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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
Kwh*
Energy in
KgOE20348.6 53568.2 73916.84
% Share in
KgOE27.53% 72.47% 100.00%
HSD28%
Grid Power72%
Share of Energy in KgOE
Third Party Audit Report
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
Third Party Audit Report
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
Third Party Audit Report
Cooling Tower Evaluation
CoolingTower
Cooling Tower Range oC 2.6
Cooling Tower Approach oC 3.5
Cooling Tower Effectiveness % 43.0
Third Party Audit Report
Heat loss in IM Machine
Third Party Audit Report
❖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
Third Party Audit Report
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.
Third Party Audit Report
Load and Harmonic Profile
0.0
50.0
100.0
150.0
KW Profile
0.0
20.0
40.0
60.0
Ave. I THD
0.0
1.0
2.0
3.0
4.0
5.0
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AVE.V THD
AS Per IEEE V THD & I THD should be less than 5%
Third Party Audit Report
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.
Third Party Audit Report
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.
-1.50
-1.00
-0.50
0.00
0.50
1.00
1.50
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Axi
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tle
Avg. PF Measured
0.86
0.88
0.90
0.92
0.94
0.96
0.98
1.00
PF as in Utility Bill
PF
Third Party Audit Report
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
220
230
240
250
260
270
280
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VLN Ave.
Third Party Audit Report
❖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
annum
❖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
Third Party Audit Report
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
Third Party Audit Report
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
4
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
0.974
0.976
0.978
0.98
0.982
0.984
0.986
0.988
0.99
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
0.98
0.99 0.99
VA
LUE
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
0.00
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
VA
LUE
IN IN
R (
LAK
H)
PERIOD
ANNUAL BASIC SALES V/S ENERGY COST
ANNUAL SALES ENERGY COST
Part NameMachine
Capacity
No. of
Cavity
Cycle
Time
(Sec)
Hourly
production
(Nos)
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
4
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
month
Rs.18.0 lakh per
annuum
Solution Finding
Setting up of World
Class
“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
Cr
UNLEASHING THE POWER OF COLLECTIVE GROWTH
Creation of a Cluster
Campaign
Road Shows
Series of Meetings
SIDBI
The World Bank
BEE
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!
