AN ENERGY AUDIT REPORT

FOR
UHUA-PLAS INDUSTRIES SDN. BHD.,
RAWANG, SELANGOR

Prepared by:
GBI INNOVATION SDN. BHD.
December 2017

Funded under RMK-11: Energy Efficiency Projects - Energy Audit Conditional Grant for
Industrial Sector
The Audited Factory Address

UHUA-PLAS Industries Sdn. Bhd

5, Jalan KPK 1/3,
Kawasan Perindustrian Kundang,
Kundang Jaya, 48020 Rawang,
Selangor Darul Ehsan,
Malaysia.

GBI Innovation Sdn Bhd (979988-T)

Unit B716, Block B, 7th Floor, Kelana Square,
No.17, Jalan SS7/26, Kelana Jaya,
47301, Petaling Jaya, Selangor.
Phone : 603-7803 2677
Fax : 603-7806 2677
i
 Prepared by:

IR. LEE YUEN HOW

DIRECTOR
GBI INNOVATION SDN BHD

.............................................................
(Signature and Date)

Mr. BARRY WONG

PRODUCTION MANAGER
UHUA-PLAS INDUSTRIES SDN. BHD.
.............................................................
(Signature and Date)

Approved by :

.............................................................
(Signature and Date)

ii
Contents

Audited Factory Details i

Signature Page ii
Contents iii
List of Figures v
List of Tables vi
Glossary vii
EXECUTIVE SUMMARY VIII
1. INTRODUCTION AND SCOPE OF WORK 1
1.1 Company Business and History 1
1.2 Project Scope 1
1.3 Scope of Work 2
1.4 Objectives 2
1.5 Methodology 2
1.6 Energy Audit Team Member 5
1.7 Energy Audit Equipment 6
2. OPERATION REVIEW OF THE FACTORY 8
2.1 Building Area and Location 8
2.2 Final Product 9
2.3 Factory Details 10
3. TECHNOLOGICAL DESCRIPTION OF THE PROCESS 11
3.1 Overall Description of the Process 11
3.2 Utility System 13
4. ENERGY SUPPLY AND DEMAND 18
4.1 Monthly Electricity Usage Pattern 18
4.2 Monthly Production Pattern 20
4.3 Energy Baseline 20
5. TECHNICAL-FINANCIAL FRAMEWORK AND 23
CONSTRAINTS (FINDINGS)
5.1 Energy Management Practice 23
5.2 Load Profiling 24
5.3 Load Analysis 25
6. ENERGY SAVING MEASURES 43
6.1 Energy Management System 43
6.2 Energy Saving Measures 43

iii
Contents (cont.)

7. SUMMARY AND IMPLEMENTATION PLAN 49

8. SUSTAINABILITY PLAN 51
9. FINANCIAL PLAN 53
10. REFERENCES 54
Appendix A: TNB Bills 55
Appendix B: Power Logger Calibration Certificate 81
Appendix C: Digital Pressure Gauge Calibration Certificate 82
Appendix D: Organizational Profile Shapes 83
Appendix E: Chiller Measurement Data 84

iv
List of Figures
Figure 1 Plant View of the Plant 1
Figure 2 Flow chart showing the overall methodology adopted in this energy audit. 4
Figure 3 Photo of Measuring Equipment 6
Figure 4 Aerial View of the Uhua Plas Sdn. Bhd. Plant (from Google Map) 8
Figure 5 Relative positions of the main sections in the factory building 9
Figure 6 Some of the Products 9
Figure 7 Plant Work Flow 11
Figure 8 Photo of Compressor System 15
Figure 9 Block Diagram for Compressor System 15
Figure 10 Photos of Lamps at production lines 16
Figure 11 Photo of Chiller 17
Figure 12 Block Diagram for Chillers 17
Figure 13 Energy and Cost Pattern 19
Figure 14 Energy Cost and Production Pattern 19
Figure 15 Monthly Energy Consumption and Total material processed (Jul-17 to 21
Oct-17).
Figure 16 Specific Energy Consumption (SEC) and electricity cost per kg material 22
processed
Figure 17 Power Logger 1730 Connection Diagram 24
Figure 18 (a) Current clamp and voltage probes connections to Bus bar (b) Auditors 25
at work.
Figure 19 Weekly Profile for Uhua-Plas Industries Sdn Bhd 25
Figure 20 Load for one day of operation 26
Figure 21 Pie Chart for percentage of power consumed by Blower Machines, 26
Lighting, Compressor and other loads.
Figure 22 Power consumption pattern for Blower Machine 1. 29
Figure 23 Power consumption for all Single and double Blower Machines 29
Figure 24 Power consumption pattern for Crusher Machine B 30
Figure 25 Typical Efficiency, Speed and Current curves for IE1 three phase 31
induction motors
Figure 26 Details for Crusher Machine 31
Figure 27 Power for Compressor system 35
Figure 28 Pressure values at nearest point 36
Figure 29 Valve Leakage near to BM26 36
Figure 30 Pressure values at Furthest point. 37
Figure 31 Proposed new compressor system 38
Figure 32 Photos of chiller and logging activities 39
Figure 33 Hourly Trend for Process Cooling System Power (5HP) 39
Figure 34 Hourly Trend for Process Cooling System Power (10HP) 39
Figure 35 Mini Chiller by Pass flow Isolation 41
Figure 36 Design Concept Centralized Chiller system 42
Figure 37 Gantt Chart for implementation of ESMs 50

v
List of Tables
Table 1 Equipment used for Energy Audit 6
Table 2 Uhua-Plas Industries Sdn Bhd factory details 10
Table 3 Process flow and Explanation 12
Table 4 Details of Blower, Injection and Crusher Machines 14
Table 5 Specification for Compressor System 15
Table 6 Specification of Chiller System 16
Table 7 Historical Electricity Consumption and Production Data 18
Table 8 Details of Material used for Processing 20
Table 9 Energy Management Practice Chart 23
Table 10 Details on Energy Management Practice Chart 23
Table 11 Running Hours per day 27
Table 12 Details of Blower machines 28
Table 13 Details for Crusher Machines 30
Table 14 Number of light bulbs based on location and light bulb type 32
Table 15 Summary of average lux level at different locations 33
Table 16 Details of Required Lux for various Applications (MS1525) 34
Table 17 Compressor Pressure at Generation 35
Table 18 Specification of Chillers 38
Table 19 Typical 5 HP Process cooling system 40
Table 20 Typical 10 HP Process cooling system 40
Table 21 ESM1: Replacing New Five Double Station Blower Machine 45
Table 22 ESM2 : Operate only Crusher Machine A, C and D 45
Table 23 ESM3 : Change to LED Lamps 46
Table 24 ESM4: Air Compressor- Rectify Leakages and install Air Receiver 46
Table 25 ESM5 : Optimization of Chiller System 47
Table 26 Technical and Financial impact 48
Table 27 Summary of Energy Saving Measures 50
Table 28 Target Energy Management Practice Chart 52
Table 29 Financial plan for ESM 53

vi
Glossary

hp Horse Power
HDPE high-density polyethylene
kW Kilo Watt (Power)
kWh Kilo Watt Hour (Energy)
Lux Illuminance
PET polyethylene terephthalate
PP Polypropylene

vii
EXECUTIVE SUMMARY
Uhua-Plas Industries Sdn Bhd, Kundang, Rawang, Selangor produces bottle, jar and container
closure packaging from HDPE, PP and PET materials. Production output for this factory is
measured based on total weight of materials processed and converted to the products.
The annual electricity baseline consumption and TNB bills in 2017 is RM 1,583,194 or 3,325,236
kWh equivalent to 2,300 tonnes of CO2 emission. The plant processes in average 250,000 kg of
materials in a month and the factory’s specific energy consumption (SEC) is 1.16 kWh/kg. The
energy data captured reveals that 64% of electric energy consumed are due to 24 blower machines
(BM1 to BM28).
Five energy saving measures are proposed for this plant to achieve a total of 15.63% savings in
electricity bill. Blower Machines, 13 out of 24 machines have been operating for more than 15
years, and twelve of them are single station machines. There are also 6 reconditioned machines
(operating more than 15 years). It is proposed to replace 10 single station old machines to 5 double
station new machines. Yearly savings of RM130, 000 anticipated through this measure which is
9 % savings in electricity bill. This measures involve investment about RM750,000 with simple
payback period 5.74 years. The payback period could be reduce by including the salvage amount
for the old machine.
Next, there are six crusher machines (A to F) used to crush waste materials for recycling for
production. Out of six, only five crusher used and they run for 20 hours per day. Daily requirement
for crushed material is 4200 kg and this can be achieved by running only Machines A, C and D
while pushing Machines C &D to optimum operation. This will reduce electricity bill by RM
37,000 yearly or 2.5 % savings from total energy bill. This measures involve zero capital
investment.
There are generally nine types of light bulbs currently being used in the plant. Office blocks were
found to be overlit whereas some part of production areas are underlit. It is proposed to change
fluorescent light bulbs into more energy saving LED light bulbs. This measure is expected to give
savings of RM 4,300 yearly or 0.3% savings in electricity bill. This measures also involve
investment of RM7,350 investment.

