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Energy Efficiency
Best Practices
Handbook for
SMEs
Energy Efficiency in
Rice Mill Sector
Project Supported and
Implemented By REEEP and The
Alliance to Save Energy
Acknowledgement:
The Alliance to Save Energy is thankful to the Renewable Energy and Energy Efficiency
Partnership (REEEP) for giving an opportunity to conduct the feasibility study on “Increasing
Energy Efficiency SMEs through Innovative financing and carbon trading mechanism”. We are
expressing our sincere gratitude to all the concerned officials for their support and guidance
during the project.
The project team is thankful to “Sivagangai District Rice Mill Owners Association, Puduvayal” for
their support and active participation during the project implementation. We take this
opportunity to express our appreciation for the excellent support provided by various rice mill
owners. We are grateful for their co-operation extended during the project period..
Rice Mills & Association
Mr. Periasamy - Proprietor Malar Modern Rice mill
Mr. Karthik - Proprietor, Tamanian Modern Rice Mill
Mr.Subramaniam - Proprietor, Sri Naruvizhi Ambal Modern Rice Mill
Mr. Vellaisamy - Proprietor, Muthuraja Modern Rice Mill
Mr. Jamal Ahmed - Proprietor, Rahmania Modern Rice Mill
Alliance is also thankful to all the rice mill owners and employees as mentioned above with
whom the project team worked closely during the project period.
Alliance to Save Energy
Disclaimer:
The findings, interpretations, and views expressed herein are those of the authors and do not
necessarily reflect the views of the REEEP or other agencies or individuals. We have taken due
care and caution in compilation of data as has been obtained from various sources including
which it considers reliable. However, we do not guarantee the accuracy, adequacy or
completeness of any information and it is not responsible for errors or omissions or for the
results obtained from the use of such information and especially states that it has no financial
liability whatsoever to the subscribers/users of this report.
We as the project team encourages use and distribution of our reports and publications.
Content from this document may be used freely and copied accurately into other formats
without prior permission, provided that clear attribution is given to the original source, and that
content is not used for commercial purposes.
Abbreviations:
MSME Micro, Small and Medium Enterprises
BEE Bureau of Energy Efficiency
ECM Energy Conservation Measure
GDP Gross Domestic Product
IGA Investment Grade Energy Audit
SEC Specific Energy Consumption
EMC Equilibrium Moisture Content
RH Relative humidity
EE Energy Efficiency
GHGs Green House Gasses
FCI Food Corporation of India
SEB State Electricity Board
DGs Diesel Generators `
TPD Tones Per Day
MC Moisture content
mmWC Millimeter Water column
FAD Free Air Delivery
kWh Kilo Watt Hour
kVA Kilo Volt Amperes
kVAr Kilo Volt Amperes Reactive
BAU Business as Usual
MWh Mega Watt Hour
Rice Mill Sector – An Overview
Background:
Rice is one of the principal dominant food crops in India, In India majority of the farm lands in
India having been used to grow rice. India's annual rice production is average around 85-90
million tons and annual consumption is around 85 million tons. India is one of the largest rice
producers in the world, accounting for approximately 20% of world rice production. In India,
rice is cultivated in both seasons - winter and summer. West Bengal, Uttar Pradesh, Andhra
Pradesh, Punjab, Tamil Nadu, Bihar, Orissa, Assam, Karnataka and Haryana are the major
producing states. More than 50% of total production comes from the first four states. Food
Corporation of India (FCI) purchases around 20 to 25% of the total rice production in the
country both under levy from the rice mills and directly in the form of paddy from the farmers
at minimum support prices fixed by the Government. More than 4000 varieties of rice are being
grown in India.
Figure 1: Rice Production in India in typical years
Paddy processing and rice production is became an important agro processing industry in India,
processing over one-fifths of world rice. In India, there are around 33,000 rice mills to process
the paddy and majority of the Indian rice mills fall under the category of SME sector. These rice
mills are located near the paddy growing belts. Broad state-wise details of rice mill clusters in
India are given in the Table 1 and also shown on the map in following pages.
