Energy Audit on a

Manufacturing Company
Yashashvi Verma (I064)

Naman Dalsania (A021)

Raj Tanishq (A085)

Aum Sampat (I043)

1
Energy Audit and its
Objectives
● Primary goal is resource
protection,climate protection and
energy saving

● Verification,monitoring & analysis of

energy use & a report with
recommendations for improving energy
efficiency.

● Cost benefit analysis–reduce amount

of input in the system without affecting
the output

2
 Description of the Facility

● Terminal Technologies is a 20,000 sq ft

manufacturing facility in Goregaon West that
was established in 2008.

● Uses approx. 1,000,000 kWh of energy

annually.

● The site contains variety of electric appliances.

3
 Recommendations
Category A
Clean bulbs and tubing regularly.
Replace existing lighting by
CFLs
Change the AC filter monthly.
Turn off home office equipment
when not in use.
Turn off the lights when not
required.
Category B
Use IR sensors, motion sensors,
timers, dimmers, solar cells, and
automatic timers.
Set the room air conditioners
thermostat to 25 °C for best
comfort at low cost.
The hopper reuses the air and
saves the energy. With the use
of energy metre, this saved
energy can be quantified..
Category C
Use the same brand of air
conditioners and light bulbs for
less upkeep.
Installation of carbon dioxide and
carbon monoxide sensors in
machine section.
Incorporating a solar powered
solution for powering the
equipment.
4
Lighting

Observations Recommendations

1. It has been observed that there are a lot 1. Turn off the lights when not required.
of unnecessary lights on. 2. Use IR sensors, motion sensors,
timers, dimmers, solar cells, and
2. Lights are on even when not being used.
automatic timers.
3. Regularly clean the bulbs and tubing
3. Bulbs and tubes are not cleaned & replacing existing lighting with CFLs
regularly. or LEDs

5
6
Managing Air Conditioners

Observations Recommendations
1. Air conditioning contributes to about 62% 1. Set the room air conditioners thermostat
of overall power consumption.
to 25 °C for best comfort at low cost.
2. When not cleaned regularly, cooling
takes a lot of time. 2. Every month, change the air conditioner's
filter. When not in use, turn off your home
office equipment.
3. Brand and model not consistent so high
cost of maintenance. 3. Use same brand throughout for cheap for
maintenance cost.

7
Managing Machine Efficiency
Observations
1. The value of power factor obtained for
last year is found to be satisfactory.But
still there is a lot of scope of
improvement.
2. Material must be preheated for injection
moulding. This happens in the injection
moulding machine hopper. Material is
heated in the hopper according to the
product's needs. They are heated
between 170 and 220 degrees Celsius.
In this instance, hot air is squandered as
exhaust air.
Recommendations
1. The effective incentive reduces monthly
energy prices by 7% if the power factor is
maintained between 0.995 and 1.000.
Instead of Rs. 29027.96, monthly
earnings may be Rs. 48980.59.
2. In the hopper, this air can be used once
again. As a result, energy savings are
attainable. With the use of an energy
metre attached to a hopper, this saved
energy can be quantified in real time.
8
 TABLE 1:Incentive Scheme of Maharashtra State Electricity
Board
Sr No Range of PF PF Level Incentive(%)

1 0.951 to 0.954 0.950 0

2 0.955 to 0.964 0.960 1

3 0.965 to 0.974 0.970 2

4 0.975 to 0.984 0.980 3

5 0.985 to 0.994 0.990 5

6 0.995 to 1.000 1.000 7

9
10
Building Efficiency

Observations Recommendations
1. Too much energy consumption in 1. Start and stop timer for AC’S in war
building and poor building efficiency. rooms and conferences.

2. Installing status alarms for injection

moulding machines and Smoke detectors
in the machine section.

3. Installation of carbon dioxide and carbon

monoxide sensors in machine section.

11
Industry Equipments - Computers,
printers & other accessories
Observations
1. A computer that runs 24 hours a day
uses a great amount of power.
2. Chargers for batteries, such as those for
computers, cell phones, and digital
cameras, use a lot of energy every time
they are plugged in.
Recommendations
1. When not in use, putting computers,
monitors, and copiers in sleep mode can
reduce energy expenses by about 40%
2. Shutting computers down when you are
finished using them actually not only
reduces system wear but also saves
energy.
3. Solar panels charge rechargeable
batteries, which power phones. If you
charge your battery during the day, you
can charge your phone when there is no
sunshine.
12
 Energy Bill
Table 2.Energy Bill of Industry from Feb 21-Jan 22.
Month Power Total Electricity Avg. Unit Cost
Consumption Cost (Vatu) / Month (Rs. / kWh)
(kWh) / Month

Jan-22 96290 77980 8.10

Mar-21 58620 496158 8.46

May-21 132400 838639 6.33

Jul-21 89590 772760 8.63

Sep-21 87340 741720 8.49

Nov-21 80030 701540 8.77

The total units consumed for the period is 1,095,630 and the total billing amt is 8,929,397
These figures are derived directly from an industry's monthly electricity bills 13
 Electricity Consumption Breakdown

● Figure identifies the main uses as stamping and

moulding machines.
● Although other areas don't contribute much,
installing BMS technology can save a lot of
energy and money.

● The area of injection moulding machines houses

our main EMOs. According to the graph above,
injection moulding machines use 61% of the
energy, whereas stamping machines use 28%.

14
 Energy Saving for Moulding Machines

● Comparative investigation reveals that injection moulding machines

have significant EMOs. Variable Frequency Drives (VFDs) can be
placed in machinery to lower the energy consumption of motors.

● Variable Frequency Drives (VFDs) are placed in machinery to lower the

energy consumption of motors. It is also referred to as an Adjustable
Speed Drive (ASD), Variable Voltage Variable Frequency Drive
(VVVF), and Variable Speed Drive (VSD)

● . By adjusting the voltage and frequency of the electricity supplied to the

motor, variable frequency drives (VFD) can alter the speed of the motor.

15
 Energy Saving for Moulding Machines

● VFDs have the following benefits: -

➔ Significant energy savings at lower speeds
➔ Longer component life due to lower operating speeds
➔ Reduced noise and vibration levels
➔ Reduced thermal and mechanical strains

● Each machine with an installed VFD saves 3.14 kWh.At all speeds,
every VFD maintains a consistent output voltage to frequency ratio.
Hence energy saving is the same.

● Shorter payback periods make investments more advantageous.

Payback period is less than a year, which suggests that investing in
VFD’s is worthwhile and cost effective.

16
Lighting Inventory
TABLE 3.Types of lights used and their consumption

Appliance Quantity Power Consumption

T8 Fluorescent Tube 11 1025 W

T5 Fluorescent Tube 32 2540 W

Compact Fluorescent 16 1030 W

17
 Air Condition & Fan Inventory
TABLE 4.
AC’s and Fans and their consumption

Brand Type Quantity Rated Power Temp Hours/d

Consumption Setting ay
Air
Conditioner

Samsung Split 5 100 21 9

Hitachi Split 5 90 25 9

Sanyo Split 8 250 24 9

Fan

Brand - Ceiling 15 1022.36 - 6

Normal type
18
Machines used
TABLE 5.Types of machines used and their consumption

Machine Type Quantity Power Consumption

Moulding Machine 16 47,043.36 W

Stamping Machine 6 21,840 W

Toyo SI 6 678 W

19
20
Thankyou!

21