EAR/23-24/KISEM/IITI-16/02
The subject plant is located in district of and falls under NIC Category-11. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.
General Info
Principal Product
Instant Tea Powder – Green teas and Black teas
Plant Area (Sq.ft)
12,373
No. of Employees
320
Production Hours
8,472
Annual Production
13,31,000
Annual Sales
₹1,00,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹13,56,19,400
Total Recommended Investment(one time)
₹49,72,000
Total Recommended Savings(per year)
₹1,27,84,494
Energy Costs Calculation
Electricity
Annual Usage
4,35,000
Unit
kWh
Unit Cost
₹7.24
Annual Cost
₹31,49,400
Wood chips
Annual Usage
12079000
Unit
kg
Unit Cost
₹5.25
Annual Cost
₹6,34,10,000
Furnace oil
Annual Usage
13,95,000
Unit
kg
Unit Cost
₹43.2
Annual Cost
₹6,02,30,000
Spent leaves
Annual Usage
9403000
Unit
kg
Unit Cost
₹
Annual Cost
₹
Diesel
Annual Usage
84,600
Unit
Ltr
Unit Cost
₹104.5
Annual Cost
₹88,30,000
Total Energy Costs(per year)
₹13,56,19,400
Observations & Recommendations
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakages are found to be high at different points of the circuit | Arrest air leakages regularly by conducting maintenance of compressed air system consisting of the plant, circuit, and fittings. | 20,612 | ₹1,49,236 | ₹1,12,000 | 10 | |
| The existing Cut-off pressure is 7.5 bar. whereas the maximum pressure requirement is 6 bar and same pressure is used for cleaning applications | Proposed to change the cutoff pressure from 7.5 bar to 6.5 bar. Use hand blowers to meet cleaning requirements | 11256 | ₹81,494 | ₹ |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Steam leakages at various points | Arrest the steam leakages by properly sealing the gaps | 10,06,280 | ₹11,92,340 | ₹1,10,000 | 2 | |
| Thermal energy lost in condensate circulating in steam traps | Maintain Traps and Recover Condensate | 1059985 | ₹1,255,976 | ₹120,000 | 2 | |
| Thermal energy lost as flash steam | Recover condensate using a SOPT Pump and pumping condensate directly to feed water tank | 1551781 | ₹1,838,704 | ₹700,000 | 5 | |
| Non insulated surfaces of steam distribution lines and condensate lines | Provide thermal insulation at the high temperature surfaces and save fuel | 147720 | ₹175,033 | ₹50,000 | 4 | |
| Wood fired HOSKO Boiler - Excess Air fed for boiler combustion is high | Optimize Excess Air demand by controlling FD fan speed in closed loop mode using O2 sensor and VFD | ₹ | ₹ | |||
| Wood fired HOSKO Boiler - Excess Air fed for boiler combustion is high | Fuel Savings | 2439138 | ₹3419724 | ₹1000000 | 4 | |
| Wood fired HOSKO Boiler - Excess Air fed for boiler combustion is high | Electricity Savings in FD Fan Motor | 32130 | ₹232621 | ₹ | ||
| FO fired IAEC Boiler - Excess Air fed for boiler combustion is high | Optimize Excess Air demand by controlling FD fan speed in closed loop mode using O2 sensor and VFD | ₹ | ₹ | |||
| FO fired IAEC Boiler - Excess Air fed for boiler combustion is high | Fuel Savings | 47161 | ₹161483 | ₹200000 | 15 | |
| FO fired IAEC Boiler - Excess Air fed for boiler combustion is high | Electricity Savings in FD Fan Motor | 25108 | ₹25108 | ₹ |
ALS - Alternate Source of Power
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Process heat rejected in Cooling Tower could be reclaimed | Reclaim waste heat using suitable Heat Exchanger and serve hot water adjacently | 402907 | ₹696,286 | ₹1,000,000 | 18 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Daily Energy Losses are high compared to standard similar rating Transformers | Carry out overall maintenance and oil filtration of the Transformer | 141012 | ₹1030798 | ₹1000000 | 12 | |
| Billed MD is low compared to minimum quota of CD allotted (Source - 1) | Surrender CD from 1300 to 950 kVA and save minimum demand charges | ₹912600 | ₹50000 | 1 | ||
| Billed MD is low compared to minimum quota of CD allotted (Source - 2) | Surrender CD from 130 to 90 kVA and save minimum demand charges | ₹194220 | ₹50000 | 4 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Withering of tea leaves is done using 24 Nos of fans and water is again added post withering | For juice extraction process, withering could be avoided and the fans can be switched off permanently | 88471 | ₹640,530 | ₹ |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The overall efficiency of the Aseptic Chiller, UF1 and UF2 Feed Pumps are low. | Replace with proper size and Energy Efficient Pumps | 61100 | ₹442360 | ₹70000 | 2 | |
| Gentle Extractor - Hot water pump operated in throttling condition | Install VFD and save energy lost in throttling | 17820 | ₹129017 | ₹360000 | 34 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Conventional Metal blades are used in Cooling Tower Fans | Replace with Energy Efficient FRP blades and save energy | 28586 | ₹206964 | ₹150000 | 9 |