20.58
34.58
42.22
53.63
74.29
82.5486.08
89.6884.98
93.0894.2
0
10
20
30
40
50
60
70
80
90
100
Ric
e P
rod
uct
ion
in
(M
Ts)
TYpical years
Table 1: Major rice mill clusters in India
Name of clusters State
No. of Units in
Cluster
East Godavari, Vijayawada, West Godavari,
Nizamabad, Nalgonda Andhra Pradesh 12,500
Kaithal, Karnal, Kurukshetra Haryana 400
Shimoga Karnataka 3,800
Scattered across state Madhya Pradesh 1,200
Cuttack, Sambalpur, Balangir, Koraput Orissa 800
Bhandara, Chandrapur, Gadchiroli, Gondiya Maharastra 1,400
Amritsar, Kapurthala, Ferozpur, Faridkot Punjab 500
Madurai, Thanjavur, Puduvayal Tamil Nadu 3,500
Muzaffarnagar, Saharanpur, Rudrapur Uttar Pradesh 1,400
Source: World bank and Winrock Analysis on SME clusters in India
Amritsar
Kapurthala
Ferozepur
Faridkot
Kurukshetra
Kaithal
Karnal Muzaffernagar
Cuttack
Rudarpur
Sambalpur
Bhandera
Chandrapur
Nizamabad
Shimoga Krishna West Godavari
Koraput
East Godavari
Balangin
Gadchiroli
Madurai Thangavur
Gondia
REEEP and the Alliance to Save Energy Program
The Alliance had implemented a Small and Medium Enterprise (SME) Energy Efficiency project
in India supported by the Renewable Energy and Energy Efficiency Partnership (REEEP). The
project objective was to improve the energy efficiency of Indian rice mill units through
developing innovative procurement and financing mechanism.
The Alliance had partnered with Puduvayal Rice mill
cluster in Tamil Nadu to do a feasibility analysis to
implement energy conservation measures (ECMs)
using Innovative procurement, financing and carbon
trading mechanism. Five pilot Investment Grade
Energy Audit (IGA) studies were conducted in the
cluster; the study shows savings potential up-to 20-
30% by implementing EE measures and adopting
best operational practices. To assess the wider applicability of common ECMs in the cluster, an
equipment audit study was conducted in additional 26 small and big sizes mill in the cluster. It
was observed that 70–80% of the EE measures identified during IGA study are applicable to
other mills in the cluster.
Discussions with the mill owners reveal that the majority of the owners were convinced that EE
retrofits can achieve significant energy cost savings, but they lacked confidence in investing in
EE projects.
The other main objectives of this project were to explore innovative financing options to
procure energy efficient equipments. To boost the confidence and decision making abilities of
the mill owners, the Alliance organized a demonstration project of energy saving measures at
one of the selected mill. One of the key findings of the audit study was the application of
variable frequency drives (VFD), which regulate the volume of air moved at the boiler ID fan to
match the actual demand.
The successful demonstration of VFD application has strengthened the confidence of the mill
owners in the cluster. The other major findings of the demonstration exercise were reduction in
the broken quantity of the rice as a result of regulated and controlled operations. The dual
benefits; 1) reduction in the operational cost and 2) reduction the broken rice percentage was
eye opening for the mill owner.
Puduvayal Rice mill C
Overview:
Puduvayal is situated in the Sivagangai district in Tamil Nadu, one of the leading rice production
belt in Tamil Nadu. The rice mill industry in Puduvayal is more than three decades old. It is
estimated that there are around 90
are in Puduvayal. These rice mills contributes significant share of
These rice mill owners have recently formed the association
Owners and Paddy, Rice Merchants Association. These units are in operation since last 20
years and most of rice mills are family ow
The major machineries in operations are rubber shellers, polishers, dryers, whiteners, boilers,
elevators, air compressors, motors, etc which are operated
State Electricity Board (SEB).
to run the units during the power cut. Main fuels used in the cluster are rice husk and wood.
Rice husk is used in boilers as a fuel to produce steam which is required for different process in
parboiled rice mills.
Classification of Rice Mills
Rice mills in Puduvayal Rice mill
capacity (Tons/day) and type of boiler used.
Classification based on paddy processing
Rice mills in Puduvayal cluster
The following figure shows the percentage of
processed per day.
Figure 2: Percentage distribution of
processed per day
32%
13%
< 20 TPD of Paddy 20-50 TPD of paddy >50 TPD of paddy
Rice mill Cluster, Tamil Nadu
Puduvayal is situated in the Sivagangai district in Tamil Nadu, one of the leading rice production
The rice mill industry in Puduvayal is more than three decades old. It is
estimated that there are around 90-120 units in Sivagangai district and almost a
hese rice mills contributes significant share of rice export from Tamil Nadu.
These rice mill owners have recently formed the association known Sivagangai District Rice Mill
Owners and Paddy, Rice Merchants Association. These units are in operation since last 20
years and most of rice mills are family owned.
The major machineries in operations are rubber shellers, polishers, dryers, whiteners, boilers,
elevators, air compressors, motors, etc which are operated through grid power supply
State Electricity Board (SEB). A few of the large size mill owners also have diesel generator set
power cut. Main fuels used in the cluster are rice husk and wood.
ice husk is used in boilers as a fuel to produce steam which is required for different process in
lassification of Rice Mills:
Rice mills in Puduvayal Rice mill cluster are broadly classified based on paddy processing
capacity (Tons/day) and type of boiler used.
paddy processing capacity
luster are classified based on the capacity of paddy processed per day.
