KMB-IIT-BOM-29.08.22-02
The subject plant is located in Pirangut district of Maharashtra and falls under NIC Category-29301. This assessment was carried out by the IEAC Center, IIT Bombay, during the course of the year 2022.
General Info
Principal Product
Automobile Electrical Components Manufacturer
Plant Area (Sq.ft)
8,000
No. of Employees
150
Production Hours
8,400
Annual Production
Annual Sales
₹
Assessment Summary
Total Energy Costs(per year)
₹1,39,52,366
Total Recommended Investment(one time)
₹6,29,100
Total Recommended Savings(per year)
₹16,19,747
Energy Costs Calculation
Grid Electricity
Annual Usage
10,88,591
Unit
kVAh
Unit Cost
₹9.60
Annual Cost
₹1,04,03,820
Diesel Generator
Annual Usage
58533
Unit
kWh
Unit Cost
₹9.60
Annual Cost
₹1859011
Solar Panel
Annual Usage
242401
Unit
kVAh
Unit Cost
₹9.60
Annual Cost
₹1689535
Total Energy Costs(per year)
₹1,39,52,366
Observations & Recommendations
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 140/215 kVar is only inline in which all capacitors are derated. APFC controlling is by single phase sensing. | Recalculated and replace the APFC with "FC + APFC " Scheme. The sensing mechanism should be upgraded to Three phase sensing. | 77,100 | ₹7,40,160 | ₹1,40,000 | 2 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Pre-heat Zone 4 motor is too noisy | Replace the motor with BLDC of 1/2 HP | 800 | ₹7680 | ₹7500 | 11.7 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakages are high | Arrest air leakages regularly. | 63300 | ₹6,07,680 | ₹100000 | 2 |
CHR - Chiller
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Chiller 3 & 4 load is too low and they are taking much power | Change the loads in Chiller 3 & 4 to Chiller 1 & 2 | 5700 | ₹54720 | ₹15000 | 3.3 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Dry-Heat zone 6 was not working in plant on inspection time and Dry-Heat Zone 8 material output is too high. | Temperature settings can be optimised. | 7400 | ₹71040 | ₹10000 | 1.7 |
LT - Lighting
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| There were 89 number of 36 W Fluorescent Tube Light | Replace with LED Tube Light of 22 W | 4543 | ₹43616 | ₹35600 | 9.8 | |
| There were 107 Ceiling Fans of 60 W. | Replace with BLDC fans with 28 W | 9880 | ₹94851 | ₹321000 | 40.6 |