Recommendations
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The Cooling tower is underloaded and effectiveness is found low | Improve range and thereby reduce waterflow demand through intermediate operation of fan and pumps by installing a timer control system | 795 | ₹6,995 | ₹15,000 | 26 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Efficiency of Induction Motor used in Mixing Mill is low due to ageing and underloaded operation | Replace 25HP Induction motor with 20HP IE3 Efficiency class Induction Motor | 2315 | ₹20,368 | ₹75,000 | 45 | |
| Efficiency of Induction Motors used in Compression Moulding Hydraulic Pressing Machines is low due to ageing and underloaded operation | Replace 3 Nos of 5HP and 7 Nos of 3HP Induction motor with IE3 Efficiency class Induction Motors of same ratings | 5830 | ₹51,308 | ₹60,000 | 15 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Heat lost through air gaps near door edges and top of Curing Oven - 1 | Seal the air gaps and provide thermal insulation at the high temperature surfaces | 132 | ₹1,159 | ₹5000 | 52 | |
| Heat lost through air gaps near door edges and top of Curing Oven - 2 | Seal the air gaps and provide thermal insulation at the high temperature surfaces | 94 | ₹828 | ₹5000 | 73 | |
| Heat lost through surface of Hot plate Preheating oven | Seal the air gaps and provide thermal insulation at the high temperature surfaces | 137 | ₹1,205 | ₹3,500 | 35 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ceiling fans used in the plant area and office are inefficient conventional type | Replace 16 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC ceiling fans | 2575 | ₹22,660 | ₹51,200 | 28 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Air- Conditioners used in the office premises are inefficient window type in aged condition | Replace 2 Nos of 1.5 TR Window Air-Conditioners with BEE 5 Star Label Inverter Air-Conditioners of same rating | 1097 | ₹9,654 | ₹70000 | 88 |
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Curing Ovens are operated in ON/OFF control mode which demands full electrical power to deliver required thermal energy | Install a PID Controlled Thyristor power converter and reduce Maximum Demand by 18 kVA and save demand charges | ₹4,41,757 | ₹1,00,000 | 3 |
ALS - Alternate Source of Power
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Electricity is consumed from utility grid alone and there is no source of renewable energy in the plant | Install a Rooftop 22 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy | 60000 | ₹5,28,000 | ₹2500000 | 57 |