The following figure shows the percentage of rice mills in cluster based on capacity of paddy
Percentage distribution of rice mil units in Puduvayal rice mill cluster based on tons of paddy
55%
>50 TPD of paddy
Puduvayal is situated in the Sivagangai district in Tamil Nadu, one of the leading rice production
The rice mill industry in Puduvayal is more than three decades old. It is
120 units in Sivagangai district and almost around 80 units
export from Tamil Nadu.
Sivagangai District Rice Mill
Owners and Paddy, Rice Merchants Association. These units are in operation since last 20-30
The major machineries in operations are rubber shellers, polishers, dryers, whiteners, boilers,
through grid power supply from the
owners also have diesel generator set
power cut. Main fuels used in the cluster are rice husk and wood.
ice husk is used in boilers as a fuel to produce steam which is required for different process in
classified based on paddy processing
based on the capacity of paddy processed per day.
in cluster based on capacity of paddy
cluster based on tons of paddy
From the above figure it is clear that, majority of the rice mills in cluster
Day (TPD).
Classification based on type of boiler used
In Puduvayal rice mill cluster conventional an
Figure 3: Percentage distribution of Rice mill cluster break up based on type of boiler used
From the above figure it is clear that 70% of rice mills in the cluster are using conventional
boiler and only 30% of the rice mills are using high pressure boiler for the par boiling process.
Rice mills using conventional boiler are having conventional wo
after parboiling.
From the above figure it is clear that, majority of the rice mills in cluster are
Classification based on type of boiler used
In Puduvayal rice mill cluster conventional and high pressure boilers are in use for steam
Percentage distribution of Rice mill cluster break up based on type of boiler used
From the above figure it is clear that 70% of rice mills in the cluster are using conventional
rice mills are using high pressure boiler for the par boiling process.
Rice mills using conventional boiler are having conventional wood fired dryer to dry the paddy
70%
30%
Rice mills with conventional Boiler
Ricemills with High pressure Boiler
are under <20 Tons Per
are in use for steam generation.
Percentage distribution of Rice mill cluster break up based on type of boiler used
From the above figure it is clear that 70% of rice mills in the cluster are using conventional
rice mills are using high pressure boiler for the par boiling process.
od fired dryer to dry the paddy
Production Process in Typical Rice Mill
Paddy is fed manually to the paddy silo, which takes the paddy to the pre-cleaning section
where dust, grit, dry leaves and straw is removed. The pre-cleaned paddy is then stored in an
overhead reservoir. The reservoir diverts the paddy to the parboiling silos, where paddy is
Electrical Energy Thermal Energy
Par boiling (Direct steam injection
Thermal Energy
Thermal Energy
Electrical Energy
Electrical Energy
Paddy procurement
Paddy soaking
Paddy Drying (Indirect heating)
Paddy destoning
Powder and Bran removal
Polishing
Grading & color Sorting
Paddy Cleaning
Electrical Energy
Electrical Energy
Energy consuming process
Packing and dispatch
Electrical Energy
soaked in hot water (85-90oC), for 8-12 hours. The soaking time depends on the moisture
content of the paddy i.e. in summers; the soaking time is 10-14 hours, whereas in winters, the
soaking time decreases to 6-8 hours. During soaking, the hot water is re-circulated in the tank
after every 2-3 hours, to maintain uniform temperature within the silo. After soaking, the water
from the silos is discharged and steam is passed in the paddy for 10-12 minutes. The parboiled
and steamed paddy is then dried by using mechanical driers. The dried paddy is again passed
through a secondary cleaning system to remove the other particles. The cleaned paddy is de-
husked in huller mill with the help of rubber roll hullers. The husk thus separated is either sold
or sent to the boiler section for use as fuel. De-husked paddy is passed through table separators
and then to polishing section. In the polishing section the thick brown layer of the paddy is
removed with polishers/whiteners. The polished rice is then passed through sieves to remove
broken. The unbroken polished rice finally passes through sorters to remove discolored rice and
then sent for packaging.
Energy Consumption in T
The energy consumption (thermal & electrical energy) in typical rice mill in cluster depends on
capacity of the mill and type of the machineries
through the grid and thermal
thermal energy consumption of ri
Table 2: Average annual energy consumption
Tones of Paddy
Process/Day
Annual e
energy consumption
(Lakhs kWh
<20 TPD 1.33
20 - 50 TPD 2.2
>50 TPD 5.5
Source: The Alliance assessment and
Energy Consumption Profile
The major energy consuming areas in
the chart below.
