IIT Madras

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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-11. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.

General Info

Principal Product

Packaged Black and Green Tea Powders (6 Brands / 14 Blends)

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



Annual Usage




Unit Cost


Annual Cost



Annual Usage




Unit Cost


Annual Cost


Total Energy Costs(per year)


Observations & Recommendations
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Overall air leakages are found to be high at different points of the circuitArrest air leakages regularly by conducting maintenance of compressed air system consisting of the plant, circuit, and fittings.58,238₹4,54,256₹80,0003
PP - Pumps
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Vacuum Pump System used for conveying stock from mobile trolley to packaging machine hopper is energy intensive.Switch from Vacuum pump system to Bucket elevator system which consumes comparatively less energy111186₹867251₹8000000111
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Cyclone 2 and Tipping Hopper motor - Motor VFD is set at full speed, where VFD is not utilized for speed controlBypass VFD and save energy lost in VFD990₹7721
The conveyed length of push conveyor near packeting machine is very lowEliminate motor driven push conveyor and change to sliding manual conveying system3504₹27331₹200009
ALS - Alternate Source of Power
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
The present 30 kVA UPS is loaded at 33% and self consumption energy losses are highReplace with optimum capacity 15 kVA or nearest UPS to improve loading and save energy2,628₹20,498₹30,00018
TR - Transformer
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
The transformer is more than 25 years aged and Daily Energy Losses are high compared to standard similar rating TransformerReplace the existing transformer with energy efficient Transformer of optimal capacity7183₹56029₹800000172
Billed MD is low compared to minimum quota of CD allottedSurrender CD from 220 to 180 kVA and save minimum demand charges₹58800₹5000011
System Power factor is maintained less than 0.95Improve Power factor to 0.99 and save penalty / incentive charges₹25000₹5000024
Section wise energy consumption is not available due to absence of feeder sub energy meters and non functioning of certain sub metersInstall sub energy meters with remote monitoring and accounting facility for all feeders and sub feeders₹800000
LT - Lighting
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Lights are switched ON at Tea bag packing sections and common areas during break timeInstall more skylights and switch OFF unwanted lights during break time and daytime584₹4555
DG - Diesel Generator
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Specific Energy Generated (kWh/Ltr) is found lowUndergo routine maintenance and checks to improve SEC and save fuel14131₹117360₹30,0004