There are 2 screw air compressor in this plant. Air Compressor system is proposed to have
additional receiver tank and to reduce leakages. This measure is expected to give savings of RM
10,500 yearly or 0.73% savings in electricity bill.
Finally, UHUA Process Cooling System consist of 8 number of 10HP and 13 number of 5HP mini
chiller. It is proposed to set shilled water supply temperature y 1.5 degree Celsius higher and
centralised the chiller system with supply and return header. This measure is expected to give
savings of RM 46,000 yearly or 3.2% savings in electricity bill.
Table below gives the summary of energy saving measures (ESM) for this energy audit. There are
five ESMs proposed in this study: ESM1 - Replacing New Five Double Station Blower Machine,
ESM2 – Operate only Crusher Machine A, C and D, ESM3 – Change to LED Lamps: ESM4 – Air
Compressor- Rectify Leakages and install Air Receiver Tank and ESM5 - Optimization of Chiller

viii
System. Total Energy saving estimated is 15.75 % yearly which is equivalent to reduction of
energy usage of 519,652 kWh/year and reduction of 360 tonnes of CO2.

ix
Summary of Energy Saving Measures (ESM)

Overall
Capital Payback CO2 Ease of
Saving (Yearly) saving in Priority
No Measures Expenses period Reduction* Implementation
kWh
kWh RM RM Year Tonne %
ESM1: Replacing New Five Double Station Blower Machine
1 Blower Molding
296,400.00 130,712.40 750,000.00 5.74 205.70 8.91 Y3 Moderate
Machine
ESM2: Operate only Crusher Machine A, C and D
2
Crusher 84,864.00 37,425.02 0.00 0.00 58.90 2.55 Y1 Easy
ESM3: Change to LED Lamps
3
Lighting 9,906.62 4,368.82 7,350.00 1.68 6.88 0.30 Y2 Moderate
ESM4: Air Compressor- Rectify Leakages and install Air Receiver Tank
4
Air Compressor 24,024.00 10,594.58 22,600.00 2.13 16.67 0.72 Y2 Moderate
ESM5: Optimization of Chiller System
5
Chiller 104,457.60 46,065.80 150,000.00 3.26 72.49 3.14 Y3 Moderate
Total 519,652.22 229,166.63 929,950.00 4.06 360.64 15.63

* CO2 tonnage is calculated based on the 2014 Grid Electricity Emission Factors for Peninsular Malaysia, which is 0.694 tCO 2/MWhr, # Y1- Year 1, Y2 – Year
2, Y3 – Year 3

Overall
Baseline (2017) Estimated
Saving
Production Energy Bill SEC Energy Bill SEC (%)
(kg) (kWh) (RM) (kWh/ kg) (kWh) (RM) (kWh/ kg)
2,866,850 3,325,236 1,583,194 1.16 2,805,584 1,237,262 0.98 15.63

viii
1. INTRODUCTION AND SCOPE OF WORK
1.1 Company Business and History

UHUA-PLAS Industries Sdn. Bhd. (161533-T) was established on 18th May 1987. They
specialize in plastic blow-molding, injection and screen printing under the supervision of their
Managing Director who had more than 20 years of experience in plastic containers manufacturing.
They provide manufacturing "HDPE, LDPE, PP, PET" type of bottle, jar and container closure
packaging. Their products are suitable for Pharmaceutical, Toiletries, Cosmetics, Detergent,
Lubricants and Food and Beverage.

Currently, their facilities are able to manufacture product ranging from 100ml up to 10 liter. In
addition, they also offer silk screen printing and labeling services. They also do provide custom
packaging design from Mould fabrication to mass production. Feel free to inquire us for more
information.

In this project, energy audit is performed on the plant located at No 5, Jalan KPK 1/3, Kawasan
Perindustrian Kundang, Kundang Jaya, 48020 Rawang, Selangor Darul Ehsan, Malaysia.

1.2 Project Scope

The audited site is a factory plant (Figure 1) consists of an office building which is attached to the
factory building. The plant is involved in the production of plastic products, and encompasses the
whole process chain, the whole process chain is done within a machine and these process is known
as the “ Plastic Blow Moulding “.

Figure 1: Plant View of the Plant

1
The plant uses three main sources of energy is electricity. Hence, the focus of this energy audit is
on the electricity consumption of the factory, where the current electricity consumption pattern has
been identified and methods for improving electricity usage and efficiency are proposed.

1.3 Scope of Work

This energy audit covers the energy management system and implementation as well as energy
balance for the factory, where load profile, energy distribution breakdown and motor efficiency
analysis are given.

Based on the analysis, energy saving measures are suggested with the compulsory scope as below.

1. ACMV Optimization
2. Motor optimization
3. Inverter implementation and performance analysis
4. Lighting optimization

Item 2 and 3 above were done with the machine itself as both motors and inverters are integrated
into the blower and injection machines. While Crusher machine motors were analyzed separately
with their electromagnetic starters.
1.4 Objectives

The objectives of this energy audit are as follows:

1. To establish the overall electricity consumption of the factory.
2. To identify the energy consumption of major equipment.
3. To proposed methods to improve energy usage and energy efficiency in the plant.

1.5 Methodology

In order to ensure that the main factors that affect the energy usage and energy efficient at the site
are effectively captured in this energy audit, a systematic approach has been adopted. The overall
methodology of this energy audit is illustrated in Figure 2

As visible from the flowchart, the project methodology can be divided into the following stages:

Stage 1: Kick Off Meeting

The project commences with the first kick off meeting where the project team is assembled. At
this initial stage of the project, a general project schedule is decided and the work scope is
formulated.

Stage 2: Desktop Audit

Before visiting the actual project site, desktop audit is first conducted. At this stage of the project,
the project team gathers preliminary information on the project site by studying the site layout
and activities based on documents provided by Uhua Plas Sdn. Bhd. This includes collecting
historical electricity bills to establish the base line electricity energy consumption. By the end of

2
this stage, the project team is able to gain basic understandings on the operation of factory in
order to establish a feasible work plan during the subsequent site investigation.

Stage 3: Site Investigation

In the stage, the project team visits the actual project site. Site walkthrough is done with the
factory manager to understand the various sections of the plant and their respective operations.
The site investigation allows the project team to confirm the information obtained from desktop
audit and to understand the potential sources of energy consumption/wastage at the site.

Stage 4: Field Data Collection

Once the operation of the site has been established, field data collection can be done. An energy
logger is first installed at the main power intake of the plant to record the for overall electricity
energy consumption profile for 4 weeks.

3
 Kick Off Meeting
- Form audit team
START
- Form energy audit schedule
- Decide work scope

Desktop Audit
- Study site layout & activities
- Obtain historical bills
Data used for - Understanding operation
report writing

Site Investigation

Field data collection

- Electricity data logging
- Update single-line diagram
- Lux measurement at site
- Interview with staffs
- Individual motor measurement
Additional
data
required
Data Analysis

Report writing

Report presentation
to client

Final Report FINISH

Figure 2: Flow chart showing the overall methodology adopted in this energy audit.

In order to perform energy measurement on individual equipment, the project team needs to
update single-line diagram of the plant. During this stage of the project, Lux measurement is
performed in the main working areas in the factory. Based on the information obtained from
previous stages, the project team narrows down a list of machineries which are potentially
wasting energy. Electricity consumption data is then collected for these machineries using
additional energy logger. Discussions with the staffs in the factory are done as well to understand

4
 their perceptions towards energy usage in the site, and to cross check the information obtained
from desktop study.

Stage 5: Data Analysis

Once the team has collected sufficient field data from the site, analysis is performed to explore
the potential measures to improve energy usage and energy efficiency at the site. Several
additional visits to the sites were performed for additional data collection in order to make sure
that the information available are comprehensive enough for good recommendations to be made.

Stage 6: Report Writing and Presentation

A preliminary report is prepared based on the data obtained in Stage 4 and the analysis done in
Stage 5. The results are presented to the client to obtain their feedbacks on the findings in the
preliminary report. Modifications are made to the report based on the feedbacks from the client.

Stage 7: Final Report Submission

The project ends with the submission of the final report by the project team.

1.6 Energy Audit Team Member

This energy audit involves members from three different parties, GBI Innovation Sdn. Bhd.,
Uhua Plas Sdn Bhd., as well as Malaysian Green Technology Corporation, with the members
being as listed below:
Company and Names
GBI Innovation:
Assoc. Prof. Ir. Dr. Gobbi Ramasamy (Lead Auditor)
Ir. Lee Yuen How (Auditor)
Khairul Aqil (Assistant Auditor)
Viven Ravi (Assistant Auditor)
Uhua-Plas Industries Sdn. Bhd.
Mr. Barry Wong
Malaysian Green Technology Corporation
Nik Mohd Haikal Mohamad Shafie

5
1.7 Energy Audit Equipment
The list of equipment used in the energy audit for Uhua Plas Sdn. Bhd. is as given below Table
1. Figure 3 shows the photo of the measuring equipment.
Table 1: Equipment used for Energy Audit

No Equipment Brand/model Specification

(a) Power Logger Fluke 1730 [Ref. 2]
Ranges: 0 - 50,000 Lux
(b) Lux Meter Himitzu LX1010B
Accuracy: ±5%
Range 30 to 300,000 FPM
(c) Stroboscope Fluke 820-2
Accuracy 0.02 %
Additel
(d) Digital Pressure Gauge ADT680W-25-GP300- 0 – 300 psi
PSI-N
YSI ±0.01°C
(e ) Thermistor
Beta THERM ±0.2°C
(f) Flow meter Ultrasonic Pana ±2~5%

(a) (b)

(c ) (d)
Figure 3: Photo of Measuring Equipment

6
(e) (f)

Figure 3: Photo of Measuring Equipment (cont.)

7
2. OPERATION REVIEW OF THE FACTORY
2.1 Building Area and Location

Figure 4 : Aerial View of the Uhua Plas Sdn. Bhd. Plant (from Google Map)

2.1.1 Office Building

This is an attached building housing office personnel, meetings rooms and other administration
materials.
2.1.2 Factory Building

The factory building constitutes the major part of the plant and is where all the large machineries
are located. Hence it is the focus of this energy audit.

Based on the activities conducted in each, the factory building can be further divided into several
sections with their relative position as shown in Figure 5 (Note: drawing not to scale). The sections
and their respective activities are as follow:

8
 Figure 5: Relative positions of the main sections in the factory building.

2.2 Final Product

The final products of Uhua-Plas Industries Sdn Bhd are HDPE, LDPE, PP, PET type of bottle, jar
and container closure packaging. Their products are suitable for Pharmaceutical, Toiletries,
Cosmetics, Detergent, Lubricants and Food and Beverage.

Figure 6: Some of the Products

9
2.3 Factory Details

Table 2 shows the factory details. The factory currently operating at 93.7% from its full
capacity.

Table 2 : Uhua-Plas Industries Sdn Bhd factory details

Main Product Units (material Installed Actual Percentage
processed) Capacity Production Capacity (%)
(thousand) (thousand)
HDPE, LDPE,
PP, PET type of kg 270 253 93.7
bottles

10
3. TECHNOLOGICAL DESCRIPTION OF THE PROCESS
3.1 Overall Description of the Process
Based on the explanation on the various sections of the factory, the process flow for plastic
production in Uhua-Plas Industries Sdn. Bhd. is depicted in Figure 7.

•Raw Material In
1

•Material heated in screw barrel until it melts while the motor rotates the screw to the extruder
2

•Melted material (parison) flow out through extruder head

3

•Mold closes and hot knife cuts parison

4
•Compressed air blow into the mould to fill the space of the mould.
5 •At the same time,the chilled water from chiller cool down the mould.

•Mould opens and produce the final product.

