KMB-IIT-GUW-230529-01
The subject plant is located in Pacharia Dalar Pathar district of Assam and falls under NIC Category-21. This assessment was carried out by the IEAC Center, IIT Guwahati, during the course of the year 2023.
General Info
Principal Product
Cosmetics, Health care & Ayurvedic products
Plant Area (Sq.ft)
30,000
No. of Employees
50
Production Hours
7,200
Annual Production
Annual Sales
₹10,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹8,55,66,729
Total Recommended Investment(one time)
₹69,00,000
Total Recommended Savings(per year)
₹1,04,87,219
Energy Costs Calculation
Annual Usage
77,09,258
Unit
kWh
Unit Cost
₹7.4
Annual Cost
₹5,71,30,778
Annual Usage
11,77,439
Unit
Kg
Unit Cost
₹9
Annual Cost
₹1,05,96,951
Annual Usage
2,07,196
Unit
Litres
Unit Cost
₹86.1
Annual Cost
₹1,78,39,000
Annual Usage
9,07,593
Unit
Kwh
Unit Cost
₹
Annual Cost
₹
Total Energy Costs(per year)
₹8,55,66,729
Observations & Recommendations
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Chillers actual kW/TR is higher than the designed kW/TR | Proper maintenance like tube cleaning is required so that it will reduce the evaporator & condenser approaches which will improve the kW/TR | 3,90,000 | ₹30,81,000 | ₹25,00,000 | 10 | |
| Actual flow of condenser and evaporator is higher than the designed flow | Condenser pumps should be provided with VFD so that the flow will be optimized | ₹ | ₹ |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Water flow is not evenly distributed and fills are chocked. | Clean all fills frequently. | 1,40,832 | ₹11,12,573 | ₹10,00,000 | 10.8 | |
| Water TDS is around 800 ppm. | Maintain water TDS less than 400 ppm. | ₹ | ₹ |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| AHU fan runs all time even when the temperature reaches set point | AHU fan can be controlled in such a way that once the set temperature reached it should be at low speed by using VFD | 3,25,000 | ₹25,67,500 | ₹25,00,000 | 11.7 | |
| AHU uses old conventional fans. | Change normal AHU fans with Electronically Commutated fans (EC fan) | ₹ | ₹ |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| In process CT 1 for Ayurvedic section, Actual flow is higher than designed flow | Operate the pump with VFD at 45 HZ | 28,800 | ₹2,27,520 | ₹0 | 0 | |
| In process CT 2 for HCD section, Parallel pumps running with different heads | Switch-off the low head pump | 17,200 | ₹1,35,880 | ₹0 | 0 |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Oxygen percentage in exhaust air is very high ~ 18% where limit is 6 – 8 % | Replace the oxygen sensor & control FD & ID fan according to the same. | 41200 | ₹3,70,490 | ₹2,00,000 | 6.5 | |
| Feed water TDS is very high due to which blowdown loss increases (4%) | Maintain the feed water TDS (<100 ppm) so that blowdown loss will be less | 20300 | ₹1,82,700 | ₹ | ||
| Most of the steam traps are not in working | Steam trap should be maintained | ₹ | ₹ |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Pressure setting maintained is 7.4 - 8 bar | Change the pressure setting to 6 – 6.5 bar. | 60,000 | ₹4,74,000 | ₹ | ||
| High Compressed Air Leakage (Average 180 cfm per hour). | Arrest the leakages | 1,94,400 | ₹15,35,760 | ₹5,00,000 | 3.9 | |
| High unloading hours (Average 6 hours/day) | Use VFD Compressor for variable loads & Non-VFD compressor for base loads | 48,240 | ₹3,81,096 | ₹ |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| All UPS are at 20-25 % loading for 6 months | Install control system for loading the UPS at 50 - 60 %. | 53,000 | ₹4,18,700 | ₹2,00,000 | 5.7 |