Can we foreseegreenbusinesscentre.com/energyaward2017presentation… · · 2017-09-07(India) B-22...

Can we

foresee

Tomorrow…?

1. JAIRAJ ANCILLARIES PVT LTD Plant-1

Established: 1985

(Plastics Division): 3-B-23,

BP, NIT Faridabad - 121001,

Haryana (India)

(Metal cutting, Machining &

Turning Division):

Plot No.66, Sector-27-A,

Faridabad-121002, Haryana

(India)

B-22 Rudrapur Industrial

Estate, Rudrapur, Dist.

U.S.Nagar,

Uttarakhand(India)

20A/4 Industrial Area NIT

Faridabad-121001, Haryana

(India)

5. JAIRAJ PLASTOCHEM PVT LTD .

Established 1987

2. JAIRAJ ANCILLARIES PVT LTD Plant-2

Established: 2007

Our Plants

4 JAIRAAJ GLOBAL RUDRAPUR Plant-4

Established: 2007

(Plastics Division):

Plot No. 105/1/1, MIDC

Waluj, Aurangabad

(Maharashtra)

3. JAIRAJ ANCILLARIES PVT LTD Aurangabad Plant

Established: 2016

Presentation : Energy Efficiency Measures

• Plastic Injection & Blow Moulded components

manufacturing

• Alongwith Sheet Metal, Machining & Turned Automotive &

Engineering Components and Assemblies

ISO/TS 16949:2009 Certified

Injection Moulding

Blow Moulding

Machinery Facility

Power Presses

- Mould designing - Tool Room- Injection Moulding- Blow Moulding- Machining - Plastic hot plate welding- Spin welding- Ultrasonic welding- Vibration welding

In House Facility

Dust Cover Maruti - 4 W Shocker Assembly

YJC frontYRA frontYP8 frontYAD Dust Cover

Automobile Parts

Oil Reservoir Assembly forDisc Brakes- Bajaj 3-W

Oil Reservoir Assembly for General Motors-4W (Car)

Guides Springs

Dust Covers forShocker Assembly

Valve Seals

Piston Rings

Our Products

Team for Energy Conservation

Energy Sources

Electricity Fuel

Water Compressed Air

Lighting

Process Flow Diagram

Third Party Audit Report

Dalkia Energy Services Ltd

Energy Consumption details

Pur Power80%

HSD Cost20%

Share of Electrical Power by Cost

Energy Cost Distribution (2011-12)

Particular Rs.(Lakh) % of Total

Grid -

Electricity33.17 79.86

Diesel -DG 8.37 20.14

Total 41.54 100.00

Energy Type HSDGrid

PowerTotal

Energy

consumption20800 Lt

622886

Energy in

KgOE20348.6 53568.2 73916.84

% Share in

KgOE27.53% 72.47% 100.00%

HSD28%

Grid Power72%

Share of Energy in KgOE

Production and Specific energy consumption

❖ Cost of raw material consumed during January to March is Rs. 72.68 Lakh

❖Cost of Energy during January to March is Rs. 9.22 Lakh

❖The total power consumed during January to March is 143.82 Mwh

❖The contribution of energy cost wrt cost of raw material is 12.69%

❖ The Specific Energy Consumption is 1.98 Mwh for every Rs one lakh cost of

raw material

Evaluation of DG SetDetails of DG Set

Sr. No. Parameters UOM D.G. No.1 D.G. No.2

1 Make

2 Rating KVA 125 125

3 Phase No. 3 3

4 Frequency Hz 50 50

5 Rated Voltage Volt 415 415

6 Rated Current Amp 174 174

7 Power Factor No. 0.8 0.8

8 Measured PF No. 0.78 0.81

9 Maximum Load KW 57.15 78.94

10 Average Load Kw 40.62 61.78

11 Loading factor % 71.08% 78.26%

12 Flue Gas TempoC 222 294

13 HSD Consumption Lt/Hr 18 18

14 SEC Kwh/Lt. 2.26 3.43

Cooling Tower Evaluation

CoolingTower

Cooling Tower Range oC 2.6

Cooling Tower Approach oC 3.5

Cooling Tower Effectiveness % 43.0

Heat loss in IM Machine

❖Observation

❖About two third of IM machine is having very low PF

❖Surface temperature of IM machine number 9 & 10 is inthe range of 48 to 58 Deg C which is satisfactory.