6

Figure 7: Plant Work Flow

The process starts with the raw material being brought in. The raw material mixture is done
depending on customer demand and specifications. As all the raw material ingredients is done, the
mixture is then heated in the screw barrel until it melts. While the mixture melts, the motor rotates
the screw to the extruder.

The melted material is known as “parison” which will flow out through the extruder head. The
mould will then close with the parison inside. Excess parison is then cut by a heated metal wire.
Compressed air is then being blown into the mould to enable the parison to fill the shape of the
mould. When this process is taking place, chilled water from the chiller will cool down the mould.
This causes the molded material to harden. Finally the mould opens and the final product is being
produced. The final product is then packed and stored in storage area. The details are given in
Table 3.

11
Table 3: Process flow and Explanation
Process
1. Raw material goes in
2. Material is heated in
screw barrel until it melts,
while the motor rotates
the screw to the extruder
3. Melted material (parison)
flow out through
extruder head
4. Mold closes and hot knife
cuts parison
Photo Explanation of process
1. The process starts with the raw
material being brought in.
2. The raw material mixture is
done depending on customer
demand and specifications.
3. As all the raw material
ingredients is done, the
mixture is then heated in the
screw barrel until it melts.
4. While the mixture melts, the
motor rotates the screw to the
extruder.
1. The melted material is
known as “ parison “ which
will flow out through the
extruder head.
1. The mould will then close
with the parison inside.
2. Excess parison is then cut
by a heated metal wire.
12
Table 3: Process flow and Explanation (Cont.)
Process Photo Explanation of process

1. Compressed air is then

5. (a) Compressed air blow being blown into the mould
into the mould to fill the to enable the parison to fill
space of the mould. the shape of the mould.
2. When this process is taking
5. (b) At the same time,the place, chilled water from
chilled water from chiller the chiller will cool down
cool down the mould. the mould.
3. This causes the molded
material to harden.

1. Finally the mould opens and

the final product is being
produced.
6. Mould opens and produce
the final product.
2. The final product is then
packed and stored in storage
area.

3.2 Utility System

3.2.1 Motors and Drives - Blower Molding, Injection and Crusher Machines
Table 4 shows the details of blower molding (BM), injection machine (IM) and crusher machines.

A total of 24 blower machines, 10 Injection machines and 6 crusher machines are used in this
plant. Table 4 show the details.

As far as blower and injection machines are concerned, there is no separate motor and drive used
for any productions. All machines have both the motor and drives integrated into the machine.
Hence analyzing motor and drives separately is not appropriate hence not included in this report.
Only crusher machines motors were analyzed.

13
 Table 4: Details of Blower, Injection and Crusher Machines

Qty Power Motor type

(kW)
BLOWER MACHINE
1. BM 1 1 42.6 MK 225S
2. BM 2 1 18.5 BAA 180 M4-B5
3. BM 3 1 18.5 AEAF
4. BM 5 1 22 AEEBUO
5. BM 6 1 18.5 Y200 L1-6
6. BM 7 1 18.5 BAA 180 M4-B5
7. BM 8 1 18.8 AEVBKA
8. BM 9 1 18.5 AEVBKR – AP
9. BM 10 1 18.5 A5ABAC
10. BM 11 1 N/A Not visible
11. BM 12 1 11 AEVBKA
12. BM 13 1 11 A5AFAC
13. BM 15 1 22 EMF 180L-4 B5
14. BM 16 1 11 A4C 160 M4 B3
15. BM 17 1 N/A Not visible
16. BM 18 1 30 AEEFAC
17. BM 19 1 22 EMP 180L
18. BM 20 1 30 AEEFAC
19. BM 21 1 22 AEVBAP
20. BM 22 1 11 AEAFAC
21. BM 23 1 18.5 BAA 180 M4 B5
22. BM 25 1 N/A AEAF
23. BM 26 1 5.5 132S-4
24. BM 28 1 37 F AWAR22654THTF
IM MACHINES
1. IM 1 1 17.9 n/a
2. IM 2 1 22 n/a
3. IM 3 1 22 n/a
4. IM 5 1 22 n/a
5. IM 6 1 22 n/a
6. IM 7 1 22 n/a
7. IM 8 1 20 n/a
8. IM 9 1 17.9 n/a
9. IM 10 1 17.9 n/a
10. IM 11 1 22 n/a
CRUSHER MACHINE
1. Crusher Machine E 1 22 n/a
2. Crusher Machine C 1 15 n/a
3. Crusher Machine A 1 5.5 n/a
4. Crusher Machine F 1 7.5 n/a
5. Crusher Machine D 1 15 n/a
6. Crusher Machine B 1 11 n/a

14
3.2.2 Compressor Air System
There are 2 screw air compressor units (compressor 1 and 2) both rated at 75 kW. Table 5 shows
the details of the system. Figures 8 and 9 show the photo and the block diagram of the system
respectively.
Table 5 : Specification for Compressor System
System No. Model Specification
1 Ingersoll Rand SSR ML-75 7.5 Bar, 75kW, 13 m3/min
Air Compressor
2 Euro Screw 75kW 8.0 Bar, 75kW
1 Dancomair 150 Psi, 1000 litre
Air Receiver
2 QCEManufacturing 1000 litre
Tank
3 HO/HT/339/94 22 psi, 500 litres
Refrigerant 1 Puroair HT 150A 14 BarG, 13.5 m3/min, R22
Dryer 2 Puroair HT 100A 12 BarG, 13.5 m3/min, R22

Figure 8: Photo of Compressor System

Figure 9 : Block Diagram for Compressor System

15
One compressor will be running and the other will remain at standby. The generated compressed
air is stored in 3 receiver tank which are 1000L Dancomair receiver tank, 1000L QCE
Manufacturing receiver tank and 500L receiver tank and then the dried air is going through a dryer
system before supplying the rest of the facilities. The dryer system consists of 2 refrigerant dryer
units, one unit of Puroair HT150A and Puroair HT 100A. The connection in the receiving area is
in a loop connection where BM 26 is the nearest point and BM 11 is the furthest point. The block
diagram for the compressor system is shown in Figure 9

3.2.3 Lighting System

The production lines use 36W florescent lights and 180W LED high bay. Figure 10 shows the
photos.

Figure 10: Photos of Lamps at production lines.

3.2.4 Chiller System
UHUA Process Cooling System consist of 8 nos 10HP and 13 nos 5HP mini chiller. The
specifications of the system as Table 6 below. Each chiller supplies chilled water for one or more
machines (injection molding machine and blower machine). Figure 12 shows the block diagram
for the chiller system.

Table 6: Specification of Chiller System

System Quantity Specifications

Mini
Chillers 1) Brand Name : Industrial Chiller - China
8 nos Chilled Water Supply Setting: 20 degC
10HP
(Running 8 nos) Voltage: 415V

Mini 2) Brand Name : Industrial Chiller - China

13 nos Chilled Water Supply Setting: 19 degC
Chillers
(Running 9 nos) Voltage: 415V
5HP

16
 Figure 11 : Photo of Chiller

Chiller 12
Chiller 10

Chiller 11
Chiller 1

Chiller 7

Chiller 8
Chiller 6
Chiller 5
Chiller 2

IM1 IM3 BM5 BM15 BM3 IM10 IM5

IM2 BM20 IM11
BM6 BM12 BM25 IM6
BM16 BM13 BM23 IM7
Chiller 22

Chiller 25
Chiller 16

Chiller 23

Chiller 26
Chiller 14

Chiller 17

Chiller 20

Chiller 21

BM IM8 BM8 BM1 BM10 BM7

BM2 22 IM9 BM26
BM9 BM11 BM20 BM17 BM28
BM27
BM19 BM12 BM21 BM18

Figure 12 : Block Diagram for Chillers

17
4. ENERGY SUPPLY AND DEMAND
4.1 Monthly Electricity Usage Pattern

For the purpose of this audit, Uhua Plas has provided the monthly electricity bill from December
2015 till December 2017 as well as the monthly total production (Note that total production data
only available from July 2017 as only since then the data was recorded). The details are shown in
Table 3.

The data shows that the energy consumption of the factory varies approximately in the range of
150 MWh to around 391 MWh. This in turn resulted in monthly electricity bill that varies from
RM 100k to RM 170k. Table 7 shows the details and Figures 13 and 14 show the pattern.

Table 7 - Historical Electricity Consumption and Production Data

Month Consumption Cost TOTAL

(kWh) (RM) PRODUCTION
(kg)
Dec-15 303,649 129,658.12 -
Jan-16 362,825 154,926.28 -
Feb-16 250,396 106,919.09 -
Mar-16 391,247 167,062.47 -
Apr-16 298,977 127,663.18 -
May-16 313,177 133,726.58 -
Jun-16 316,003 139,345.12 -
Jul-16 298,951 131,825.19 -
Aug-16 314,233 138,564.55 -
Sep-16 299,644 132,130.80 -
Oct-16 308,184 135,896.94 -
Nov-16 309,919 136,662.08 -
Dec-16 324,083 138,383.44 -
Jan-17 268,114 116,897.70 -
Feb-17 237,158 103,400.89 -
Mar-17 323,498 141,045.13 -
Apr-17 287,012 125,137.23 -
May-17 117,913 136,564.36 -
Jun-17 301,219 132,825.38 -
Jul-17 207,177 119,135.86 173,970
Aug-17 288,581 127,252.02 245,338
Sep-17 286,422 126,299.90 249,000
Oct-17 324,725 143,191.53 266,025
Nov-17 344,409 157,865.33 309,325
Dec-17 339,008 153,578.76 299,990

18
 400,000 180,000.00

350,000 160,000.00

140,000.00
300,000
Energy Usage (KWh)

120,000.00
250,000

Cost (RM)
100,000.00
200,000
80,000.00
150,000
60,000.00
100,000
40,000.00

50,000 20,000.00

0 0.00

Month

Energy Cost

Figure 13 : Energy and Cost Pattern

350000 180,000.00

160,000.00
300000
140,000.00
250000
120,000.00
Production (kg)

Cost (RM)
200000 100,000.00

150000 80,000.00

60,000.00
100000
40,000.00
50000
20,000.00

0 0.00

Month

Production Cost

Figure 14 : Energy Cost and Production Pattern

(Note that total production data only available from July 2017 as only since then the data was recorded)

19
Based on the information found in the electricity bill, Uhua-Plas Industries Sdn Bhd is currently
drawing power from Tenaga Nasional Berhad under the D-33 Low Voltage Industrial Tariff.
Details of the tariff are given below.

