1

P K Industries

98

An engineering unit engaged in manufacturing of tractor parts.

2

Alvind Industries

264

An engineering unit engaged in manufacturing of Bogie Bolsters, Brake Beam, L.S. Beam, Brake Heads, BSS Bracket, Levers etc.

3

Saluja Motors Pvt. Ltd.

65

Car servicing centre and FORD Vehicles dealership enterprise.

4

Oscar Leathers Pvt. Ltd.

497

Manufacturer of leather shoes & sandals.

5

Alfa Industries

28

Manufacturer of gear shift rods and hollow shift rods for Tractors.

6

S.R. Engineers

76

Custom manufacturer that provides Wire Cut, Vertical Milling & Turning, machining services.

7

Rajwant Industries

39

Manufacturers of Tractor Parts.

8

SAAK Auto Accessories

46

Manufacturer and distributor of Auto Parts.

9

Apex Motors

20

TATA Motors & Vintage cars servicing centre.

10

Elektratek Engineers

59

Manufacturing of diesel generators

11

Esspee Industries

45.7

Sheet metal Works Manufacturing

12

Devindra Engg. Works

413

Fasteners Industry (Rivet & Hinge manufacturer)

13

JMD Engineers

77

Custom manufacturers of Auto & Tractor Parts, high precision machining and hydraulic transmission components.

14

Diamond Engg. Works

49

Tractor Parts Manufacturer (Bush, Rocker link assembly, wire ring, ring holder, cover plate for tractors etc).

LIGHTING

Energy Conservation Measures

1. Replacement of conventional tube light T12 (52W) and T8 (46W) with T5 (30W) [Savings potential= 34.5% to 42.3%].
2. Replacement of Conventional HPSV (150W) with LED  (45W) and Bulb (200W)with LED (65W) [Savings potential = 67.5% to 70%]
3. Replacement of Conventional Bulb (60 W/100W/200W) with CFL (15 W/27W/65W) [Savings potential = 67.5% to 75% ]
4. Using LED based Task lighting instead of conventional lights [ Savings potential = 95.6% to 96.2%]
5. Replacement of Magnetic choke (10W) with Electronic choke (6W)
6. Use of PVC corrugated sheets for day lighting instead of conventional lights
7. Savings by turning off lights based on occupancy
8. Lowering of Tube lights in industry with high roofs
9. Cleaning of dust on Luminaries and Transparent sheets for better lighting

Basic Implementation done

1. Many of the industries have already switched to Electronic ballasts & T8 for lighting from T12 and magnetic ballasts.
2. Many of the industries have also replaced the bulbs and task lights by CFLs.
3. The old Halogen lamps are replaced by Metal Halide lamps.
4. The industries are now engaging in O&M to keep the luminaries clean & dust free.

HEATING , VENTILATION & AIR CONDITIONING

Energy Conservation Measures

1. Replacement of conventional Fans with Energy Efficient Fans (50W) [Savings potential = 37.5%]
2. Replacement of conventional Fans with Energy Efficient Fans (50W) [Savings potential = 37.5%]
3. Evaporative cooling on the condenser side of the air conditioners.

Basic Implementation done

Some of the Industries have already installed the BEE star rating Air conditioners.

ELECTRIC INDUCTION MOTORS

Energy Conservation Measures

1. Installation of an APFC (Automatic Power Factor Controller) in the main panel.
2. Increasing production, motor loading to improve operational efficiency.
3. Conversion to permanent star connection for the under loaded motors.
4. Replacement with more energy efficient IE3 motors.
5. Variable Frequency Drive application for energy conservation by reducing the motor rpm.
6. Selection of proper size motor for an application.
7. Replacement of old and worn out V belt drives by synchronous belt drives. [upto 8% savings]

Basic Implementation done

1. The officials have now understood the importance of motor loading and have decided to standardize their machinery so that they can benefit by operating in the appropriate loading range of 50%-100% of the motor.

Relevant Points

1. The industries in sector have a very wide range of machinery each brought in situations of production bottlenecks. All the operations can be performed on each one of them. Hence many a times they function in either overloaded or underloaded zone.

AIR COMPRESSOR

Energy Conservation Measures

1. Prevention of leakage in compressor [Majority of the industry proper operational strategy for the compressor, so replacing it offers savings upto 20%to 30%.
2. Installation of variable frequency drive (VFD) on screw type air compressors saves the no load power consumption.

Basic Implementation

1. The officials have been conveyed about the high value of the compressed air and they are now engaging in replacement of old ball valves, leakage testing.

Relevant Points

1. The workers earlier used to waste a lot of compressed air, some of them even used the same for cleaning. Such practices have been discontinued now.
2. It was observed that many of the industries have a faulty compressed air circuit or poor pressure control system. In some places the compressor was compressing the air and then a release air valve was opening to pump out the excess air.