❖Surface temperature of rest of IM machine are requiredto be brought in the same range.

❖Sum of measured running load of twelve IM machine is50.71 Kw

❖Heat loss in the same set of machine is about 4.32KWh/Hr ( Except IM Machine number 9&10)

Heat loss in IM Machine

Lighting Evaluation❖ Lux Level

❖Maximum lux measured is 199 luman in Director Room. ❖Minimum lux Measured is 17 luman in gallery area.❖Av lux level is 67 luman

❖ LPD ❖Maximum LPD is 45.9 W/sq M in MD store ❖Minimum LPD is 1.7 W/sq M in conference room❖Av LPD is 9.1 W/sq M

❖ ILER value is less than 0.50 in almost all area of plant. Average ILER for complete plant is 0.27 which is not satisfactory and it require immediate attention.

❖ Lux level also need to be improved.

Load and Harmonic Profile

KW Profile

Ave. I THD

16/11/2012…

17/11/2012…

AVE.V THD

AS Per IEEE V THD & I THD should be less than 5%

Baseline Parameters❖The contribution of energy cost wrt cost of raw

material is 12.69%

❖ The Specific Energy Consumption is 1.98 Mwhfor every Rs one lakh cost of raw material

❖SFC of DG1 is 2.26 Kwh/Lt

❖SFC of DG 2 is 3.43 Kwh/lt

❖Present Av PF 0.94

❖Present av Voltage 257.7 V

❖Grid Power cost (variable) is Rs. 5.1 per unit.

❖HSD cost is Rs. 40.22 per litre.

EPIA1: Improvement in Power factor

Present Condition

• Present av. Power factor as shown in utility bill is 0.94

• Av Power during Measurement is 0.936

Proposed Scheme

• It is recommended to improve it to 0.99 by installing PF controller along with additional 25 KVAR capacitor Bank

Saving

• Minimum reduction in KVAh demand: 33457 kVAh per annum

• Monetary benefit: Rs. 170681 per annum

Assumptions

– It is based on last year KWh consumption

– Rate:Rs. 5.1 per KVah.

Avg. PF Measured

PF as in Utility Bill

EPIA-2: Voltage optimization for single phase load

Present Condition

❖Single phase connected load: 33.224 kW❖Single phase av. voltage: 257.7 V ❖Single phase Min voltage: 240.1 V ❖Single phase Max voltage: 271.9 V

VLN Ave.

❖Proposed Scheme❖Recommended single phase voltage: 210 volts❖Recommended to install servo stabilizer for single

phase load to maintain 210 volts. ❖Reduction in single phase voltage level: 18.52 %

❖Saving❖Reduction in KWH consumption: 67000 Kwh per

❖Saving in Rs. : Rs 328303.00 per annum

❖Assumption

❖Average working hour is 20 per day and 300 day in year and Rate: Rs. 5.1 per KVah.

EPIA-2: Voltage optimization for single phase load

EPIA-3: High Efficiency lighting system

Present ConditionPresently low efficacy lighting like Incandescent lamps and FTL 40 are in useProposed SchemeIt is recommended to change bulb to CFL and FTL 40 to T5 Saving

Present Wattage Proposed Wattage No of appliance Saving in KW

Bulb 100 W 100 CFL 23 77 2 0.154

FTL 40 W 54 T5 28 30 42 1.26

FTL 36 W 50 T5 28 30 17 0.51

FTL 20 W 32 T5 14 16 24 0.384

Total 2.308

Annual saving in Kwh 13848

Av Rate of Power 5.1

Saving in Rs per annum 70625.00

EPIA 4: Insulation of IM Machine❖ Present Condition❖ Presently most of machine are having surface temperature in the range of 88

