KMB-IIT-MAD-23.05.17-08
The subject plant is located in Chennai 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 2023.
General Info
Principal Product
Automotive parts
Plant Area (Sq.ft)
30,000
No. of Employees
50
Production Hours
7,200
Annual Production
5,00,000
Annual Sales
₹2,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹93,04,813
Total Recommended Investment(one time)
₹10,93,000
Total Recommended Savings(per year)
₹17,19,507
Energy Costs Calculation
Electricity
Annual Usage
10,63,240
Unit
kWh
Unit Cost
₹8.75
Annual Cost
₹93,04,813
Total Energy Costs(per year)
₹93,04,813
Observations & Recommendations
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Current Harmonics | Install Harmonic Filters | ₹ | ₹3,00,000 | 11.3 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| ₹ | ₹30,000 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Arrest all identified air leakages and regularly check for air leaks | 1,20,750 | ₹10,56,563 | ₹2,00,000 | 2.3 | |
| Power consumption during unloading | The actual plant CFM load should be calculated accurately and there should be one compressor meeting the base air load by running at full load and the other for meeting peak/fluctuating loads by operating it with a VFD; | 26250 | ₹2,29,688 | ₹50000 | 2.6 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Specific power consumption | Install Air Conditioning Units and Heat Pumps Having the Highest Practical Efficiency | 46,200 | ₹4,04,250 | ₹4,20,500 | 12.5 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Old Type Fans | Use BLDC Fan of 30 W with same velocity | 3315 | ₹29,006 | ₹92500 | 38.3 |