For the first 200 kWh (1 -200 kWh) per month 38.00 cents/kWh
For the next kWh (201 kWh onwards) per month 44.10 cents/kWh

4.2 Monthly Production Pattern

The data in Table 6 shows that the energy consumption of the factory varies approximately in the
range of 150 MWh to around 391 MWh as the amount of material processed 173,000 kg to 309,000
kg. This in turn resulted in monthly electricity bill that varies from RM 100k to RM 170k.

4.3 Energy Baseline

4.3.1 Linear Regression
The monthly electricity energy consumption (in kWh) is found linearly correlated with total
material processed. Total material processed in kilogram is the sum of virgin material (raw material)
and recycle material (materials which are crushed and processed again), both in kilogram. Table 8
shows the details of materials used to process. Clearly, R-square value is 0.968 and hence
confirming that energy consumption in this factory is directly correlated with the monthly material
processed.

Table 8 : Details of Material used for Processing

Month Virgin Recycle/Crushing Total
Material Material (kg) Material
(kg) Processed
(Kg)
Jul-17 107,861 66,109 173,970
Aug-17 130,038 115,300 245,338
Sep-17 149,000 100,000 249,000
Oct-17 154,125 111,900 266,025
Nov-17 196,975 112,350 309,325
Dec-17 187,850 112,140 299,990

20
 350000

300000

250000
Total Material (kg)

200000

150000

100000
R² = 0.968
50000

0
150,000 200,000 250,000 300,000 350,000 400,000
Monthly kWh

Figure 15: Monthly Energy Consumption and Total material processed (Jul-17 to Dec-17).

Based on regression analysis, the following equation (1) was derived.

𝑌 = 1.175𝑋1 + 0.332𝑋2 + 32049 (1)

Where Y is the monthly Energy (kWh), X1 is the virgin material processed in a month in kg and
X2 is the recycle material processed in a month in kg. It is noted that when there is no production
activities, minimum energy of 32049 kWh are used.

4.3.2 Specific Energy Consumption (SEC)

Using the data from Table 2, the electricity consumption per kg material processed is illustrated in
Figure 16. As seen from the Figure 16, average specific energy consumption is 1.16 kWh/kg
whereas average electricity cost is 0.52 RM/kg measured from July 2017 to December 2017.

21
 450,000 1.24

400,000 1.22

1.2
350,000

1.18
300,000
1.16
250,000
1.14
200,000
1.12
150,000
1.1

100,000
1.08

50,000 1.06

0 1.04
Jul-16

Jul-17
Apr-16
May-16
Jun-16

Nov-16

Apr-17
May-17
Jun-17

Nov-17
Dec-15
Jan-16
Feb-16
Mar-16

Mar-17
Aug-16
Sep-16

Dec-16
Jan-17
Feb-17

Aug-17
Sep-17

Dec-17
Oct-16

Oct-17
Montly kWh SEC (kWh/kg)

Figure 16: Specific Energy Consumption (SEC) and electricity cost per kg material processed
Based on the data obtained for the July 2017 to December 2017, the annual specific energy
consumption (SEC) can be calculated as

Total material processed = 1,543,648 kg

Total energy consumption = 1,790,322 kWh
Specific Energy Consumption, SEC = 1.16 kWh/kg.

This will serve as the energy baseline for Uhua-Plas in this energy audit.

22
5. TECHNICAL-FINANCIAL FRAMEWORK AND CONSTRAINTS
(FINDINGS)
5.1 Energy Management Practice

Table 9 shows the summary of findings on energy management practice in Uhua Plas

Table 9: Energy Management Practice Chart

Table 10 : Details on Energy Management Practice Chart

No Criteria Level Score Rationale

1 Energy Policy
2 Organisation
3 Motivation
1 Only unwritten set of guidelines used
Energy management is the part time
1 responsibility of someone with only
limited authority of influence
0 No contact with users

No information system, no accounting

4 Information System 0
for energy consumption.

5 Marketing 0 No promotion of energy efficiency

No investment in increasing energy

6 Investment 0
efficiency in premises

Based on the current Energy Management Practice Chart evaluation, it falls under the shape of
Low Balanced where score of all the columns are less than level 3. There is room for further
improvements on every aspects with the commitment provided by their directors after the energy

23
audit report provided. These can be done by having an Energy Policy, formation of Energy
Committee, Action Plan and also regular review to be chaired by Mr Wong. In addition, with the
experience obtained by the operation managers during the energy audit, they will be qualified to
become an Energy Manager to strengthen the initiative for a sustainable energy improvement.
Furthermore, in our suggestion there should also be sub metering installed for monitoring and
measurement of energy continuously.

5.2 Load Profiling

In order to have a detailed picture of the energy consumption pattern in the plant, an energy logger
has been installed at the main intake of the plant for load profiling. Electricity consumptions from
15 September to 9 October 2017 (approximately 24 days), have been recorded.

A Fluke Power Logger 1730 was used for this study. Three current clamps rated at 1500A each
were used to measure current at each of the lines. Four voltage probes rated at 1000V were used
to measure line and phase voltages. Figure 17 shows the connection diagram for the measurement.
Interval of data averaging is 1 minute whereas demand interval was set to 30 min. Figure 18 shows
the actual site setup for measurement.

Factory Loads

Power Logger 1730

4 x 1kV Voltage Probe (L1, L2, L3 and N)

3 x 1.5kA Current Clamp (L1, L2 and L3)

1500A
4P ACB

From TNB
Figure 17: Power Logger 1730 Connection Diagram

24
 (a) (b)
Figure 18: (a) Current clamp and voltage probes connections to Bus bar (b) Auditors at work.

5.3 Load Analysis

Based on data collected 15 September to 9 October 2017 (approximately 24 days), the load profile
for Uhua Plas is found to exhibit consistent pattern. A typical one week load profile, as logged at
the main intake of Uhua Plas is shown in Figure 18. The factory works 24 hours daily for 6 days
in a week. Two working shifts are in practice in this factory, shift one from 8AM to 8PM and
second shift is from 8PM to 8 AM.

Figure 19: Weekly Profile for Uhua-Plas Industries Sdn Bhd

25
To facilitate analysis and further discussion, the operation cycle for one day of the plant can be
summarized as shown in Figure 20. It is noted that during the first shift (8 AM to 8 PM) average
power of 550kW is drawn and it is extended up to 10PM. At night after 10 PM, the average power
reduced to 486 kW. The drop in power value is due to some of the loads (office block, printing
machines, PET bottle machine) which are switched off from 10PM to 8 AM.

8.00 AM 10.00 PM

550 kW

486 kW

Figure 20: Load for one day of operation

As shown in Figure 21, the total energy consumption of Blower Machines themselves is 64%
compared to other loads which include lighting, Compressor, Injection Machines, Chiller and
Others. It is noted that the loads are operating mostly for 20 hours. Table 11 shows the details.
Others
Chiller System
3%
9%
Lighting
4%
Compressor
13%

Injection Molding
Machine Blower Machine
7% 64%

Figure 21: Pie Chart for percentage of power consumed by Blower Machines, Lighting,
Compressor and other loads.

26
 Table 11: Running Hours per day

RUNNING
MEASURED
MACHINES TIME

P(kW) V(V) I(A) pf Hours

Ventilation Fan 0.6 242.1 2.4 0.35 20
UV Heater C 3.8 240 14.5 0.59 10
UV Heater B 3.4 239 8.25 0.99 10
PET Heater Machine 4.2 240 17.2 0.62 10
Office Block 14.2 240 31 0.7 8
IM9 3.7 240.9 8.4 0.57 20
IM8 2.6 240.7 5.7 0.53 20
IM7 7.3 240.1 17 0.59 20
IM6 5 241.5 10.6 0.69 20
IM11 14.9 241.2 31.5 0.64 20
IM10 2.1 241.3 6.7 0.41 20
IM1 4.7 241.5 8.3 0.73 20
Heater Converyor Machine 3.8 240 14 0.88 10
Fan 2 0.5 241.9 2.3 0.32 20
Exhaust Fan 1.7 241.9 2.4 0.98 20
Crusher Machine E 14 249 26 0.6 20
Crusher Machine C 1.3 246 10.24 0.2 20
Crusher Machine A 3 249 6 0.6 20
Crucher Machine F 4 249 8 0.5 20
Crucher Machine D 1.3 246 10.24 0.2 20
Crucher Machine B 7 249 13 0.7 20
Compressor for PET Machine 2.78 241 26.4 0.87 10
Compressor for Other Machines 77 241.5 147.3 0.75 20
BM9 14 238.9 24.8 0.84 20
BM8 14.1 239.1 23.5 0.8 20
BM7 17.1 238.5 29.8 0.8 20
BM6 27.1 238.2 49.7 0.85 20
BM5 13.9 239 22.7 0.82 20
BM3 13.3 242.1 27.3 0.66 20
BM28 22.2 242.4 41.8 0.7 20
BM26 21.8 240.8 33.4 0.77 20
BM25 12.3 242.3 22.1 0.76 20
BM23 12.9 244.4 29.4 0.6 20
BM22 9.1 243 19.4 0.63 20
BM21 18 239.2 31.5 0.79 20
BM20 24.2 239.3 39.5 0.84 20
BM2 11.7 240.3 26.9 0.64 20
BM19 19.7 238.7 32.5 0.86 20
BM18 15.8 239 30.7 0.73 20
BM17 8.8 238.5 16.2 0.77 20
BM16 6.3 239.6 14.8 0.57 20
BM15 21.1 240.8 35.3 0.84 20
BM13 15.5 239.1 27.4 0.78 20
BM12 12.3 240.1 23.6 0.71 20
BM11 7.2 240.1 22 0.46 20
BM10 16.6 241.3 32.1 0.68 20
BM1 21.3 240.5 36.1 0.87 20
Chiller System 46.5 240 n/a n/a 24

27
5.3.1 Motor and Drives 1 - Blower Machines (BM1 to BM28)

There are 24 machines running 20 hours daily. There are two type of blower machines, one with
single station where only one mold can be installed at a time whereas double station machine can
operate two different molds (hence products) at the same time. Power consumption of these
machines are directly dependent on the molds used. Thirteen out of 24 machines have been
operating for more than 15 years, and twelve of them are single station machines. There are also 6
reconditioned machines (operating more than 15 years). Table 12 shows the details of the Blower
machines.

