KMB-IIT-MAD-04.07.22-07
The subject plant is located in Tiruchirappalli district of Tamil Nadu and falls under NIC Category-29301. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2022.
General Info
Principal Product
Engineering & Manufacturing
Plant Area (Sq.ft)
20,000
No. of Employees
100
Production Hours
7,200
Annual Production
3,00,000
Annual Sales
₹75,00,000
Assessment Summary
Total Energy Costs(per year)
₹51,27,095
Total Recommended Investment(one time)
₹5,75,000
Total Recommended Savings(per year)
₹9,54,549
Energy Costs Calculation
Electricity
Annual Usage
6,57,935
Unit
kWh
Unit Cost
₹7.8
Annual Cost
₹51,27,095
Total Energy Costs(per year)
₹51,27,095
Observations & Recommendations
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Poor Power Factor | Replace the de-rated capacitors with new capacitors | 9,256 | ₹72,197 | ₹25,000 | 4.2 | |
| Insufficient Capacitor Rating | Add new capacitors as per the requirement | 12,376 | ₹96,533 | ₹50,000 | 6.2 | |
| APFC Panel Failure | Restore the faulty APFC panels | 0 | ₹0 | ₹50,000 | 0 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 38,500 | ₹3,00,300 | ₹50,000 | 2.0 | |
| Over Rated for Cleaning Requirement | Use a small air compressor when major production load is off. | 31,500 | ₹2,45,700 | ₹2,00,000 | 9.8 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Operated at Partial Load | Install Soft Starter cum Energy saver for fully loaded motors | 7,896 | ₹61,589 | ₹75,000 | 14.6 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess Current Consumption | Periodically check for heater resistor and replace if necessary | 18,000 | ₹1,40,400 | ₹25,000 | 2.1 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Old Type Fans | Use BLDC fan with equivalent velocity | 4,850 | ₹37,830 | ₹1,00,000 | 31.7 |