KMB-IIT-BOM-210423-13
The subject plant is located in Sambhaji Nagar district of Maharashtra and falls under NIC Category-29301. This assessment was carried out by the IEAC Center, IIT Bombay, during the course of the year 2023.
General Info
Principal Product
Manufacturer and Supplier of plate clutches
Plant Area (Sq.ft)
5,00,000
No. of Employees
200
Production Hours
7,200
Annual Production
Annual Sales
₹30,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹1,21,00,000
Total Recommended Investment(one time)
₹24,90,000
Total Recommended Savings(per year)
₹40,34,977
Energy Costs Calculation
Electricity
Annual Usage
12,90,000
Unit
kWh
Unit Cost
₹9.4
Annual Cost
₹1,21,00,000
Total Energy Costs(per year)
₹1,21,00,000
Observations & Recommendations
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| All APFC are contactor type and many derated capacitors are found | APFC operating mechanism should be rechecked and corrected with thyristor based | 14,875 | ₹1,40,422 | ₹80,000 | 7 | |
| APFC controlling is by single phase sensing | The sensing mechanism should be upgraded to Three phase sensing | ₹ | ₹ |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 8 Rectifiers in Barel Line has huge energy loss and high ripple factor | Change the old DIAC based rectifiers with PWM IGBT based rectifiers | 83,700 | ₹7,90,128 | ₹7,00,000 | 10.6 | |
| In VAT line new rectifier loss is around 1.7 kW | If possible derate the rectifier or add larger materials | 50,280 | ₹4,74,643 | ₹2,00,000 | 5.1 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| There are total 15 ( 9* 3kW + 6*4kW) heaters and 1.5 TR AC and chiller is there | Go for Heat pump which will save more energy. | 2,78,489 | ₹26,29,784 | ₹15,00,000 | 7 |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The electrodes are not cleaned and in some time the proper connection is not getting | It Should be Properly clean and frequently also | ₹ | ₹10,000 |
ALS - Alternate Source of Power
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Waterlogging at lower side of panel due to low tilt angle. This results in soiling, degrading of glass surface which may result in moisture ingress | Install water drainer clip | ₹ | ₹ | |||
| One of the solar panels is damaged | Replace the damaged solar panel | ₹ | ₹ |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Cooling tower fan is not there due to maintenance | Cooling tower Fan should be maintained as early as possible | ₹ | ₹ | |||
| Rusting of contact in all the electrical panel | Install sealed panels or panels which are designed for chemical environments | ₹ | ₹ |