Table 12 : Details of Blower machines

Years of Station Running

Status Measured Values
MACHINES Operation (1 or 2) Time
(Year) Hour P(kW) V(V) I(A) pf
BM 1 0.7 2 20 21.3 240.5 36.1 0.87
BM 2 1 2 20 11.7 240.3 26.9 0.64
BM 26 2 2 20 21.8 240.8 33.4 0.77
BM 28 2 2 20 22.2 242.4 41.8 0.7
BM 25 3 2 20 12.3 242.3 22.1 0.76
BM 7 5 1 20 17.1 238.5 29.8 0.8
BM 15 5 2 20 21.1 240.8 35.3 0.84
BM 19 7 1 20 19.7 238.7 32.5 0.86
BM 6 9 2 20 27.1 238.2 49.7 0.85
BM 16 11 1 20 6.3 239.6 14.8 0.57
BM 5 14 1 20 13.9 239 22.7 0.82
BM 9 14 1 20 14 238.9 24.8 0.84
BM 22 16 1 20 9.1 243 19.4 0.63
BM 17 17 1 20 8.8 238.5 16.2 0.77
BM 8 17 1 20 14.1 239.1 23.5 0.8
BM 21 18 1 20 18 239.2 31.5 0.79
BM 13 19 1 20 15.5 239.1 27.4 0.78
BM 20 20 1 Recon 20 24.2 239.3 39.5 0.84
BM 18 21 1 Recon 20 15.8 239 30.7 0.73
BM 12 22 1 Recon 20 12.3 240.1 23.6 0.71
BM 3 22 1 20 13.3 242.1 27.3 0.66
BM 10 22 2 Recon 20 16.6 241.3 32.1 0.68
BM 11 23 1 Recon 20 7.2 240.1 22 0.46
BM 23 27 1 Recon 20 12.9 244.4 29.4 0.6

Summary
1. Converting 10 single station (BM 17,BM 8, BM 21, BM 13, BM 20, BM 18, BM 12, BM
3, BM 11, BM 23) old machines to 5 double station machines. Estimated power reduction
in machine 9.5kW.
2. Cost for a new double station machine (estimated RM150,000.00)

28
As shown in Figure 22, the power consumption of blower machines is consistent throughout its
operation. Interesting to note that power consumption of single station machines is more or less
about the same as double station machine. Figure 23 shows the details. Although the power
consumption is dependent to type of mold used, but clearly double station machine gives higher
output for every kWh.

Figure 22: Power consumption pattern for Blower Machine 1

30

25

20
Power (kW)

15

10

0
0 1 2 3
Station

Figure 23: Power consumption for all Single and double Blower Machines

29
5.3.2 Motor and Drives 2 - Crusher Machines

There are six crusher machines (A to F) used to crush waste materials for recycling for production.
Out of six, only five crusher used and they run for 20 hours per day. The details of the crusher
machine and motors are shown in Table 13. Efficiency of motor is estimated based on typical curve
shown in in Figure 26. Example, efficiency is 78% at 46% loading.

Figure 24: Power consumption pattern for Crusher Machine B

Table 13 : Details for Crusher Machines

Time of RUNNING POWER

MACHINES Materials kWh/kg RATED MEASURED Loading Efficiency
Crushing TIME FACTOR
Kg Hour P (kW) V (V) I (A) P(kW) V(V) I(A) Hour % %
Crusher Machine A 30 0.5 0.05 5.5 415 13 3 431 6 20 46.91 0.6 78
Crusher Machine B 20 0.5 0.18 11 415 18 7 431 13 20 54.73 0.7 79
Crusher Machine C 20 0.5 0.03 15 415 28 1.3 426 10.24 20 7.45 0.2 24
Crusher Machine D 20 0.5 0.03 15 415 30 1.3 426 10.24 20 7.45 0.2 24
Crusher Machine E 20 0.5 0.35 22 380 44 14 431 26 20 54.73 0.6 79
Crusher Machine F 0 0 0.00 7.5 415 14.1 0 431 0 0 0.00 0 n/a

As indicated in Figure 26, crusher machines C and D operates at low efficiency (24%).

30
 Figure 25: Typical Efficiency, Speed and Current curves for IE1 three phase induction motors

0.40 90
0.35 80

Motor Efficiency (%)

0.30 70
60
0.25
kWh/kg

50
0.20
40
0.15
30
0.10 20
0.05 10
0.00 0
Crusher Crusher Crusher Crusher Crusher Crusher
Machine A Machine B Machine C Machine D Machine E Machine F
Crusher Machines

kWh/kg Efficiency %

Figure 26: Details for Crusher Machine

Summary
1. Daily requirement for crushed material is 4200 kg and this can be achieved by running only
Machines A, C and D while pushing Machines C &D to optimum operation (loading now
is only 7.45 %)

31
5.3.3 Lighting

There are generally nine types of light bulbs currently being used in the plant, namely fluorescent
36W, LED fluorescent 18W, PLC Downlight 18W, LED High Bay 180W, Metal Halide 250W
and 220W. The number of light bulbs based on the location and corresponding light bulb
technology and locations in the plant is as shown in the following

Table 14 : Number of light bulbs based on location and light bulb type
LED Street
Fluorescent MHL PLC
High Bay Lamp
No Location Level LED
36W 180W 220W 250W 150W 18W
18W
1 Reception G 24 0 0 0 0 0 0
2 Production G 0 0 20 0 0 0 0
3 Warehouse G 0 0 0 3 0 0 0
4 Office Warehouse G 1 0 0 0 0 0 0
5 Raw Warehouse G 0 0 0 0 5 0 0
6 Waste Area G 0 2 0 0 0 0 0
7 Loading Area G 0 14 0 0 0 5 0
8 Printing Department G 0 0 4 0 0 0 0
9 Compressor Area G 0 0 0 0 2 0 0
10 Molding Area G 4 0 0 0 0 0 0
11 Crushing & Mixing Area G 0 0 0 0 16 3 0
12 Office Production G 0 3 0 0 0 0 0
13 Office Chin Tat G 4 0 0 0 0 0 0
14 Pantry G 4 0 0 0 0 0 0
15 Meeting Room G 4 0 0 0 0 0 0
16 Store Colour G 12 0 0 0 0 0 0
17 Corridor Store Colour G 4 0 0 0 0 0 0
18 Meeting Room 1 8 0 0 0 0 0 0
19 Pantry 1 2 0 0 0 0 0 0
20 Staircase 1 0 0 0 0 0 0 4
21 CEO Office Corridor 1 6 0 0 0 0 0 0
22 Boss Office 1 8 0 0 0 0 0 0
23 Admin Office 1 1 22 0 0 0 0 0 0
24 Store 1 4 0 0 0 0 0 0
25 CEO Office 1 12 0 0 0 0 0 0
26 Admin Office 2 1 24 0 0 0 0 0 0
Total 143 19 24 3 23 8 4

The lighting systems in Uhua-Plas Industries Sdn. Bhd. are not centralized, but instead distributed
across various points in the electrical distribution network. Due to this, load profiling for lighting
system was not possible within the duration of this energy audit. In order to evaluate the energy

32
consumption of the lighting system, estimation based on the number of light bulbs and their rated
power is performed. This gives a rated power of 17.49 kW.
For the energy consumption, the following assumptions on the operating hours of the lights, based
on locations, are used:

1. Lights in the office operate 12 hours a day.

2. Lights at the production, crushing and mixing area, warehouse and printing department
sites operate 24 hours a day.
3. All the lights operate 6 days a week, which is equivalent to 26 days a month.

For the lux measurement, the lux level for a particular location is determined by taking the
average value of the measured lux levels at multiple points of the location. The obtained lux
levels for different sites of the plant are as summarized by Table 15.

Table 15: Summary of average lux level at different locations

No Location Level Measured MS 1525 Deviation Remark
Lux Standard (%)
Lux
1 Reception Ground Floor 521 300 73.53 HIGH
2 Production Ground Floor 105 300 -65.07 LOW
3 Warehouse Ground Floor 26 300 -91.27 LOW
4 Office Warehouse Ground Floor 101 150 -33.00 LOW
5 Raw Warehouse Ground Floor 99 150 -34.00 LOW
6 Waste Area Ground Floor 56 300 -81.22 LOW
7 Loading Area Ground Floor 38 300 -87.27 LOW
8 Printing Department Ground Floor 71 300 -76.40 LOW
9 Compressor Area Ground Floor 37 300 -87.78 LOW
10 Molding Area Ground Floor 45 300 -84.89 LOW
11 Crushing & Mixing Area Ground Floor 38 300 -87.40 LOW
12 Office Production Ground Floor 398 300 32.56 OK
13 Office Chin Tat Ground Floor 306 300 2.00 OK
14 Pantry Ground Floor 324 150 116.22 HIGH
15 Meeting Room Ground Floor 409 300 36.44 HIGH
16 Store Colour Ground Floor 195 150 30.00 OK
17 Corridor Store Colour Ground Floor 199 100 98.67 HIGH
18 Meeting Room First Floor 462 300 53.93 HIGH
19 Pantry First Floor 385 150 156.33 HIGH
20 Staircase First Floor 106 100 6.33 OK
21 CEO Office Corridor First Floor 485 100 385.00 HIGH
22 Boss Office First Floor 423 300 41.00 HIGH
23 Admin Office 1 First Floor 481 300 60.47 HIGH
24 Store First Floor 201 100 101.00 HIGH
25 CEO Office First Floor 261 300 -13.07 LOW
26 Admin Office 2 First Floor 272 300 -9.27 LOW

33
Summary

1. Based on the MS1525 on illumination level, the lux level for raw material store (or
warehouse) should be above 150 while the level for production sites should be above 300.
In terms of production, the current lux levels are not sufficient.
2. For offices, MS1525 recommended lux level of 300-400. As seen in Table 16, some
adjustments to the existing lux level are recommended.
3. Changing fluorescent light bulbs into more energy saving LED light bulbs

Table 16 : Details of Required Lux for various Applications (MS1525)

34
5.3.4 Compressor

In Uhua-Plas Industries Sdn Bhd, compressed air system is located in the ground floor at the
middle of the factory. There are 2 screw air compressor which are a unit IngerSoll Rand SSR ML-
75 compressor and a Euro Screw 75kW compressor, regulating the pressure within the range 7 to
7.5 bar. The details are explained in chapter 3, section 3.22.

