KMB-IIT-GUW-230605-04
The subject plant is located in Guwahati district of Assam and falls under NIC Category-17014. This assessment was carried out by the IEAC Center, IIT Guwahati, during the course of the year 2023.
General Info
Principal Product
Packaging
Plant Area (Sq.ft)
30,000
No. of Employees
45
Production Hours
7,200
Annual Production
Annual Sales
₹5,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹81,54,895
Total Recommended Investment(one time)
₹10,08,000
Total Recommended Savings(per year)
₹22,41,775
Energy Costs Calculation
Electricity
Annual Usage
9,58,190
Unit
kWh
Unit Cost
₹8.51
Annual Cost
₹81,54,895
Total Energy Costs(per year)
₹81,54,895
Observations & Recommendations
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The Sanctioned demand of the plant is 402.35 KVA but the max. Demand that has been reached in the previous year is 203 KVA | Surrender the demand of 200 KVA | ₹8,64,000 | ₹ |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The overall transformer and stabilizer loss is high | Replace the off load transformer and stabilizer with energy efficient transformer with on load tap changer | 54,617 | ₹4,75,168 | ₹6,00,000 | 15.2 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| the overall power factor has been maintained is (0.95-0.96) below 0.97 | Improve the power factor to 0.97 to get rebate of 3% of total unit consumption | 10,386 | ₹90,358 | ₹20,000 | 2.7 | |
| In APFC, feedback signal is taken from single phase | install three phase sensing in the APFC | ₹ | ₹ |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakage is high (10 cfm). Nearly, 14 points were identified. | Arrest all the identified air leakages | 14,256 | ₹1,24,027 | ₹10,000 | 2.7 |
CHR - Chiller
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Chilled water flow from the secondary pump process is high (39 m3/hr) and VFD in the secondary pump is not working | Optimize the flow and repair the VFD | 59400 | ₹516780 | ₹100000 | 2.3 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| the difference in the temperature between the hot and cold water is very low because of mixing of water in the tank | Flow should be optimized and automated with closed loop feed back system | 12420 | ₹108054 | ₹200000 | 22.2 | |
| CT fan is not working and the water distribution in the cooling tower is not even due to the damaged fills | Repair the CT fan and install new fills and maintenance should be done regularly | ₹ | ₹ |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The power consumption by the individual exhaust fan (2 nos) is higher compared with the other fan | Repair and modify the exhaust fans | 4752 | ₹41342 | ₹50000 | 14.5 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Totally, there are 8 conventional ceiling fans running in max. working hours and consuming power of 70 W | Replace conventional ceiling fan with BLDC fans which consumes 28 W | 2534 | ₹22046 | ₹28000 | 15.2 |