Deg C to 180 Deg C❖ Total skin loss of measured IM machines is 3869 Kcal/Hr

❖ Proposed Scheme❖ It is recommended to insulate machine and bring the surface temperature in

the range of 50 deg C

❖ Saving❖ A saving of 3.5 Kwh/hr can be achieved resulting a saving of 20930 Kwh /

annum❖ Saving in Rs. is 1,06,774/annum

❖ Assumption❖ One kwh is equal to 860 Kcal❖ Unit rate Rs. 5.1/Kwh❖ Average working hour is 20 per day and 300 day in year

Roadmap for Energy conservation projects

S.No. EE Measure ImplementedYear 2014-15

Year 2015-16

Year 2016-17

Status

1Improvement of Power Factor

Done Completed

2Installation of high efficacy lighting

Done Completed

3Insulation of heater at all Injection Moulding Machines

Done Completed

Installation of chiller better cooling in Moulds and reduce cycle time 10 to 20%

Done Completed

5 Mould Modification Done on going

6Add Air Compressorwith Energy Efficient

Done Completed

7 Add Solar Power 15 KWA Done Completed

Energy Saving Check Points

Displayed WI for Energy saving

Improvement in Power Factorup to 0.99 / 1.0

Power Factor0.88

BEFORE AFTER

APFC Panel 180 KVAR added for Improving Power Factor for

annual saving of RS-170681.

BENEFITS :- Maintained the Power Factor up to 0.99 / 1.0

& resulting in Annual Saving of electricity bill Rs. 170681

Power Factor up to0.99 / 1.0

Without APFC Panel

Power Factornot use in DG set

BENEFITS :- Maintained the Power Factor up to 0.99 / 1.0 for efficiency

BEFORE AFTER

Power Factor maintained in DG set up to 0.99 / 1.0

Maintained the Power Factorup to 0.99 / 1.0 in DG Set

Daily Monitoring of Power Factor

Data of power factor is monitored on daily basis & circulated by Mail

POWER FACTOR AS ON DATE (MONTH OF August-2017) 0.99

Maintained the Power Factor up to 0.99 / 1.0April 2015 to as on till date

APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR

POWER FACTOR 0.99 0.99 0.99 0.99 0.99 0.99 0.99 0.99 0.99 0.98 0.99 0.99

0.99 0.99 0.99 0.99 0.99 0.99 0.99 0.99 0.99

0.99 0.99

PERIOD YEAR 2015- 16

POWER FACTOR 2015-16

POWER FACTOR

Maintained the Power Factor up to 0.99 / 1.0

Switch off appliances when not in use

5 & 18 Watt 40 Watt

AFTERBEFORE

LED / T5 Tube Light, Increase Lux Light (350 Lux) & Power saving

Lux Light (250 Lux)

General Tube Light 40 Watt

LED / T-5 Tube Light Installed

BENEFITS :- Annual saving and Improve Lux Light

Lighting arrangement as per Lux Light STD.

BEFOREAFTER

BENEFITS :- Improve / Maintained the Lux Light on Machines for Inspection

Replace refrigerator with Energystar ratings

AFTERBEFORE

Electricity consumption 299 Units / YearWithout star rating & Electricity consumption800 Units / Year