As explained in the earlier section, there are total of 2 compressors used alternately in Uhua-Plas
Industries Sdn Bhd, rated at 75kW. Based on the measured power consumption, it is found that
the compressor plant runs close to its full capacity most of the time. Figure 27 shows logged power
data, average of 77kW is consumed (which includes power consumed by dryer).

Figure 27 : Power for Compressor system

Based on the settings at the compressors, the compressed air pressure is set to be generated in the
range 6.9 to 7.5 bar. There are no points to log at the compressor plant, therefore, the followings
readings were recorded manually for each minutes for 10 minutes from the compressor:

Table 17: Compressor Pressure at Generation

Readings Compressors Pressure (Bars)
1 7.0
2 7.3
3 7.1
4 7.5
5 7.4
6 6.9
7 7.2
8 7.2
9 7.4
10 7.1
Average 7.21

35
 0
1
4
5
6
7

2
3
25/09/2017 11:16:58 AM
25/09/2017 11:21:28 AM
25/09/2017 11:25:58 AM
25/09/2017 11:30:28 AM
25/09/2017 11:34:58 AM
25/09/2017 11:39:28 AM
25/09/2017 11:43:58 AM
25/09/2017 11:48:28 AM
25/09/2017 11:52:58 AM

be seen in the Figure 29.

25/09/2017 11:57:28 AM
25/09/2017 12:01:58 PM
25/09/2017 12:06:28 PM
25/09/2017 12:10:58 PM
25/09/2017 12:15:28 PM
25/09/2017 12:19:58 PM
25/09/2017 12:24:28 PM
25/09/2017 12:28:58 PM
25/09/2017 12:33:28 PM
25/09/2017 12:37:58 PM
25/09/2017 12:42:28 PM
25/09/2017 12:46:58 PM
25/09/2017 12:51:28 PM
25/09/2017 12:55:58 PM
25/09/2017 1:00:28 PM
25/09/2017 1:04:58 PM
25/09/2017 1:09:28 PM
25/09/2017 1:13:58 PM
25/09/2017 1:18:28 PM

Figure 29: Valve Leakage near to BM26

Pressure (Bar) At BM26 (nearest point)

Figure 28 : Pressure values at nearest point. 25/09/2017 1:22:58 PM

maximum and minimum bar values are 6.35, 6.63 and 5.01 respectively.

25/09/2017 1:27:28 PM
25/09/2017 1:31:58 PM
25/09/2017 1:36:28 PM
25/09/2017 1:40:58 PM
25/09/2017 1:45:28 PM
25/09/2017 1:49:58 PM
25/09/2017 1:54:28 PM
25/09/2017 1:58:58 PM

Leaking at BM26
25/09/2017 2:03:28 PM
at BM26 with pressure fluctuation greater than 1 bar, which is not within an acceptable range.
From Figure 28, it is observed that the pressure has dropped slightly at the nearest point which is
To check the pressure variation of the compressed air system, pressure measurements have been
recorded on two points in the plant. Firstly, the pressure at the nearest point in the compressed air
line (after dryer system) is recorded as seen in Figure 28. As indicated in the graph, average.

After checking on the area we found that there is some leaking due to valve faulty at BM26 as can

36
The pressure at the furthest receiving end of the compressed air distribution system is shown in
Figure 30 below. Average, maximum and minimum pressure values are 6.46, 6.61 and 6.27
respectively.
Pressure (Bar) BM11 (furthest point)
6.7
6.6
6.5
6.4
6.3
6.2
6.1
25/09/2017 2:25:57 PM
25/09/2017 2:27:57 PM
25/09/2017 2:11:57 PM
25/09/2017 2:13:57 PM
25/09/2017 2:15:57 PM
25/09/2017 2:17:57 PM
25/09/2017 2:19:57 PM
25/09/2017 2:21:57 PM
25/09/2017 2:23:57 PM

25/09/2017 2:29:57 PM
25/09/2017 2:31:57 PM
25/09/2017 2:33:57 PM
25/09/2017 2:35:57 PM
25/09/2017 2:37:57 PM
25/09/2017 2:39:57 PM
25/09/2017 2:41:57 PM
25/09/2017 2:43:57 PM
25/09/2017 2:45:57 PM
25/09/2017 2:47:57 PM
25/09/2017 2:49:57 PM
25/09/2017 2:51:57 PM
25/09/2017 2:53:57 PM
25/09/2017 2:55:57 PM
25/09/2017 2:57:57 PM
25/09/2017 2:59:57 PM
25/09/2017 3:01:57 PM
25/09/2017 3:03:57 PM
25/09/2017 3:05:57 PM
25/09/2017 3:07:57 PM
25/09/2017 3:09:57 PM
25/09/2017 3:11:57 PM
25/09/2017 3:13:57 PM
25/09/2017 3:15:57 PM
25/09/2017 3:17:57 PM
Figure 30 : Pressure values at Furthest point.

By checking the pressure at the furthest receiving end, i.e. BM 11, it is found that the pressure
fluctuates within the range of 6.3 to 6.6 bar, indicating that the pressure drop is significantly small
and the pressure at the furthest point is higher than the nearest point. The BM 11 is about 70 m
from the compressor plant where the distance as the factor for pressure drop is insignificant. Since
the compressed air distribution system is in a loop piping, there is no significant effect on the
pressure at the furthest point even though the pressure in the nearest point is 1 Bar lesser due to
the leaking.

Summary

1. Remove leakages especially near BM26

2. Keep receiver tank 1 and 2 after compressor 1 and 2 respectively where receiver tank
before dryer is to provide control storage and condensate drop out.
3. Add new vertical air receiver tank 4 after dryer system 1 and 2 where receiver tank after
the dryer is to meet sudden demands for compressor and dryer capacity.

37
 Figure 31: Proposed new compressor system.

5.3.5 Chiller System

UHUA Process Cooling System consist of 8 number of 10HP and 13 number of 5HP mini
chiller. The specifications of the system as Table 18 below;

Table 18: Specification of Chillers

System Quantity Specifications

Mini
Chillers 8 nos 3) Brand Name : Industrial Chiller - China
10HP (Running 8 nos) Chilled Water Supply Setting: 20 degC
Voltage: 415V

Mini
Chillers 13 nos 4) Brand Name : Industrial Chiller - China
5HP (Running 9 nos) Chilled Water Supply Setting: 19 degC
Voltage: 415V

38
 Figure 32: Photos of chiller and logging activities

Electricity energy trending was observed by main incoming electrical consumption logging for
duration of 1 hours for typical 5 HP mini chillers. Figure 33 shows hourly daily trend for power at
UHUA Manufacturing Sdn Bhd.

Chiller (5HP) Power Trend (kW) - 1 hour Operation

8.0
6.0
4.0
2.0
0.0
12:37:19
12:38:59
12:40:39
12:42:19
12:43:59
12:45:39
12:47:19
12:48:59
12:50:39
12:52:19
12:53:59
12:55:39
12:57:19
12:58:59
13:00:39
13:02:19
13:03:59
13:05:39
13:07:19
13:08:59
13:10:39
13:12:19
13:13:59
13:15:39
13:17:19
13:18:59
13:20:39
13:22:19
13:23:59
13:25:39
13:27:19
13:28:59
13:30:39
13:32:19
13:33:59
13:35:39
Figure 33: Hourly Trend for Process Cooling System Power (5HP)

Electricity energy trending was observed by main incoming electrical consumption logging for
duration of 1 hours for typical 10 HP mini chillers. Figure 34 shows hourly trend for power at
UHUA Manufacturing Sdn Bhd.

Chiller (10HP) Power Trend (kW) - 1 hour Operation

6.0
5.0
4.0
3.0
2.0
1.0
0.0
11:17:00
11:18:40
11:20:20
11:22:00
11:23:40
11:25:20
11:27:00
11:28:40
11:30:20
11:32:00
11:33:40
11:35:20
11:37:00
11:38:40
11:40:20
11:42:00
11:43:40
11:45:20
11:47:00
11:48:40
11:50:20
11:52:00
11:53:40
11:55:20
11:57:00
11:58:40
12:00:20
12:02:00
12:03:40
12:05:20
12:07:00
12:08:40
12:10:20
12:12:00
12:13:40
12:15:20

Figure 34: Hourly Trend for Process Cooling System Power (10HP)

In Summary, process cooling system measurement for UHUA Manufacturing Sdn Bhd is as
shown in Table 19 and Table 20.
39
 Table 19: Typical 5 HP Process cooling system

Measured
Design
Mini Chiller 5HP Units Readings
Specifications
(Average)

Temperature Supply ± 1oC 19 23 oC

Temperature Return ± 1oC - 27 oC

Average flow rate GPM - 28 GPM
Average Peak kW kW - 5.5 kW
Average Peak Ton Ton - 6 Ton
Average Peak kW/Ton kW/Ton - 0.9 kW/Ton

Average tonnage Ton - 6 - 8 Ton

Total Tonnage Ton - 54 Ton

Table 20: Typical 10 HP Process cooling system

Measured
Design
Mini Chiller 10 HP Units Readings
Specifications
(Average)

Temperature Supply ± 1oC 20 23.5 oC

Temperature Return ± 1oC - 26.5 oC

Average flow rate GPM - 27 GPM
Average Peak kW kW - 5.4 kW
Average Peak Tonnage Ton - 7 Ton
Average Peak Efficiency kW/Ton - 0.77 kW/Ton

Average tonnage Ton - 5 - 8 Ton

Total Tonnage (8 units) Ton - 56 Ton

40
Summary

1. To set the chilled water supply temperature by 1.5 Deg C higher.

2. To Isolate bypass flow (Figure 33)
3. Grouping up individual mini chiller’s to centralized chiller system with supply and
return header (Figure 36)

.
To Isolate
Bypass Flow

Figure 35: Mini Chiller by Pass flow Isolation

41
Figure 36: Design Concept Centralized Chiller system

42
6. ENERGY SAVING MEASURES
6.1 Energy Management System

Based on the audit performed, it is found that there is no existing energy management system in
place for Uhua-Plas Industries Sdn Bhd. To ensure the effectiveness and sustainability of the
energy efficiency improvement in the factory, the first priority is to establish an energy
management system. This will include the setting up of energy monitoring systems (to establish
energy baseline and load profile) as well as an energy management committee at the factory to
spur the energy efficiency measures to be implemented in the future. Future elaborations on the
energy management system and its impacts will be given in Chapter 8.

