IIT Madras

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IIT Bombay

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IIT Gandhinagar

IIT Guwahati

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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-22209. This assessment was carried out by the IEAC Center, IIT Guwahati, during the course of the year 2023.

General Info

Principal Product

Thermoware,Plastic Industry

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


Total Energy Costs(per year)


Observations & Recommendations
CPF - Capacitor & Power Factor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Current harmonics is very high (16.5%)Install harmonics filter to reduce the current harmonics₹5,00,000
In previous year, apart from the month (November 2022 & December 2022) the power factor is maintained below 0.97Improve the power factor to 0.97 to get rebate of 3% of total unit consumption19,378₹1,68,589₹50,0003.6
Only 20 kVAR connected in 250 kVAR APFCReplace the derated capacity of 130 kVAR
In APFC, feedback signal is taken from single phaseInstall three phase sensing in the APFC
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Overall Air leakage is high (45 cfm). Nearly 89 air leak points were identified.Arrest all the identified air leakages60,480₹5,26,176₹50,0001.1
Compressor unloading hours is high (8 hours per day)Install VFD to reduce the unloading losses31,080₹2,70,396₹75,0003.3
Compressor current pressure setting is very high (8.9 - 9.6 bar)Reduce the pressure setting to 6.5 - 7 bar29,750₹2,58,825
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Nearly, 20 m3/hr of water is flowing through bypass from hot water tank to cold water tank.Pump no 3 (5.5 kW) can be turned off and VFD can be installed to minimize and balance the excess water flow.35,280₹3,06,936₹1,50,0005.9