BENEFITS :- Annual saving units 500

Old Refrigerator

Replace all Air Conditioner withEnergy star ratings

AFTERBEFORE

Replace all Air Conditioner with Energy Higher star ratings

Without star rating

BENEFITS :- Annual saving

AFTERBEFORE

40 KVA DG set use for lighting load

BENEFITS :- Diesel / Fuel saving

Use 125 KVA DG set

Small DG set for Lighting use

Purchase Higher star rating / Energy Efficient Motors

Energy Efficient Motors mandatory

VFD Standard

VFD is MandatoryStandard or Retrofitted

VFD Standard

Spare Barrels added to save Mould/ Material Chabge settings

Use of Natural Daylight

Use of Natural Sunlight

Insulation of Heaters at all Injection Moulding Machines

BENEFITS :- The Insulation provides personnel safety, reduces barrel

energy losses by …from 35% to 65% and reduces the load on the plant air

conditioning system

Insulation of heaters at all Injection Moulding Machines

AFTERBEFORE

Gravitas / FSCURTIS Air Compressor

BENEFITS :- Air saving

Old Local Air Compressor

Replace Air Compressorwith Energy Efficient

AFTERBEFORE

Solar Power System 15 KWA

BENEFITS :- Increase Load & Solar power systems have reduce

office electric bill.

Solar Power System 2 KWA

Utilisation of renewable energy sources (Solar Power Project)

Annual Sale v/s Energy Cost

200.00

400.00

600.00

800.00

1000.00

1200.00

1400.00

1600.00

2014-15 2015-16 2016-17

ANNUAL SALES 1517.53 1369.14 1562.06

ENERGY COST 4.36 5.03 4.21

1517.531369.14

1562.06

4.36 5.03 4.21

PERIOD

ANNUAL BASIC SALES V/S ENERGY COST

ANNUAL SALES ENERGY COST

Part NameMachine

Capacity

No. of

Cavity

Hourly

production

Production per

Shift (Nos)

% Improvement in

Productivity /Shift

BEFOREPiston Ring 60 Ton 8 18 1600 19200

Piston Ring Dia 38.5 15 Ton 1 35 103 1234

Inspection Plug seal 15 Ton 2 18 400 4800

Raching Step 15 Ton 2 22 327 3927

ORA Black Cap 60 Ton 1 35 103 1234

AFTERPiston Ring 60 Ton 16 20 2880 34560 80

Piston Ring Dia 38.5 15 Ton 4 30 480 5760 367

Inspection Plug seal 15 Ton 4 18 800 9600 100

Raching Step 15 Ton 4 22 655 7855 100

ORA Black Cap 60 Ton 8 35 823 9874 700

Summary of Energy Savings through Mould Modification

S. NO. Mould Name Project DescriptionMachine Capacity

RemarksBefore After

1 Piston Ring Convert 8 Cavity to 16 Cavity 60 Ton 60 Ton Improvement in productivity

2 Piston Ring Dia 38.5 Convert 1 Cavity to 4 Cavity 15 Ton 15 Ton Improvement in productivity

3 Inspection Plug seal Convert 2 Cavity to 4 Cavity 15 Ton 15 Ton Improvement in productivity

4 Raching Step Convert 2 Cavity to 4 Cavity 15 Ton 15 Ton Improvement in productivity

5 ORA Black Cap Convert 1 Cavity to 8 Cavity 60 Ton 60 Ton Improvement in productivity

Energy Saving through Mould Modification

Manufacturing cost reduction : Development of Multi Cavities Moulds

Piston Ring

Piston Ring Dia 38.5

Inspection Plug seal

Raching Step

ORA Black Cap

Best Suggestion & PerformanceAward- Energy saving

Energy saving awards

Chiller for better cooling in Moulds

❖ INSTALLATION OF TWO CHILLER’S FOR BETTER COOLING IN MOULDS AND CYCLE TIME REDUCE

Chiller for Better Cooling

BENEFITS :- Installation of chiller better cooling in Moulds and reduce

cycle time 10% to 20%

Rain Water Harvesting

❖ RAIN WATER HARVESTING PROVIDED

Collected of water from the roofs of buildings & surfaces on which rain falls and stored in rainwater tanks.

Energy Efficiency Measures : Actual Investment v/s Saving

Total annual Saving Rs. 13.69 Lakhs

S.No. EE Measure Implemented Status Investment (in Lakh Rs)

Energy Annual Savings(In Lakh Rs.)