22%
Drying Parboiling
gy Consumption in Typical Rice Mill
nergy consumption (thermal & electrical energy) in typical rice mill in cluster depends on
capacity of the mill and type of the machineries in operations. Electrical energy is supplied
grid and thermal energy is supplied by wood and rice husk.
thermal energy consumption of rice mill units is shown below for quick reference
verage annual energy consumption typical rice mill in of different capacities in
Annual electrical
energy consumption
Lakhs kWh)
Annual rice husk
generation (Tons)
Annual rice
consumption
1.33 1350 1012
2.2 3000 2250
5.5 6000 6000
assessment and analysis study in Puduvayal rice mill cluster
Energy Consumption Profile – Process wise
The major energy consuming areas in paddy processing are parboiling, drying and
67%
9%
2%
Parboiling Milling Other utilities
nergy consumption (thermal & electrical energy) in typical rice mill in cluster depends on
lectrical energy is supplied
. Annual electrical and
for quick reference:
of different capacities in cluster
ice husk
consumption (Tons)
Annual
wood
consumpti
on (Tons)
1012 450
2250 750
6000 N.A
cluster
are parboiling, drying and milling as shown in
Utilization of Electrical Energy Consumption:
Utilization of Thermal Energy Consumption:
Utilization of Electrical Energy Consumption:
Utilization of Thermal Energy Consumption:
Facts on Energy saving potential in steam systems
• 22°C reduction in the flue gas temperature reduces the fuel consumption by 1%
• 1 mm thick scale (deposit) on the water side of boiler could increase fuel consumption
by 5 to 8%
• Every 6 °C rise in feed water temperature by heat recovery or condensate recovery
corresponds to a 1% saving in fuel consumption in the boiler
source: BEE book on thermal utilities
Energy Efficiency Best Practices in Rice Mill Sector
Parboiling
Parboiling involves increasing the moisture content of the grain by 25-30% and then steaming
to gelatinize the starch in it. Operations involved in this section are soaking and steaming.
Steam is being used as a main source of energy for the process of soaking and steaming
operation to increase the moisture content of paddy.
One of the key sources of energy in rice mill processing is steam which is used for boiling and
drying purposes. Energy can be saved both in steam generation and distribution through some
simple measures as mentioned below.
Optimize Excess Air Intake to Boiler: Excess air is the quantity of air in addition to the
theoretical quantity required for 100% fuel combustion. Recommended excess air and O2 levels
for various fuels are mentioned in below table.
Table 3: Recommended O2 and excess air levels for various fuels
Fuel Recommended O2 level in flue gas
(%)
Recommended excess air (%)
Wood/Bio mass 4-5 20-25
Bagasse/Rice husk 5-7 25-35
Diesel 2-3 10-15
Source: BEE book on energy efficiency in thermal utilities
Most of the times combustion processes in boiler/furnace are not efficient due to lack of
required adequate air quantity. The colour of smoke coming out of the boiler chimney indicates
combustion efficiency, brown hazy colour indicates proper combustion; black colour indicates
incomplete combustion; and colourless or white smoke shows high excess air quantity as
shown in Figure below.
Figure 4 : Flue gas colour during different combustion
Source: SIDBI booklet on fruit and vegetable processing industry
� Air supply systems designed in majority of boilers are over designed, 5 % reduction in excess
air quantity (above the recommended excess air percentage) increases the boiler efficiency
by 1%. Similarly, 1% reduction of residual oxygen in the flue gas reduces fuel consumption
by 1%1.
� Analyze flue gas regularly by using portable flue gas analyzer. The parameters to be checked
are O2 (oxygen), CO (carbon monoxide), and flue gas temperature in flue gas
� It recommended that always operate the boiler close to design pressure
� Clean regularly for scale and sediment on the water side of boiler, this will increase the heat
transfer efficiency in boiler
� It is advisable to periodically clean the deposited soot, fly ash, and slag on the fire side
boiler to increase the heat transfer efficiency of the boiler
� Always preheat boiler feed water to reduce the boiler fuel consumption
� It is recommended that insulate all steam and condensate pipes, condensate and hot water
tanks with adequate insulation with respect of temperature and size of pipe as indicated in
below table.
1 BEE Book on energy efficiency in thermal utilities
Table 4: Indicative thickness (in mm) for mineral wool insulation for various steam pipe sizes
Temperature (deg C) 1 inch diameter 2 inch diameter 4-inch diameter
Up to100 25 40 65
100-150 40 50 75
150-200 50 65 100
200-250 65 75 125
Source: BEE book on energy efficiency in thermal utilities
� It is recommended that all insulated surfaces are cladded with aluminium sheet or suitable
material to avoid heat loss.