6.2 Energy Saving Measures

There are five suggestions to minimize electricity bill in the plant. Firstly, to replace 10 single
station blower machine to 5 new double station blower machine. Secondly, to optimize the usage
of crusher machines, thirdly replacing florescent lamps to LED. Fourthly, to reduce pipe leakages
and adding receiver tank for air compressor system, and finally optimizing chiller system. The
details are given in subsequent sections.

6.2.1. ESM1-Replacing New Five Double Station Blower Machine

Rationale
Thirteen out of 24 machines have been operating for more than 15 years, and twelve of them are
single station machines. There are also 6 reconditioned machines (operating more than 15 years).
These machines are running inefficiently as they consume higher power compared to new
machine.
Required action

Converting 10 single station (BM 17,BM 8, BM 21, BM 13, BM 20, BM 18, BM 12, BM 3, BM
11, BM 23) old machines to 5 double station machines. Estimated power reduction in each machine
9.5kW.

6.2.2 ESM2 – Operate only Crusher Machine A, C and D

Rationale

Daily requirement for crushed material is 4200 kg. Crusher machine B and E consumes more
energy to crush material compared to machine A, C and D.

Required action

Running only Machines A, C and D while pushing Machines C &D to optimum operation (loading
now is only 7.45 %)

43
6.2.3 ESM3- Change to LED Lamps

Rationale

Based on the MS1525 on illumination level, the lux level for raw material store (or warehouse)
should be above 150 while the level for production sites should be above 300. In terms of
production, the current lux levels are not sufficient. For offices, MS1525 recommended lux level
of 300-400.

Required action

As seen in Table 15, some adjustments to the existing lux level are recommended.
It is recommended to change fluorescent light bulbs into more energy saving LED light bulbs

6.2.4 ESM4- Air Compressor- Rectify Leakages and install Air Receiver Tank

Rationale

Leakages found at the BM26 machines and pressure drop at the nearest point (BM26) is greater
than 1 bar.

Required action

Remove leakages especially near BM26. Keep receiver tank 1 and 2 after compressor 1 and 2
respectively where receiver tank before dryer is to provide control storage and condensate drop
out. Add new vertical air receiver tank 4 after dryer system 1 and 2 where receiver tank after the
dryer is to meet sudden demands for compressor and dryer capacity.

6.2.5 ESM5- Optimization of Chiller System

Rationale

Temperature setting at supply is 23 Deg C. There are 17 individual chillers operating to both the
blower and injection machines. In order to maintain required temperature at the machine each
chiller are running with isolated bypass flow.

Required action

Set the chilled water supply temperature by 1.5 Deg C higher. Remove by-pass Flow at all the
mini chiller. Group up individual mini chiller’s to centralized chiller system with supply and
return header

44
 Table 21: ESM1: Replacing New Five Double Station Blower Machine

Current Operation AFTER ESM1

Actual New
Running Bill / Simple Pay
Power Energy/ month Power Energy/ Bill / month Savings /Yearly
Hours month Cost (RM) Back Period
Consumed (kWh) Consumed month (kWh) (RM) (RM)
/day (RM) (Year)
(kW) (kW)
Blower Machine
20 376.3 195,676.00 86,293.12 328.8 170,976.00 75,400.42 130,712.40 750,000.00 5.74
(BM)
195,676.00 86,293.12 170,976.00 75,400.42 130,712.40

Table 22: ESM2 : Operate only Crusher Machine A, C and D

Current Operation AFTER ESM2

Actual New
Running Bill / Simple Pay
Power Energy/ month Power Energy/ Bill / month Savings /Yearly
Hours month Cost (RM) Back Period
Consumed (kWh) Consumed month (kWh) (RM) (RM)
/day (RM) (Year)
(kW) (kW)

Crucher Machine 20 26.6 13,832.00 6,099.91 13 6,760.00 2,981.16 37,425.02 0.00 0.00

13,832.00 6,099.91 6,760.00 2,981.16 37,425.02

45
 Table 23: ESM3 : Change to LED Lamps

Current Operation AFTER ESM3

Actual New
Running Bill / Simple Pay
Power Energy/ month Power Energy/ Bill / month Savings /Yearly
Hours month Cost (RM) Back Period
Consumed (kWh) Consumed month (kWh) (RM) (RM)
/day (RM) (Year)
(kW) (kW)

Lightings 12 to 24 17.49 9,202.13 4,058.14 14.88 8,376.58 3,694.07 4,368.82 7,350.00 1.68

9,202.13 4,058.14 8,376.58 3,694.07 4,368.82

Table 24: ESM4: Air Compressor- Rectify Leakages and install Air Receiver
Tank
Current Operation AFTER ESM4
Actual New
Running Bill / Simple Pay
Power Energy/ month Power Energy/ Bill / month Savings /Yearly
Hours month Cost (RM) Back Period
Consumed (kWh) Consumed month (kWh) (RM) (RM)
/day (RM) (Year)
(kW) (kW)

Air Compressor 20 77 40,040.00 17,657.64 73.15 38,038.00 16,774.76 10,594.58 22,600.00 2.13

40,040.00 17,657.64 38,038.00 16,774.76 10,594.58

46
 Table 25: ESM5 : Optimization of Chiller System

Current Operation AFTER ESM5

Actual New
Running Bill / Simple Pay
Power Energy/ month Power Energy/ Bill / month Savings /Yearly
Hours month Cost (RM) Back Period
Consumed (kWh) Consumed month (kWh) (RM) (RM)
/day (RM) (Year)
(kW) (kW)

Chiller 24 46.5 29,016.00 12,796.06 32.55 20,311.20 8,957.24 46,065.80 150,000.00 3.26

29,016.00 12,796.06 20,311.20 8,957.24 46,065.80

47
The technical and financial impact for each of the energy saving measures can be summarized in
Table 26.
Table 26: Technical and Financial impact

Capital Payback CO2

Saving (Yearly)
No Measures Expenses period Reduction*

kWh RM RM Year Tonne

ESM1: Replacing New Five Double Station Blower Machine
1 Blower Molding
296,400.00 130,712.40 750,000.00 5.74 205.70
Machine
ESM2: Operate only Crusher Machine A, C and D
2
Crusher 84,864.00 37,425.02 0.00 0.00 58.90
ESM3: Change to LED Lamps
3
Lighting 9,906.62 4,368.82 7,350.00 1.68 6.88
ESM4: Air Compressor- Rectify Leakages and install Air Receiver Tank
4
Air Compressor 24,024.00 10,594.58 22,600.00 2.13 16.67
ESM5: Optimization of Chiller System
5
Chiller 104,457.60 46,065.80 150,000.00 3.26 72.49
Total 519,652.22 229,166.63 929,950.00 4.06 360.64

48
7. SUMMARY AND IMPLEMENTATION PLAN
Uhua-Plas Industries Sdn Bhd a manufacturer of "HDPE, LDPE, PP, PET" type of bottle, jar and
container closure. It is located at Kundang, Rawang, Selangor. The audited site is a factory plant
consists of an office building which is attached to the factory building. The plant is involved in the
production of plastic products, and encompasses the whole process chain.
The electricity tariff for this factory is Tariff D-33 Low Voltage Industrial Tariff. The average
specific energy consumption and average electricity cost per brick are 1.16 kWh/kg and 0.52
RM/kg respectively.
Based on the measurement data captured at main switch board of the factory in between 15
September 2017 to 9 October 2017. Total energy consumption of Blower Machines themselves is
64% compared to other loads which include lighting, Compressor, Injection Machines, Chiller and
Others. It is noted that the loads are operating mostly for 20 hours.

Five energy saving measures are recommended for this plant. Firstly, to replace 10 single station
blower machine to 5 new double station blower machine. This measure expected to give yearly
savings of RM130,000 with simple payback period of 5.74 years. Calculation for simple payback
period did not include the scrap value of the old machines in addition the cost of replacing to new
machine was set to higher side. Secondly, to optimize the usage of crusher machines. It is
recommended to limit usage of crusher machine to three instead of five, and this is expected to
give yearly savings of RM37, 000 at no cost. Thirdly replacing florescent lamps to LED, and yearly
savings expected to be RM4,368. Fourthly, to reduce pipe leakages and adding receiver tank for
air compressor system. This measure is expected to give yearly savings of RM10,000 with 2.13
years of simple pay back period. Finally optimizing chiller system to get yearly savings of
RM46,000. The details are given in subsequent sections. A total of 15.63% energy savings are
expected after all the measures are implemented.

Table 27 gives the summary of energy saving measures (ESMs) including the ease and priority of
implementation. Figure 37 shows the Gantt chart for the implementation of the ESMs.

49
 Table 27: Summary of Energy Saving Measures

Overall
Capital Payback CO2 Ease of
Saving (Yearly) saving in Priority
No Measures Expenses period Reduction* Implementation
kWh
kWh RM RM Year Tonne %
ESM1: Replacing New Five Double Station Blower Machine
1 Blower Molding
296,400.00 130,712.40 750,000.00 5.74 205.70 8.91 Y3 Moderate
Machine
ESM2: Operate only Crusher Machine A, C and D
2
Crusher 84,864.00 37,425.02 0.00 0.00 58.90 2.55 Y1 Easy
ESM3: Change to LED Lamps
3
Lighting 9,906.62 4,368.82 7,350.00 1.68 6.88 0.30 Y2 Moderate
ESM4: Air Compressor- Rectify Leakages and install Air Receiver Tank
4
Air Compressor 24,024.00 10,594.58 22,600.00 2.13 16.67 0.72 Y2 Moderate
ESM5: Optimization of Chiller System
5
Chiller 104,457.60 46,065.80 150,000.00 3.26 72.49 3.14 Y3 Moderate
Total 519,652.22 229,166.63 929,950.00 4.06 360.64 15.63

* CO2 tonnage is calculated based on the 2014 Grid Electricity Emission Factors for Peninsular Malaysia, which is 0.694 tCO 2/MWhr
Energy Saving Year 1 Year 2 Year 3
No. Priority
Measures 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
1 ESM1 Y3 X X X X X X X
2 ESM2 Y1 X X X X X X X X
3 ESM3 Y2 X X X X X X
4 ESM4 Y2 X X X X X X X X
5 ESM5 Y3 X X X X X X
Figure 37: Gantt Chart for implementation of ESMs

50
8. SUSTAINABILITY PLAN
Below is the Energy Management Plan we have drafted to assist the client to implement in their
factory for continuity and sustainability of the energy management plan.

