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A
Team:-
1. V S Iyer (Sr. VP- Operation)
2. S G Panse (GM)
3. C P Pachpande (Energy Mgr.)
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ISO:50001 Certified
Mfg.
Excellence
Award
10 Mfg.
Plants
ISO:18001 Certified
ISO:14001 Certified
ISO:9001Certified
1st prize
winner of
BEE Award
Sustainability
Award
Most Trusted
Moulded
Plastic brandState of the
Art M/C’s
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Established in 2004
Area- 20000 Sqm
Capacity- 8000 MT/Year
Injection & ROTO Molding
ENERGY POLICY 1st Prize NEC - BEE
SINNAR PLANT
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ISO:9001Manufacturing
Excellence AwardISO:14001
ISO:50001
ISO:18001
National Energy Conservation AwardISO:50001
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ISO:50001Employee
Involvement
GHG
Inventorisation
Bench-
marking
ENCON
Projects
Environment
Projects
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21%
Reduction in
SEC Since
2013-14
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We want to achieve SEC Level of All Electric Machine(Latest
Technology) in our conventional machines.
External Benchmarking
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Machine wise SEC analysed and found that SIMD- 03 & 04 machine is
having lowest SEC
Breakup of entire cycle into small steps and study done with KryKard
load manager to know the power consumption at different steps
All Values in SEC
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Difference between two machine understood and Retrofitted
Functioning
Gear box with electric motor Other M/C- Hydraulic motor
Losses Losses Losses Losses
Ele.Induction
Motor
Ele to Mech
ConvertHydraulic Pump
Mech Energy
converted to
devolope Oil
Pressure
Hydraulic valves
& Pipes
Oil Pressure Losses
in Hydraulic
Control Valves
system
Hydromotor
Oil Flow &
Pressure Energy
converted to
Mechanical
Energy
Screw
Ele. Servo Motor Ele to Mech
ConvertGear Box
Mech Energy
direct Drives…Screw
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Krycard graph
Results- Refilling Operation SEC reduce by 0.15
Total Saving
153 Lakh INR
Electrical Units
18.85 lakh
New Gear box with ele. motor
Refill power
106 KWRefill power
71 KW
Before After
* Unit Price-8.11 Rs
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Analysis of Amps done at different stage of Process
Idle current has been calculated and based on that analysis we have
decided to install VFD
Result Other Advantages of VFD
- Oil temp remain less, so hydraulic system life improves
- Cycle time consistency and product quality improves
- KVA – MD is in control
INVESTMENT
13 Lakhs
Payback
9 months
Total Saving
17.7 Lakh INR
Electrical Units
3.1 lakhs units
* Unit Price- 7.50 Rs
SOMD-09 -BEFORE SOMD-09 - AFTER
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Optimization of Mould and Machine combination
M3 – TOOL
USED
Daily Monitoring
by SMS sheet
Resulted in…
Saving 4.4 Lac Kwh.
Saving Rs.34 Lacs
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Sustainability with National Pride
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Overall Energy Cost has
come down BY 7 %
inspite of increase in
UNIT RATE by 14 %
2013-14 …….. 6.76 Rs/Kwh
2016-17 …….. 7.69 Rs/Kwh
Energy47%
Other53%
0%
0%
SINNER - MOC Breakup-2013-2014
Energy40%
Other60%
SINNER-MOC Breakup-2016-2017
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18NILKAMAL - PONDY
Project 24 : Reduction of unit consumption in SIMD1A by Heater jacket Dept: MT Month : OCT 2014
1. In SIMD1A unit consumption is high
18.7 5unit / hr.
1.Saving energy consumption = 2.9 5unit / hr.
2.Unit Savings per month = 2.95x 24 x30 = 2124
3. Saving per month in Rs = 2124 x 6 = Rs.12744
4. Savings per year = 12744 x 12 = 1.52 Lakhs
PAIN GAINAFTER ACTION
1.After installation of heater jacket energy consumption reduced to 15.8 Unit/hr
Initiator Team Member Team Member Team Member Team Member
BEFORE AFTER
Employee Involvement V 30 WINNERS SERIES 2014-15
Sandip AvhadSG PANSE RAM SHINDE GOVIND GANESH
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We are using wind energy at our Hosur plant
around 4 lakh unit/ mnth
Use of Sunlight by using transparent sheet
during day time in all plant area – No lights ON
in day time
Use of Turbo ventilator for air circulation
Saving of 6 Lac Kwh/Year Reduction of 497 Ton CO2e
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Sewage Water Treatment Plant installed investing 30 Lacs.
That water is Reused for Gardens…
Rain Water Harvesting …
Water Saving
5,000 ltr/day
Zero Water
Discharge
Plant
BOD/COD within limit
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Some More Small Energy Conservation steps taken as ….
BEFORE – ASIAN make T5 Fitting
AFTER – Bajaj Make LED Fitting
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Energy Conservation Across Nilkamal Group….
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