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Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras


The subject plant is located in district of and falls under NIC Category-31. This assessment was carried out by the IEAC Center, IIT Guwahati, during the course of the year 2023.

General Info

Principal Product

Steel Furniture Manufacturing

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
Maximum demand that has been reached in the previous year is 303 kVA. While the sanctioned demand is 588 kVAReturn the demand of 250 kVA to reduce the demand charges₹8,10,000
TR - Transformer
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Transformer Current harmonics (21.5%) is higher then the IEEE standard of 8%Install harmonics filter to avoid distortion in harmonics₹5,00,000
CPF - Capacitor & Power Factor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Overall Power factor maintained is very low. In months ( July 2022, February & March 2023) power factor is maintained only at 0.77 and penalty has been paidImprove the power factor above 0.97 to get rebate of 3% of total unit consumption33,908₹2,28,879₹15,0000.8
APFC phase sensing is done on single phaseTake APFC Phase sensing from all 3 phases to maintain PF on all phases
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Compressor unloading hours is high (7 hours per day)Install VFD to reduce the unloading losses67,200₹4,53,600₹1,25,0003.31
Compressor current pressure setting is very high (12 bar)Reduce the pressure setting to 7 bar17,700₹1,19,475
Overall air leakages is found to be high ( 25 CFM)Arrest all the identified air leakages10,800₹72,900₹15,0002.47
PP - Pumps
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
In spray painting, due to the excess flow there has been the re-circulation at the output of the pumpThe pump suction valve has been throttled and discharge valve has been opened completely21,165₹142,864
HVC - Heating Ventilation & Cooling
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Totally, there are 40 conventional ceiling fans running in maximum working hours and consuming power of 70 WReplace conventional Ceiling fan with BLDC fans which consumes 28 W4,800₹32,400₹120,00044.4