EAR/23-24/KISEM/IITI-17/01
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
650 ml Bottled Beer
Plant Area (Sq.ft)
3,85,943
No. of Employees
500
Production Hours
5,760
Annual Production
5,00,000
Annual Sales
₹20,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹6,27,10,000
Total Recommended Investment(one time)
₹62,68,000
Total Recommended Savings(per year)
₹45,01,112
Energy Costs Calculation
Annual Usage
45,20,000
Unit
kWh
Unit Cost
₹7.25
Annual Cost
₹3,27,30,000
Annual Usage
5,40,000
Unit
kWh
Unit Cost
₹4.3
Annual Cost
₹22,70,000
Annual Usage
41,26,000
Unit
kg
Unit Cost
₹5
Annual Cost
₹2,06,30,000
Annual Usage
8,75,000
Unit
kg
Unit Cost
₹4.3
Annual Cost
₹37,60,000
Annual Usage
32,200
Unit
Ltr
Unit Cost
₹103.2
Annual Cost
₹33,20,000
Total Energy Costs(per year)
₹6,27,10,000
Observations & Recommendations
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Air Leakages are found at different points of the circuit | Arrest air leakages regularly by conducting maintenance of compressed air system consisting of the plant, circuit, and fittings. | 73,619 | ₹5,15,332 | ₹1,20,000 | 3 | |
| Unloading time of Compressor 2 is high due to varying pressure demand | Existing Compressor - 2 could be retrofitted with a VFD drive and optimize power consumption according to actual pressure demand | 1560 | ₹10,290 | ₹100,000 | 117 | |
| CO2 Leakages are found at different points of the circuit | Arrest leakages regularly by conducting maintenance of the system consisting of the plant, circuit, and fittings. | ₹ | ₹ |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess Air fed for boiler combustion is high | Optimize Excess Air demand by controlling FD fan speed in closed loop mode through existing O2 sensor and VFD | 192993 | ₹238,126 | ₹25,000 | 2 | |
| Steam leakages at various points | Arrest the steam leakages by properly sealing the gaps | 37311 | ₹46,037 | ₹35,000 | 10 | |
| Thermal energy lost in condensate circulating in steam traps | Maintain Traps and Recover Condensate | 230002 | ₹283,791 | ₹100,000 | 5 | |
| Thermal energy lost as flash steam | Recover condensate using a SOPT Pump and pumping condensate directly to feed water tank | 311773 | ₹406,250 | ₹100,000 | 3 | |
| Non insulated surfaces of steam distribution lines and condensate lines | Provide thermal insulation at the high temperature surfaces and save fuel | 36785 | ₹621,091 | ₹150,000 | 3 |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess Air fed for boiler combustion is high | Optimize Excess Air demand by controlling FD fan speed in closed loop mode through existing O2 sensor and VFD (Electrical energy Savings) | 34320 | ₹240,240 | ₹ |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Steam pressure is reduced to demand requirement using PRVs | Install Co Generation - Steam Expander and generate Electricity | 258720 | ₹1811040 | ₹5500000 | 37 |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Non insulated surfaces of chilled water lines and accessories | Provide thermal insulation at the low temperature surfaces and save electricity | 1586 | ₹11104 | ₹18000 | 20 |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Range is low and CT Effectiveness is low | Improve range by reducing waterflow by intermediate operation of pump and fan | 17741 | ₹124186 | ₹20000 | 2 |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Daily Energy Losses in Transformer - 1 is high compared to standard similar rating Transformers | Carry out overall maintenance and oil filtration of the Transformer | 6935 | ₹48545 | ₹50000 | 13 | |
| Billed MD is low compared to minimum quota of CD allotted | Surrender CD from 1200 to 950 kVA and save minimum demand charges | ₹145080 | ₹50000 | 5 |