� For all indirect steam heating, it’s recommended to use steam at the lowest acceptable
pressure, since the latent heat of steam at lower pressure is higher;
� In the direct steaming process heat transfer will depend on the size of the steam bubble. To
ensure that the steam bubble is completely condensed, the surface area/volume ratio must
be as large as possible. Smaller bubbles have a greater surface area per unit volume than
larger bubbles, so it is desirable to produce very small bubbles for complete heat transfer;
� Dryness of steam- It is recommended to install the steam water separator in the steam
distribution network, because steam from the boiler carries moisture along with it, this
could be because the demand for steam is higher than the generating capacity of the boiler
and as steam travels through the distribution network additional condensation is
continuously taking place. Presence of water droplets in steam reduces the actual enthalpy
of evaporation, and also leads to the formation of scale on the pipe walls and heat transfer
surface
� It is recommended to install steam lines with a gradual fall in the direction of flow, and with
drain points installed at regular intervals and at low points
� It is recommended to install check valves after all steam traps which would otherwise allow
condensate to run back into the steam line or plant during shutdown
Piping and Tapping Connections
� It is advisable to take the steam branch line from
the top of the main stream line to avoid the debris
and condensate in the branch line. Wet and dirt
steam reaching the equipment, which will affect the
performance in both the short and long term.
� It is recommended that steam off take valve should
be positioned as near to the utilization point to
minimize condensate always accumulate on the
upstream side of the closed valve, and then be propelled forward with the steam when the
valve opens again -consequently a drain point with a steam trap set is good practice just
prior to the strainer and control valve.
Drying Process:
During harvesting the rice grain contains lot of moisture. More moisture contents in grain cause
natural respiration in the grain that effects deterioration of the rice. In addition the high
moisture attracts insects and molds that are harmful to the grain. High moisture in grain also
lowers the germination rate of rice.
Following are best practices that can be adapted in dryer system for saving energy and to
improve the quality of rice. As even short term storage of high moisture paddy rice can cause
quality deterioration.
The following table shows the recommended moisture content (MC) for storage of paddy grain,
and potential problems when the moisture content exceeds recommended limits:
Table 5: Moisture contents required for safe storage for different storage periods
Storage period Required MC for safe
storage
Potential problems
2 to 3 weeks 14 - 18% Molds, discoloration, respiration
loss
8 to 12 months 13% or less Insect damage
More than 1 year 9 % or less Loss of viability
Source: International rice research institute training manual on Paddy drying
Effect of Moisture Content
In storage, the final moisture content of paddy depends on the temperature and relative
humidity of the air that surrounds the grain. The final grain moisture content resulting from
storage is called the ‘equilibrium moisture content’ or EMC. The following table shows the
EMC of paddy under different storage conditions. The underlined & colored areas represent the
desirable environmental conditions for storage of paddy for food purposes in the tropics.
Source: International rice research institute training manual on Paddy drying
For example, at 77% relative humidity and 32ºC air temperature; paddy will attain 13.9%
moisture content (shown in red in the table above) that is safe for storage. If at the same
temperature, the relative humidity rises to 85% or higher, grain exposed to the ambient air over
time will reach an equilibrium moisture content of approximately 15.5% (shown in blue in the
table above) making the grain prone to quality deterioration.
� It is recommended to operate the dryer at the rated or near the design capacity.
� It is recommended to clean the grain by removing other foreign particles before loading of
paddy into dryer. Foreign particles moving in dryer will reduce the airflow through paddy
this will causes increase in drying time and wet spots
� It is advisable not to mix dry paddy with the wet paddy in dryer.
� Monitor the drying air temperature, especially when drying seeds, to avoid heat stress that
can cause cracking and to ensure the viability of the seeds
� Monitor the moisture content and stop the drying process at the desired MC.
� Monitor the moisture content of the paddy throughout the cycle of drying
� It is recommended to monitor the number of working hours of the dryer fans
Milling section
Rice milling is the process of removing the husk and bran layer to produce white rice. The
milling process includes pre cleaning, shelling, polishing, sieving and de-stoning. Equipment
such as hullers, centrifugal shellers and rubber roll shellers are used for de-husking and
equipments such as emery and cone polishers are used for polishing. The following are the best
practices to operate milling system efficiently;
� It is advisable to operate the milling section equipments close to the rated capacity
� It is advisable the monitor the following operational parameters in milling section:
o Quantify the material going and coming out of a equipment
o Monitor amperage of motor (milling machine and fans)
o Monitor equipment running hours
Electrical Utilities - Air Compressor
Compressed air is very expensive to produce, because only 10-30% of the input energy of the
compressor reaches the point of end use and balance 70 – 90% of input energy of compressor
being converted to unusable heat energy and to a lesser extent lost in form of friction, misuse
and noise. In rice mills compressed air will consume significant amount of electrical energy
consumption. By adopting simple and cost effective measures mill owners can save significant
Facts on Energy saving potential in Compressed air system
• Every 4°C rise in inlet air temperature results in a higher energy consumption by 1 % to
achieve equivalent output
• Increase of 1 Kg/cm2 air discharge pressure (above the desired) from the compressor would
result in about 4-5% increase in input power. This will also increase compressed air leakage
rates roughly by 10%
• Twice the pressure requirement means it will add the four times the energy cost
• Typical acceptable pressure drop in industrial practice is 0.3 bar in mains header at the
farthest point and 0.5 bar in distribution system
source: BEE book on Electrical utilities
•
amount of energy and cost in compressed air systems. Following practices can be followed for
efficient operation compressed air system.
