EAR/23-24/KISEM/IITI-06/01
The subject plant is located in Pithampur district of Madhya Pradesh and falls under NIC Category-22112. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.
General Info
Principal Product
Rubber Tyre tubes, Curing bags and Flaps Manufacturer
Plant Area (Sq.ft)
30,000
No. of Employees
45
Production Hours
7,200
Annual Production
90,00,000
Annual Sales
₹
Assessment Summary
Total Energy Costs(per year)
₹1,57,01,465
Total Recommended Investment(one time)
₹26,11,600
Total Recommended Savings(per year)
₹46,68,667
Energy Costs Calculation
Electricity (Grid)
Annual Usage
7,92,000
Unit
kWh
Unit Cost
₹9.4
Annual Cost
₹74,77,000
Electricity (solar)
Annual Usage
17356
Unit
kWh
Unit Cost
₹9.4
Annual Cost
₹
Bio Coal
Annual Usage
1189000
Unit
Kg
Unit Cost
₹6.8
Annual Cost
₹ 8125000
Diesel
Annual Usage
1047
Unit
Litres
Unit Cost
₹95
Annual Cost
₹99,465
Total Energy Costs(per year)
₹1,57,01,465
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. | 24,214 | ₹2,23,494 | ₹1,25,000 | 7 | |
| Screw compressor 2 - unloading time is high due to varying pressure demand | Existing screw compressor 2 could be retrofitted with a VFD drive and optimize power consumption according to actual pressure demand | 20640 | ₹190507 | ₹75000 | 5 | |
| Reciprocating Compressor 3 is unnecessarily used for short duration every day eventhough pressure demand is met | Switch OFF the Reciprocating Compressor (Comp 3) and operate Comp 2 alone | 48865 | ₹451024 | ₹ |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Efficiency and Loading of Induction Motors used in 6 inch Extruder is low | Replace 50 HP Induction motor with 50 HP IE3 Efficiency class Induction Motor | 12326 | ₹113770 | ₹100000 | 11 | |
| Efficiency and Loading of Induction Motor used in Mixing Mills - 1,2 and 3 is low | Replace 3 Nos of 60 HP Induction motors with 30 HP IE3 Efficiency class Induction Motor | 32224 | ₹297430 | ₹225000 | 10 | |
| Efficiency and Loading of Induction Motor used in Kneeder - 1,2 and 3 is low | Replace 3 Nos of 100 HP Induction motors with 60 HP IE3 Efficiency class Induction Motor | 55098 | ₹508551 | ₹360000 | 9 | |
| Mechanical power transmission slip found to be slightly high in Kneeder 1 and Secondary ID Fan | Reduce slippage in belt and pulley system through replacement of conventional V-belts with Cogged Vbelts and reduce motor speed using existing VFD | 2071 | ₹19116 | ₹10000 | 7 | |
| Energy loss in VFDs were found high in Boiler - Secondary ID Fan | Replace high power consuming VFDs with modern low loss VFDs and do maintenance of heat sinks in certain VFDs. | 2400 | ₹22152 | ₹25000 | 14 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The Cooling tower is underloaded and effectiveness is found low. | Improve range by reducing waterflow rate by switching OFF one pump, operating the pump using VFD and intermediate operation of fan | 14,903 | ₹1,37,558 | ₹20,000 | 2 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Heat lost through leakages and non insulated surfaces of steam mains, Steam feeders and Condensate mains distribution lines - to Curing Machines | Seal the leak points and Provide thermal insulation at the high temperature surfaces and save fuel | 23,357 | ₹1,59,526 | ₹2,00,000 | 16 | |
| Steam leakages are found at various points of the steam distribution system | Arrest steam leakages. More attention to be brought to curing machine feeder lines | 2,95,688 | ₹19,81,110 | ₹25,000 | 1 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Condensate recovery factor found 34% and condensate recovered through centrifugal pump flash steam not collected in proper system | condensate recovery can be increased up to 85 % with flash steam | 1,37,799 | ₹9,23,253 | ₹10,00,000 | 13 | |
| boiler operated at 14 bar pressure with rated capacity of 18.5 bar | Run boiler at 17 bar pressure and install PRV to get optimum pressure and increase steam quality | 15735 | ₹105425 | ₹300000 | 35 |
DG - Diesel Generator
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Specific Energy Generated by the DG Set is very low | Carry out overall maintenance of the DG set to improve SEG and save fuel | ₹61,824 | ₹30,000 | 6 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Daily Energy Losses are high compared to standard similar rating Transformer | Carry out overall maintenance and oil filtration of the Transformer | 8,979 | ₹73,987 | ₹15,000 | 3 |
LT - Lighting
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Lighting used in the office and inspection areas are low efficiency T5 fluorescent tube lights | Retrofitting 6 Nos of Conventional Tubelights - 36 W T8 FTL with 20W LED Patterns | 346 | ₹3224 | ₹3600 | 14 | |
| Lights are switched ON at Extrusion, Splicing and Boiler Sections eventhough daylight is sufficient | Install more skylights and switch OFF 10 Nos of 150W LED industrial down lights | 1600 | ₹13184 | ₹15000 | 14 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ceiling fans used in the office and inspection sections are inefficient conventional type | Replace 15 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC ceiling fans | 1822 | ₹19817 | ₹48000 | 30 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Air Conditioner used in the testing lab is old inefficient Window type | Replace 1 Nos of 1.5 TR Window AC with BEE 5 Star label Inverter Split AC | 775 | ₹6567 | ₹35000 | 64 |