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

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)

₹10,83,934

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
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
The Cooling tower is underloaded and effectiveness is found lowImprove range and thereby reduce waterflow demand through intermediate operation of fan and pumps by installing a timer control system795₹6,995₹15,00026
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Efficiency of Induction Motor used in Mixing Mill is low due to ageing and underloaded operationReplace 25HP Induction motor with 20HP IE3 Efficiency class Induction Motor2315₹20,368₹75,00045
Efficiency of Induction Motors used in Compression Moulding Hydraulic Pressing Machines is low due to ageing and underloaded operationReplace 3 Nos of 5HP and 7 Nos of 3HP Induction motor with IE3 Efficiency class Induction Motors of same ratings5830₹51,308₹60,00015
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Heat lost through air gaps near door edges and top of Curing Oven - 1Seal the air gaps and provide thermal insulation at the high temperature surfaces132₹1,159₹500052
Heat lost through air gaps near door edges and top of Curing Oven - 2Seal the air gaps and provide thermal insulation at the high temperature surfaces94₹828₹500073
Heat lost through surface of Hot plate Preheating ovenSeal the air gaps and provide thermal insulation at the high temperature surfaces137₹1,205₹3,50035
FN - Fans
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Ceiling fans used in the plant area and office are inefficient conventional typeReplace 16 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC ceiling fans2575₹22,660₹51,20028
HVC - Heating Ventilation & Cooling
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Air- Conditioners used in the office premises are inefficient window type in aged conditionReplace 2 Nos of 1.5 TR Window Air-Conditioners with BEE 5 Star Label Inverter Air-Conditioners of same rating1097₹9,654₹7000088
DM - Demand Management
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Curing Ovens are operated in ON/OFF control mode which demands full electrical power to deliver required thermal energyInstall a PID Controlled Thyristor power converter and reduce Maximum Demand by 18 kVA and save demand charges₹4,41,757₹1,00,0003
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 22 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy60000₹5,28,000₹250000057