� It is recommended to place the compressor in such a way that, it is always draw cool
ambient and dust free air from outside. Effect of inlet air temperature and effect of energy
consumption in compressor is presented in table below.
Table 6: Effect of inlet air temperature on power consumption
Inlet temperature (Deg C) Relative air delivery (%) Power Saved (%)
10.0 102.0 +1.4
15.5 100 Nil
21.1 98.1 -1.3
26.6 96.3 -2.5
32.2 94.1 -4.0
37.7 92.8 -5.0
43.3 91.2 -5.8
Source: BEE guide books on energy efficiency in electrical utilities
� It is advisable not to keep compressor near the heat sources; such as boilers, dryers and
other heat radiating equipments
Facts on energy saving potential in
Electrical system
• Maximum efficiency of a distribution
transformer is at 32-35% load of its full load
capacity
• For 1% increase in unbalance in voltages will
lead to reduction in 1% of motor efficiency
• 10 % Imbalance in voltage at motor terminal
can increase 3 - 5% in motor input power
• For every rewind of motor efficiency will
drops by 2%
• Life cost of a motor is often over 100 times
the purchase cost
• For every 10deg C drop in inlet air
temperature in DG set will lead to 2% of fuel
savings
source: BEE book on Electrical utilities
� Moisture content in the inlet air to the compressor will affects the performance of
compressor. It is recommended not to place the compressor near to cooling towers and
dryer exhaust. Moisture content in the surrounding air of these equipments has more
moisture content than ambient conditions.
� Always clearly understand the compressed air pressure requirements of particular
application/ equipment. It is recommended that not to use the high pressurized
compressed air to low pressure compressed air applications.
� If the process required two different pressure range then it is advisable to generate low
pressure and high-pressure air separately, and feed to the respective sections instead of
reducing the pressure through pressure reducing valves, which invariably waste energy;
� Keep the minimum possible range between loads and unload pressure settings;
� It is advisable that all the compressed air piping should be laid out in such a way that it
minimizes pressure drops during transmission;
� It is recommended to clean air intake filters in regular intervals to facilitate clean air intake
of compressor and low pressure drop across it;
� It is recommended to install moisture separators to get rid of any moisture in the system
before the compressed air reaches the pneumatic equipment;
� It is recommended to conduct free air delivery test (FAD) periodically to check the present
operating capacity against its design capacity;
� It is recommended that leakage test should be
conducted monthly once, to remove air leaks in
the compressed air system and to reduce the
energy wastage;
� Minimize low-load compressor operation; if air
demand is less than 50 percent of compressor
capacity, consider change over to a smaller
compressor or reduce compressor speed
appropriately (by reducing motor pulley size) in
case of belt driven compressors.
Electrical Distribution System
� Control the maximum demand by auto-tripping
of the non-critical loads through demand
controller. This will avoid the penalty due to
excess demand usage than the sanctioned
� It is recommended to stagger the non-critical
load and shift to the off peak times if possible
according to the electricity tariff to reduce electrical energy bill;
� Maintain the power factor at the main feeder greater than 0.9 to avoid penalty and further
improve it to above 0.95 to avail the rebate. The benefits of higher power factor will lead to
reduce demand, better voltage, high system efficiency and rebate from the electricity
supplying company;
� It is recommended to install automatic power factor relay for effective power factor
management;
� It is recommended to Install capacitor at the load end to have the benefit of reduced
distribution loss (line losses, and cable loading;
� Transformers are normally designed to operate at maximum efficiency between loadings of
35% to 40% of its full capacity depending upon the size of the transformer. If the load on
the transformer increases beyond its rated loading parameters, it is advisable to go for a
new or bigger transformer to avoid transformer losses.
� It is recommended to balance system voltage, to reduce the distribution losses in the
system;
� Minimize losses in distribution system due to weak links in distribution network such as
jumpers, loose contacts and old brittle conductors;
Motors
� Motor run most efficiently near their designed conditions, it is recommended to operate
motor between 75 -100 percent of full load rating. Oversized motors would result in
unnecessary energy wastage due to poor efficiency and power factor. If motor is
continuously running below 45% of its design load, it is recommended to reconfigure the
motor delta to star connection or by installing delta star converter. This measure will give
energy savings of up to 10%.
� It is recommended to replace the existing old motors with energy efficient motor;
� Proper voltage balance supply is essential for achieving rated performance of a motor.
