A software aided tool developed to forecast

  • Over-all energy consumption for the plant
  • Energy target with respect to planned production quantity
  • Derive specific energy consumption norms for each site/key process
  • Depict the energy map, equipment category wise at   section level

Conventional Approach

  • Energy consumption components
  • Energy Model – Introduction
  • Inputs to Model
  • Out Put
  • Methodology
  • Assistance required

Lacunae in Conventional Approach

  • Fixed energy component is not explicit
  • Relation between production volumes and power consumption not established
  • Lack of information on effect of variations in process and utility efficiencies
  • Inability for correct intra-plant comparison


Depends upon

  • Cycle times of product
  • Product Characteristic
  • Equipment Capacity
  • Compressed air for Pumps and Packing Machines
  • Pneumatic Conveying Systems
  • Thermopack & Boiler Fuel


Depends upon

  • Lighting
  • Compressed Air- Instrument Air
  • Room Air Conditioning
  • Cooling Water Systems
  • Power plant auxiliaries
  • Thermo-pack Hot Oil Circulation System
  • Sectional Fixed Loads
  • Others (UPS, Admin etc)
  • Insulation Losses


  • Period of analysis
  • Forecast / Actual
  • Operating shifts and days
  • Production plan/actual
  • Intermediates production plan/actual
  • Volume mix of products in various equipment types
  • Operation of utilities


Phase I – Measurement

  • Listing various process streams
  • Identifying representative batches
  • Tracking of representative batches
  • Compilation of data pertaining to installed facilities
  • Segregation of variable and fixed loads
  • Measurement of utility parameters
  • Evaluating efficiencies of utilities

Phase II – Analysis and Modeling

  • Developing the energy model

Phase III – Validation and simulation

  • Simulation of model through past data
  • Scrutiny of section-wise model
  • Modeling with standard cycle times

Phase IV – Rollout


  • Explanation of Production Planning & Material Codification
  • Identification of Representative Batches
  • Coordination for Batch Tracking
  • Single Line Electrical Diagram & MCC wise Connected Load Details
  • Capacitor & Transformer Installation Details
  • Details of Metering & Monitoring System & Report Formats
  • Installation Details of Utility Systems
  • Design Requirement of Utility Systems
  • Installation Details for Lighting Fixtures, Fans, Water Coolers & Air Conditioners
  • Monthly Power & Fuel Consumption Records of Last Year