PRELMINARY ENERGY AUDIT REPORT OF

KAIRALI POLYPACK PVT. LTD

VINEETH KUMAR C G

M130512EE

IPA

COMPANY DETAILS

Name : Kairali polypack private limited

Address : 1/537, Exhibition road,

west hill, Calicut – 673005,

Tel: 0495 2382132, 2382144

e-mail: kairalipolypack@yahoo.co.in

Location : West hill, Kozhikode

Work type : 24 hours, 2 shifts

Transformer : 500 kVA, 26.24 A HV, 666.64 A LV, 50 Hz,

3 phase, ONAN, % impedance = 4.2

Connected load : 290 kW

Contract demand : 250 kVA

Maximum demand : 186 kVA

Products : HM, HDPE, LDPE, Polyethylene packing materials

(50 - 400) microns

PRODUCT DETAILS

PROCESS FLOW DIAGRAM

PRODUCTION PROCESS IN DETAILS

LOAD DETAILS

ProductMain

motor

AC blower

motor

DC winding

motor

DC rolling and

pressing motorHeater

Total

(HP)

1 15 0.5 0.5 0.5 14.5 31

2 15 0.5 0.5 0.5 14.5 31

3 15 0.5 0.5 0.5 14.5 31

4 15 0.5 2 0.5 17 35

5 15 0.5 0.5 0.5 11.5 28

6 15 0.5 2 1 13 31.5

7 30 1 4 9 56 100

8 15 0.5 0.5 4 11.5 31.5

9 10 3 1 3 11.5 28.5

10 10 3 1 3 11.5 28.5

Oth

er l

oa

ds 11

12

13

14

15

20 20

1 1

25 1.2 26.2

6 6.5 12.5

0.5 0.5

436.2

Lighting:

Total No. of Fluorescent Tube lights = 20 nos.

Average Power saved per bulb = 26 W

Total Power saving = 20 x 26 W

= 0.52 kW

Average Use of bulbs per year = 320 x

12h = 3840h

Total Energy saved per year = 3840 x 0.52 kWh

= 1996.8 kWh

Saving in Rs. Per year = Rs. 1996.8 x 5.3

= Rs. 10583

Average Cost of Replacing bulb = Rs. 180

Total Cost of Replacing all bulbs = 20*180

= Rs. 3600

Capital Cost Recovery time = (3600)/(10583)

= 0.34 yrs.

= 4 months

ENERGY CONSERVATION

SUGGESTIONS

Put UPS of sufficient capacity for uninterrupted power supply

Replace existing 40W tube lights with 14W CFL.

Replace inefficient under loaded motors with new energy efficient motors.

Give sufficient maintenance and lubricate rotating gear parts properly to avoid

losses

Replace old conveyer belts with new ones

Provide APFC so that overall power factor can be improved.

Use transparent sheets to use day lights and reduce lighting load at day time.

Replace existing CRT monitors with LED monitors in office.