Unbalanced three-phase voltage affects a motor's current, speed, torque and temperature
rise. Equal loads on all three phases of electric service help assure voltage balance while
minimizing voltage losses. voltage unbalance will probably leads to power factor problem
and extremely high current which results in leads to overheating and premature motor
failure
� Regular maintenance (Lubrication and cleaning should be performed periodically) of motor
will help in minimize friction loss, heat loss and extends motor life
� It is recommended to replace the old motor which has undergone rewinding 3 times. All
new replacements should be done with energy-efficient motors having 3%–5% higher
efficiency than conventional motor
� Motors frequently drive variable loads such as pumps, hydraulic systems and fans. In these
applications, motor efficiency is often poor due to operation at low loads. It is appropriate
to use the variable speed drive (VSD) with the motor;
� It is recommended to Install the capacitors across the higher rating motors to reduce the
distribution losses from transformer to motors;
Fans & Blowers:
Fans and blowers in the rice mill industry mainly used in the transfer of material, air distribution
and other low air pressure requirement areas.
� Minimize blower inlet and outlet obstructions for free flow of air
� Clear screens, filters and fan blades regularly
� It is recommended too use aerofoil shaped fan blades
� Check belt tension regularly to reduce transmission losses
� It is recommended to use energy efficient flat belts, or, cogged raw edged belts, in place
of conventional V belt systems, for reducing transmission losses. It will save 3-5% of
energy as compared to V belt system;
� It is recommended to use variable speed drives for large variable blower loads
� Avoid long narrow ducts with many bends and twists to pull the air through them, this
will require more energy
� It is recommended to optimize excess air level in combustion systems to reduce load on
blower
� Minimizing system resistance and pressure drops by improvements in duct system
References:
1. Small industry Development bank booklet on energy conservation measures in fruit and
vegetable sector available at:
http://www.msmefdp.net/Documents/green%20initiatives/Pune%20Energy-Efficiency.pdf
(accessed on 20/11/2010)
2. Small industry Development bank booklet on energy conservation measures in Engineering
sector available at:
http://www.msmefdp.net/Documents/green%20initiatives/Engineering.pdf (accessed on
20/11/2011)
3. Bureau of energy efficiency guide book on energy efficiency in thermal utilities
4. Bureau of energy efficiency guide book on energy efficiency in electrical utilities
5. Spirax Sarco steam engineering tutorials available at :
http://www.spiraxsarco.com/resources/steam-engineering-tutorials.asp (accessed on
20/9/2010)
6. International Rice Research Institute (IRRI) Training manual on Paddy drying, available
at:http://www.knowledgebank.irri.org/ericeproduction/PDF_&_Docs/
Training_Manual_Paddy_Drying.pdf (accessed on 26/03/2011)
7. http://www.energymanagertraining.com/bee_draft_codes/best_practices_manual-
TRANSFORMERS.pdf ( accessed on 20/9/2010)
8.
Annexure:
Annexure1: Energy efficient equipment suppliers/vendors relevant to rice mill technologies
S.No
Energy
Conservation
measure
Name Adress of company Contact details mail id
1
Installation of
Variable
frequency drive in
Boiler FD fan
Mr. R. K. Iyer Dynaspede Integrated System Limited; 302-303
Money chambers 6KH Road Bangalore India 080-22109117/118/123 [email protected]
Mr. M.Sathyanarayanan Jeltron Systems India Pvt Ltd.;
Coimbatore -25
0422-2406445
Mob: +91-9344677788
om
Mr. Bhaskar madalam
Schneider Electric India (P) Ltd; No.44 P
Electronic city Phase II,Hosur Road,Bangalore-
560100
080-39102730 [email protected]
neider
Mr. Sundar
Versa Drives Private Limited; 351B/2A,
UzhaipalarStreet, GN Mills Pos Coimbatore,
Tamil Nadu - 641 029
0422-2648280/2648281
Mr. Anil
Crompton Greaves Limited; 4th Floor, Minerva
House,94 P B 1670
Sarojini Devi Road, Secunderabad-500003