Energy Management Plan

8.1 Measure/benchmark current energy consumption. Establishing a baseline against which

future reductions will be measured is an important first step in tracking progress. Once
a baseline has been established, the client can continue to track consumption on an
ongoing basis and quantify the savings from reduction efforts. The client will be utilizing
the baseline obtained during the energy audit we provided.

8.2 Develop an energy use profile. An energy use profile will demonstrate how energy use
is distributed among building systems (e.g., motors, lighting, office, compress air and so
on, as demonstrated in the figure below. Submetering can be provided to further
distinguish the performance of those systems and to help identify further reduction
opportunities. Breaking down energy consumption data by discrete systems allows a
more strategic approach to target improvement efforts. The energy use profile is
provided in this report for the client’s reference.

8.3 Assist client in forming an Energy Management Committee which consists of

representatives from the top management as well as from the relevant departments that
share the responsibilities in planning, monitoring and improving energy usage in the
factory.

8.4 Set short- and long-term energy reduction goals. It is important to set both short- and
long-term reduction goals for energy and emissions reductions and integrate them into a
meaningful and achievable energy management plan. Based on the data gathered during
baseline-setting in the energy audit, energy use-profiling, and GHG inventory to help
establish reasonable goals that are consistent with basic, intermediate or advance
approach. This is to develop strategic action plans for improvement and to help in
identifying and choosing those low hanging fruits for immediate implementation.

8.5 Support client in adopting a strategic energy management plan (SEMP). The SEMP is a
written plan that includes an integrated approach to ALL aspects of energy management,
including short- and long-term reduction strategies.

8.6 Track, measure, and report. It's important to begin to track energy for several reasons:

8.6.1 to verify they are meeting the intended goal

8.6.2 to track cost and operational savings,
8.6.3 to monitor staff satisfaction, and
8.6.4 to report on all successes or failures in order to inform your next steps and give
you traction as you prepare for the next project.

8.7 Train, educate, and celebrate. Effectively communicating the need for energy
management and providing training and guidance on how to implement specific
strategies can help an organization achieve greater reductions and gain more support for
initiatives with the help of MGTC energy management training program. It should be
kept in mind that informed staffs are engaged staffs. Success is easier to achieve when
users are educated on the reasons for any changes, trained on work practice changes and

51
regularly informed on how action plan progress is matching up to goals and progress
reports. Training and education can be both formal, i.e. with specific learning objectives
and informal. . Recognizing individual and collective efforts through awards or other
recognition programs also provides opportunities to celebrate and communicate the
valuable work being accomplished. Don't let a success go unrecognized.

Table 28 Target Energy Management Practice Chart

52
9. FINANCIAL PLAN
The client is committed and plan to implement 70% of the ESM proposals immediately
especially those with the Return on Investment (ROI) are less than 3 years using internal
funding. Below is the summary of the financial plan for the ESM agreed by the client.

Table 29: Financial plan for ESM

Energy Saving Investment Internal External

No. Priority
Measures (RM) Funding Funding
1 ESM1 Y3 750,000.00 Yes No
2 ESM2 Y1 0.00 Yes No
3 ESM3 Y2 7,350.00 Yes No
4 ESM4 Y2 22,600.00 Yes No
5 ESM5 Y3 150,000.00 Yes No

53
10. REFERENCES
1. MS 1525:2014, Malaysian Standard “Energy efficiency and use of renewable energy for
non-residential buildings - Code of practice (Second revision)”

2. FLUKE website :http://www.fluke.com/fluke/r0en/power-quality-tools/three-phase/fluke-

1730.htm?pid=77038# , visited on 6 June 2017, 5.20 PM.

3. IEC 60034-30-Rotating electrical machines –Part 30: Efficiency classes of single-speed,

three-phase, cage-induction motors (IE-code)

4. Uhua-Plas Industries Sdn Bhd website - http:// http://www.uhuaplasindustries.com/ ,

visited on 15 September 2017, 1.20 PM

54
Appendix A: TNB Bills

55
Appendix A: TNB Bills (Cont.)

56
Appendix A: TNB Bills (Cont.)

57
Appendix A: TNB Bills (Cont.)

58
Appendix A: TNB Bills (Cont.)

59
Appendix A: TNB Bills (Cont.)

60
Appendix A: TNB Bills (Cont.)

61
Appendix A: TNB Bills (Cont.)

62
Appendix A: TNB Bills (Cont.)

63
Appendix A: TNB Bills (Cont.)

64
Appendix A: TNB Bills (Cont.)

65
Appendix A: TNB Bills (Cont.)

66
Appendix A: TNB Bills (Cont.)

67
Appendix A: TNB Bills (Cont.)

68
Appendix A: TNB Bills (Cont.)

69
Appendix A: TNB Bills (Cont.)

70
Appendix A: TNB Bills (Cont.)

71
Appendix A: TNB Bills (Cont.)

72
Appendix A: TNB Bills (Cont.)

73
Appendix A: TNB Bills (Cont.)

74
Appendix A: TNB Bills (Cont.)

75
Appendix A: TNB Bills (Cont.)

76
 Appendix A: TNB Bills (Cont.)

Bil Elektrik Dan Invois Cukai

UHUA PLAS INDUSTRIES SDN BHD

NO 5, JLN KPK 1/3
KAW PERINDUSTRIAN KUNDANG
No. Akaun : 220385366303
48020 KUNDANG JAYA
Deposit : RM 260,000.00
SELANGOR No. Kontrak : 246079

Jumlah Perlu Bayar : RM 147,592.10 Kod Tarif : D:Perindustrian

Tunggakan :RM 1,250.00- Tarikh Bil :

Caj Semasa :RM 148,842.11 01.11.2017
Penggenapa Tempoh Bil :
n :RM 0.01- 01.10.2017 - 31.10.2017 (31 hari)
Jumlah Bil :RM 147,592.10 Bayar Sebelum 01.12.2017 No. Invois Cukai :
000752485683

Bil dan Pembayaran Terdahulu

Bil Terdahulu RM 212,307.40 Bayaran Terakhir RM 81,283.85
(01.10.2017) (31.10.2017)

Untuk maklumat bil dan

Caj Semasa bayaran terdahulu, sila layari
www.mytnb.com.my
Tidak Kena Kena
atau hubungi
Keterangan GST GST Jumlah
TNB Careline
Kegunaan kWh kWh 0.00 324,725.00 324,725.00
1-300-88-5454 / 15454
Kegunaan RM RM 0.00 143,191.53 143,191.53
ICPT (RM0.0152-) RM 0.00 4,935.82 - 4,935.82 - Untuk pertanyaan, sila hubungi :
TNB RAWANG
Kegunaan Bulan Semasa RM 138,255.71 138,255.71 JLN MAXWELL
6% GST (6% X RM138,255.71) RM 8,295.34 48000 RAWANG
KWTBB (1.6%) RM 2,291.06 SELANGOR
Tel: 03-60927000
Faks: 03-60916330

Subsidi 2.54 sen / kWh dibiayai oleh

KerajaanPersekutuan RM 8,248.02
(untuk makluman sahaja)

KWTBB - Kumpulan Wang Tenaga Boleh Baharu

ICPT - Pelepasan Imbangan Kos Penjanaan

Bayaran melalui cek sah setelah

Caj Semasa RM 148,842.11 penjelasan cek oleh bank
(Untuk maklumat terperinci sila rujuk muka surat 2)

77
Appendix A: TNB Bills (Cont.)

78
Appendix A: TNB Bills (Cont.)

79
Appendix A: TNB Bills (Cont.)

80
Appendix B: Power Logger Calibration Certificate

81
Appendix C: Digital Pressure Gauge Calibration Certificate

82
Appendix D: Organizational Profile Shapes

83
 Appendix E: Chiller Measurement Data

Figure E1 : Uhua Manufacturing Sdn Bhd Chilled Water Return Temperature (5HP)

Findings on Uhua Manufacturing Sdn Bhd chilled water return readings;

• Building Operation Hours : 24 Hours
• Maximum : 28.05 ˚C
• Minimum : 25.2 ˚C
• Average : 27 ˚C

84
 Appendix E: Chiller Measurement Data (cont.)

Figure E2 Uhua Manufacturing Sdn Bhd Chilled Water Supply Temperature

Findings on Uhua Manufacturing Sdn Bhd chilled water supply readings;

• Building Operation Hours : 24 Hours
• Maximum : 26 ˚C
• Minimum : 22 ˚C
• Average : 23 ˚C

Figure E3 Uhua Manufacturing Sdn Bhd Chilled Water Flow (GPM)

85
 Appendix E: Chiller Measurement Data (cont.)

Findings on Uhua Manufacturing Sdn Bhd chilled water flow readings :

• Building Operation Hours : 24 Hours
• Maximum : 28.8 GPM
• Minimum : 27.25 GPM
• Average : 28 GPM

Figure E4 Uhua Manufacturing Sdn Bhd Tonnage (TON)

Findings on Uhua Manufacturing Sdn Bhd tonnage:

• Building Operation Hours : 24 hours
• Maximum : 9 TON
• Minimum : 3 TON
• Average : 6 TON

86
 Appendix E: Chiller Measurement Data (cont.)

Figure E5 Uhua Manufacturing Sdn Bhd Chilled Water Return Temperature (10HP)

Findings on Uhua Manufacturing Sdn Bhd chilled water return readings;

• Building Operation Hours : 24 Hours
• Maximum : 27.3 ˚C
• Minimum : 25.8 ˚C
• Average : 26.6 ˚C

87
 Appendix E: Chiller Measurement Data (cont.)

Figure E6 Uhua Manufacturing Sdn Bhd Chilled Water Supply Temperature (10HP)

Findings on Uhua Manufacturing Sdn Bhd chilled water supply readings;

• Building Operation Hours : 24 Hours
• Maximum : 24.7 ˚C
• Minimum : 22.2 ˚C
• Average : 23.5 ˚C

Figure E7 Uhua Manufacturing Sdn Bhd Chilled Water Flow (GPM) -10HP

88
 Appendix E: Chiller Measurement Data (cont.)

Findings on Uhua Manufacturing Sdn Bhd chilled water flow readings :

• Building Operation Hours : 24 Hours
• Maximum : 32 GPM
• Minimum : 26 GPM
• Average : 27 GPM

Figure E8 Uhua Manufacturing Sdn Bhd Tonnage (TON) – 10 HP

Findings on Uhua Manufacturing Sdn Bhd tonnage:

• Building Operation Hours : 24 hours
• Maximum : 10.5 TON
• Minimum : 5 TON
• Average : 7 TON

89