KMB-IIT-MAD-23.05.18-09
The subject plant is located in Chennai district of Tamil Nadu and falls under NIC Category-28. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2023.
General Info
Principal Product
Injection Molding & Mold Manufacturing
Plant Area (Sq.ft)
3,000
No. of Employees
50
Production Hours
7,200
Annual Production
50,000
Annual Sales
₹2,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹71,73,955
Total Recommended Investment(one time)
₹4,30,000
Total Recommended Savings(per year)
₹10,46,320
Energy Costs Calculation
Electricity
Annual Usage
7,57,790
Unit
kWh
Unit Cost
₹9.47
Annual Cost
₹71,73,955
Total Energy Costs(per year)
₹71,73,955
Observations & Recommendations
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Poor power factor | Do regular maintenance for optimum performance. | 6,062 | ₹57,407 | ₹50,000 | 10.5 |
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Demand Underutilization | Surrender unutilized sanctioned demand | ₹3,30,000 | ₹ | 0 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Low Power Factor | Replace the de-rated capacitors with new capacitors | ₹ | ₹40000 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Arrest all identified air leakages and regularly check for air leaks | 14,400 | ₹1,36,368 | ₹20,000 | 1.8 | |
| Power consumption during unloading | The actual plant CFM load should be calculated accurately and there should be one compressor meeting the base air load by running at full load and the other for meeting peak/fluctuating loads by operating it with a VFD; | 17472 | ₹1,65,460 | ₹95000 | 6.9 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Specific power consumption | Install Air Conditioning Units and Heat Pumps Having the Highest Practical Efficiency | 7,895 | ₹74,766 | ₹1,80,000 | 28.9 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The water flow is high | Periodically Clean Plugged Cooling Tower Water Distribution Nozzles. | 28,552 | ₹2,70,387 | ₹20,000 | 0.9 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Old Type Fans | Use BLDC fan with same velocity | 1260 | ₹11,932 | ₹25,000 | 25.1 |