040-40002308 [email protected]
om
2 Installation of
voltage stabilizer
Mr. S. Mariappan Consul Consolidated Pvt ltd; Plot no. 361, 1st
Floor, East 4th Cross St., K.K.Nagar, Madurai-
0452 – 2520564/ 2534688 [email protected]
m
in milling system 625 020
Mr. S .Balamurugan
Universal Electronics; No-14, Mosque Street,
Easwaran Nagar, Annasalai, Pammal, Chennai,
Tamil Nadu - 600 075
044-65874772/22486452 [email protected]
Mr. V. Vevekanandan
Zenelec Power Systems Pvt. Ltd; No. 37, Block
II, SIDCO Electroincs Complex, Guindy Industrial
Estate, Chennai, Tamil Nadu - 600 032
044-22501787/65399888 [email protected]
Mr.jalal
Golden Electronic Controls India Pvt. Ltd;
14/237-D,Gandhiji Layout, Pollachi Main Road,
SIDCO Industrial Estate Post, Coimbatore, Tamil
Nadu - 642 001
0422-
2676622/2671777/267923
2 and 91-9363126622
3 Energy efficient
motors
Mr. M.Sathyanarayanan Jeltron Systems India Pvt Ltd.;
Coimbatore -25
Tel / Fax : +91-422-
2406445
Mob: +91-9344677788
om
Mr. Bhaskar madalam
Schneider Electric India (P) Ltd; No.44 P
Electronic city Phase II,Hosur Road,Bangalore-
560100
080-39102730 [email protected]
neider
Mr. Anil
Crompton Greaves Limited; 4th Floor, Minerva
House,94 P B 1670 Sarojini Devi Road
Secunderabad-500003
040-40002308 [email protected]
om
4
Installation of
moisture
controller in Drier
Mr. P.Dhamodaran Sree Balaji Industries; 20.Ishwar Trade centre,
GreyTower,Coimbatore-641018 0422-2303763
balajitechnologies_2006@y
ahoo.co.in
Agromech Engineers; 374, Patel Road
Coimbatore 641009 Tamil Nadu India 0422 - 5540654/2235054
Mill Mech Engineering; 105-F, Athipalayam
road, Ganapathy Coimbatore, 641006
Tamil Nadu
0422 - 2666574/5532372
5
Replacement of
conventional
Boiler with
Energy Efficient
high pressure
Boiler
Thermax Ltd; 312, Anna Salai, Teynampet,
Chennai, Tamil Nadu 600018 044 2435 3831
Mr.M.Chandra mohan Veesons Energy Systems (P) Ltd; New No-22,
New Giri Road, T Nagar, Chennai, Tamilnadu 044 2826 7339 [email protected]
Mr. Narashimam Ghanti
Cheema Boilers Limited; H.No.7-1414/19,
Flat :301B ,Naga Sai Nivas, Sreenivasa Nagar(E)
S.R. Nagar , Hyderabad-500 038
040-66821160 cheemahyd@cheemaoilers
.com
Matrix Boilers (P) Ltd; No2, Quaide milleth
street, Mannarpuram
Trichy Tamil Nadu India 620020
0431-2424241 &
9367744009
Ennar Engineers; 2 Vavila complex,Near Tamil
Nadu Theatre, Palladam Road Tirupur 641604
Tamil Nadu, India
0421 - 2212147
6
Installation of
back pressure
turbine in place
of PRV system
Mr. Arun Khetrapal
Maxwatt Turbines Pvt ltd. Max watt Energy
System Pvt Ltd; 605, Deepshikha, rajendra
Place, new Delhi-110 008
011-41538031/8033 and
9971888431 [email protected]
Mr. Narashimam Ghanti
Cheema Boilers Limited; H.No.7-1414/19,
Flat :301B ,Naga Sai Nivas,
Sreenivasa Nagar(E) S.R. Nagar ,
Hyderabad-500 038
040-66821160 cheemahyd@cheemaoilers
.com
Mr.N Ram Pranav
Turbo tech precision Engineers Pvt Ltd; A-343;
2nd stage, Penys industrial estate, Bangalore-
560025
91-080-22164000 /
28391624 / 28394721
marketing&turbotechindia.
com
7 Energy efficient
dryer fans
MR. Sadashiva Amin
Mysore Driers; Plot No. 39, 2nd Phase, KIADB
Industrial Area, Antharasanahalli, Tumkur -
572106, Karnataka , India
Phone:91-816-
5530166/2212565
Mobile : +919886893467,
Fax : 91-816-2212565
Mr. Nirav Shah Heat Flow Engineer; Shop no F-6, Sagunacasa
tower, Sattelite road, Jodhpur, Ahmedabad
079-
40320270/09825007390 [email protected]
8
Installation of
Energy Efficient
lamps in place of
conventional FTLs
GE Lighting India ( P ) Ltd; CFA/ Kapila
Automotive Agencies (P) Ltd
No:22 NP, Guindy Industrial Estate
Ekkattuthangal,Chennai-600097
044-22323369/ 22323469 /
22323375
e.com
Mr.Vijay
Polycoat;
"SKANDA" #385, 24TH B CROSS,
BSK II STAGE, BANGALORE- 70.
Mob: 9900506855. [email protected]
Mr. Swaminathan
narayan
Wipro Lighting;No.41, Chokkampudur Main
Road, Sriram Nagar,
Telungupalayam Post, Coimbatore- 641 039.)
0422-247784 / 2478751 swaminathan.narayanan@
wipro.com
Philips Electronics India Limited; Temple
Towers, 5th Floor,Old No: 476, New No :
672,Anna Salai, Nandanam,
Chennai - 600035, India.
044-66501000
