KMB-IIT-MAD-02.05.23-06
The subject plant is located in district of and falls under NIC Category-13111. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2023.
General Info
Principal Product
Garments
Plant Area (Sq.ft)
20,000
No. of Employees
200
Production Hours
7,200
Annual Production
4,27,00,000
Annual Sales
₹76,86,00,000
Assessment Summary
Total Energy Costs(per year)
₹8,54,55,403
Total Recommended Investment(one time)
₹48,15,000
Total Recommended Savings(per year)
₹1,55,10,000
Energy Costs Calculation
Electricity
Annual Usage
77,68,673
Unit
kWh
Unit Cost
₹11
Annual Cost
₹8,54,55,403
Total Energy Costs(per year)
₹8,54,55,403
Observations & Recommendations
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Demand Underutilization | Surrender unutilized sanctioned demand | ₹19,80,000 | ₹ |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Current Harmonics | Install Harmonic Filters | ₹ | ₹300000 | |||
| High Current Harmonics | Install Harmonic Filters | ₹ | ₹300000 | |||
| High Current Harmonics | Install Harmonic Filters | ₹ | ₹400000 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 315000 | ₹34,65,000 | ₹50000 | 0.2 | |
| High specific energy consumption | Replace old compressor with energy efficient low specific energy consumption (kW/CFM) compressor; | 1,35,000 | ₹14,85,000 | ₹1850000 | 14.9 |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Duct Leak | Eliminate ductwork leaks. | 180000 | ₹19,80,000 | ₹200000 | 1.2 |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Pressure | Minimize blower speed. | 30000 | ₹3,30,000 | ₹15000 | 0.5 |
HF - Humidification Plant
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Improper maintenance | Exhaust filters must be cleaned at least once a day and in case of louver & eliminator sheet, the cleaning should be done based on the drop in air volume in the department | 283500 | ₹31,18,500 | ₹300000 | 1.2 | |
| Rewinded Motors | Replace rewound motors with energy efficient motors | 40,500 | ₹4,45,500 | ₹12,00,000 | 32.3 | |
| Supply cfm is lower | The air supply must be 5% more than the air exhaust and this is to be maintained in all the departments | 81000 | ₹8,91,000 | ₹0 | 0.0 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Poor Ventilation | Provide proper ventilation(Motor life will be halved for every 10°C rise) | 27000 | ₹2,97,000 | ₹50000 | 2.0 | |
| Cylinder Speed | Use adjustable frequency drive or multiple speed motors on existing system | 18000 | ₹1,98,000 | ₹50000 | 3.0 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Poor Ventilation | Provide proper ventilation(Motor life will be halved for every 10°C rise) | 72000 | ₹7,92,000 | ₹80000 | 1.2 |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Duct Leak | Eliminate ductwork leaks. | 48000 | ₹5,28,000 | ₹20000 | 0.5 |