1Improvement of Power Factor

Completed 1.81 1.7

2Installation of high efficacy lighting

Completed 0.33 1.05

3Insulation of heater at all Injection Moulding Machines

Completed 1.2 2.19

Installation of chillerbetter cooling in Moulds and reduce cycle time 10% to 20%

Completed 1.2 2.8

5 Mould Modification Completed 8.4 5.95

Total 12.94 13.69

ZERO PPM Award: 8 June 2017

JaiRaj Plant-1 / JPPL : Awarded excellent performance in achieving

Quality & Delivery targets from Gabriel India Ltd. (Gurgaon).

100% Delivery Performance Award: 8 June 2017

JaiRaj Plant-1 / JPPL : Awarded excellent performance in achieving

Quality & Delivery targets from Gabriel India Ltd. (Gurgaon).

Exceptional Response to New Developments

Award: 21 July 2017

JaiRaj Plant-1 / JPPL : Awarded for Response to New Developments

from Gabriel India Ltd.

State Award for JaiRaj

JaiRaj Plant-1 Awarded State-level Second Prize, Trophy and Rs.50,000

from Govt. of Haryana for Energy Conservation in Small Industry Category

• “Best Supplier Award”

• “Best Vendor Award

• “Star Performer Trophy and Award”

• “High Performance”

Awards & Accolades

• Member of the “CII Cluster Development Progamme”conducted by L.M. Thapar Center for Competitiveness.

• Member of the “Factory Improvement Programme”conducted by ILO

• Member of lean Manufacturing Cluster

Striving for best manufacturing practices

Enlightened by knowledge

Supported by technology

Strengthened by our team

Encouraged by our bankers

Governed by business ethics

Passionate towards environment

Committed to social responsibility

Trusted by our customers.

FOUNDING PRINCIPLES

50+ Awareness Sessions on Energy Efficiency

1000+ Walkthrough Audits

400 DPRs and Audits

400 MSMEs made Energy Efficient

LED THE WORLD BANK FUNDED GEF PROJECT IN FARIDABAD AS CLUSTER COORDINATOR

Awakening

Solution Finding

Resource Mobilization

Campaign

Challenges

Implementation

Awakening

Losses identified

through Efficiency

drop upon repair/

rewinding of Motors

Rs.1.5 lakh per month

Rs.18.0 lakh per

annuum

Awakening

Losses identified

through Efficiency

drop upon repair/

rewinding of Motors

Rs.1.5 lakh per

Rs.18.0 lakh per

annuum

Solution Finding

Setting up of World

“Motor Knowledge Centre”

One Stop Centre for

Repair, Rewinding &

Testing

Skill Development for

Electricians & Motor

Rewinders

Resource

Mobilization

Cost of Testing Centre:

Rs.1.0 Cr

Cost of Repair &

Rewinding Centre: Rs.1.5

UNLEASHING THE POWER OF COLLECTIVE GROWTH

Creation of a Cluster

Campaign

Road Shows

Series of Meetings

The World Bank

RESULTS

The World Bank…

Rs.30 lakh Grant for

Testing Centre

BEE…

Supporting Partner

Challenge

Repair/ Rewinding Facility..?

Bridge the Huge Gap in Resources

Create Mobile Facility

New SME Law

If anything goes wrong,

Fix it!

(To hell with Murphy)

New Support

Govt. of Haryana steps in

Grants Rs.1.80 crore

Entrepreneurs contributing

Rs.50 lakh

Centre of

Excellence for

Electric Motors

Faridabad

Active wear, Sports wear,

Yoga wear…

1. Responsible Cotton

2. Recycled PET

IAmNewIndia

I am New India

Entrepreneur

I decide

NOT just to raise

Problems

But Find or Create

Solutions.

ENERGY EFFICIENCY

is our commitment!

Can we foreseegreenbusinesscentre.com/energyaward2017presentation… · · 2017-09-07(India) B-22...

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