CAPACITORS

Energy Conservation Measures

• The capacitors were derated and the replacement of the same has been recommended
• In some industries the capacitor bank was inappropriately sized and hence the power factor was not being maintained even after APFC installation . So proper sizing was recommended.

Basic Implementation done

• Few of the industries in Punjab had PF incentive and surcharge however they had not installed the APFC panel. The benefits of the same were communicated to them and they agreed to the same.

Relevant Points

• Many of the industries did not have power factor surcharge of incentive and hence were not so keen on ensuring the health of their capacitor banks

TRACTOR  MANUFACTURING UNITS

Energy Conservation Measures

• Power Press-2, Power Press-3 and Surface Grinder motors are overloaded. It is recommended that the load on these machines be reduced and in case that the reduction of load is not possible an exchange based optimization or a replacement with more efficient motor of higher rated power is recommended.
• USING NN POWER PLANNER IN MOTOR in power press which provides a simple, effective, reliable & economical solution to the problems of an ac Induction Motor.
• Increasing operational efficiency of hacksaw machine by cutting 6 rods at a time instead of 4.
• Use of regenerative system to recover kinetic energy of braking in CNC. Installation of Touch probes to quickly find datum for a task in CNC machines, optical encoders for efficient operation of Servo-motors of CNC should be implemented to get an upper hand on energy savings.
• Replacement of CRT with LCD monitor.

Basic Implementation done

• Hacksaw’s loading was increased by cutting 6 rods at a time in place 4 as done before. Thus the power savings increased considerably.

Relevant Points

• In plants the production capacity is very low as compared to the maximum production capacity. The workers have a poor work efficiency and also the amount of business these units get is season based and less. Hence the majority of the motors operate in their under loaded region.

SHEET METAL WORKS

Energy Conservation Measures

• On machines like power press and shearing machine it is essential to build torque by reducing rpm at the end of transmission. It is recommended to provide a kind of add on to a power press and a shearing machine which will then measure the no. of presses or cuts made by the operator and also record the on time.
• By using inverter based weld set power source leading to an overall system efficiency of about 78.7%

Basic Implementation done

• The range of power press available at sheet metal works industry is large. However the industry has not standardized their selection of these machines for a particular job. All machines almost are used to perform all sets of operations. It was recommended to standardize the job size each machine will handle.  The same was agreed upon by the officials and the implementation was done.

Relevant Points

• It was found that some of the industries used compressed air for cleaning of plants which is a vey inefficient practice.

AUTO SERVICE REPAIR

Energy Conservation Measures

• Saving in Fuel consumption due to excess air reduction of Painting Booth [16% saving in HSD consumption].
• Installation of a switch to control the water pump, used for pressurized water for washing of cars, on the other side of car washing.

Basic Implementation done

• The compressed air circuit was prone to leakage with inefficient control settings and inappropriately maintained compressed air circuit. The same was communicated to the officials and they are undertaking relevant O&M measures

LEATHER WORKS

Energy Conservation Measures

• Replacing Air Cooling System by Evaporative Cooling System in chiller [Savings Potential = 15%-16%]
• Use of high grade lubricants in bearings to reduce friction.

Relevant Points

• Lighting fixtures planning in the work area is very good.

Energy Conservation Measures

• Slotting machines- These machines have a series of contraptions all mechanically automated. However they suffer due to jamming.  It was observed that at any point of time around 15 of the machines were jammed and the net production during this state was 0 for that machine. However the motor running the series of contraptions and mechanisms was still running. The power consumption of the motor when producing was 0.7kw and when jammed was 0.68kw. A control system which will detect the jamming, turn off the system and raise an alarm is recommended.
• Specific energy consumption- On machines like power press and rolling machine it is essential to build torque by reducing rpm at the end of transmission. The maximum energy in a power press goes in developing and maintaining this torque. The work is done only when the operator engages the cam. Hence the specific energy consumption largely depends upon the operator. A recommendation here would be to provide a kind of add on to a power press and a shearing machine which will then measure the no. of presses or cuts made by the operator and also record the on time. A certain standard for the same can be proposed and the industry owners can monitor that
• Belt drives- Almost every motor based machine has a belt drive. The condition of belts is very poor with most worn out and many sagging. Recommendation to use new belts and also shift to synchronous belt drives in high energy applications

Basic Implementation done

• For the slotter machine energy consumption reduction, a simple measure was suggested to have an foreman in each section to just turn off the machines which are jamming until the other foreman came and repaired the machine

Relevant Points

• Motors- Majority of the motors have undergone rewinding for more than 5-6 times thus decreasing the motor operation efficiency substantially
• The belt drives are very old and slip a lot, so it is recommended that the same are replace with new synchronous belt drives