IIT Madras

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IIT Bombay

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IIT Gandhinagar

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IIT Ropar

Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras


The subject plant is located in Aurangabad 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

Auto mobile parts

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
DM - Demand Management
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Last year, In October and November month contract demand is exceeded. due to that penalty has been charged.
CPF - Capacitor & Power Factor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Many capacitors are not working and Most of the time reactive power is negative.Change the APFC into detuned, SCR based system and Add small capacitor for fine tuning21,389₹2,02,126₹2,00,00011.9
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Three Furnaces are operating in ON/OFF control mode and consuming maximum demand. Only 1 furnace has SCR out of four remaining furnaces has only ON/OFF contactor, based temperature sensing by RTD. Power and demand consumption pattern of furnaces with SCR respectivelyInstall PID controlled thyristor converter and reduce maximum demand₹3,29,290₹3,00,00011
Around 17 h per day the furnace mouth is open which can be closed to reduce radiation lossesCover the furnace mouth with automated lid so that radiation loss can be reduced.79,948₹7,55,509₹2,00,0003
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
28 major leakage points identifiedArrest all air leakages1,03,243₹9,75,646₹50,0001
Mixing of high pressure and low pressure compressed air usagesCompressed air required to PDC plant is 4.5/6.5 bar and for product cleaning is 3 bar. separate the whole compressor87,350₹8,25,458₹20,0000.3
All three compressor are without VFD and unloading hours of two compressors are highInstall VFD to both compressors wich are 133 & 134 CFM after seperating the compressor line for PDC machine.42,450₹4,01,153₹3,00,0009
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Hot water and cold water is getting mixed in sumpInstall VFD for the pump so that the flow/pressure should be maintained.20,526₹1,93,971₹5,00,00031
The cooling tower is not maintained properly (cooling water contains too much algae).Maintain the cooling tower properly and should be cleaned regularly
ALS - Alternate Source of Power
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Solar panel are not cleaned properlyCleaning of solar panel should be done regularly. Install water drainer clip