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KIRLOSKAR PNEUMATIC COMPANY LIMITED Saswad, Pune (Maharashtra)

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KIRLOSKAR PNEUMATIC COMPANY LIMITED Saswad, Pune (Maharashtra) Certificate of Merit General Category KIRLOSKAR PNEUMATIC COMPANY LIMITED Saswad, Pune (Maharashtra) Unit Profile Kirloskar Pneumatic Company Limited (KPCL) which was founded in 1958 & commenced manufacturing air compressors with technology from Broom & Wade, UK is a part of the Kirloskar group of companies. Shri. S.L. Kirloskar, the founder had a vision of providing tailor-made engineering products & solutions to the Indian Industry. The company started manufacturing of refrigeration compressors in 1961, transmission products in 1963 at Hadapsar and Road Railer units in 2013 at Nashik. In 1985 company shifted manufacturing of refrigeration compressors at Saswad plant. Currently the company serves major sectors like oil & gas, engineering, steel, cement, food & beverage through engineered products and solutions. Executive Chairman Mr. Rahul C. Kirloskar & MD Mr. Aditya Kowshik provide guidance & directions to the organization. KPCL has 5 strategic business units (SBUs) viz. Air Compressor division (ACD), Air Conditioning & Refrigeration division (ACR), Process Gas Systems (PGS), Transmission division (TRM) and Road Railer (RR). Considering future growth and focus on specific applications and market needs, during the year FY’14, ACR & PGS division was split into two independent divisions viz: ACR division and PGS division. Operation at Saswad plant started in 1963 to fulfill the demand of growing Air Conditioning & Refrigeration market as well as of Process gas division market. ACR & PGS has its Head Office in Hadapsar, Pune with manufacturing facilities at Saswad, which is in operation since 1985. 200 It has three sub divisions, Equipment, Refrigeration systems & Process Gas systems. Equipment sub division products are sold & serviced through authorized dealers, supported by Regional Offices & Branch Offices. Project Sub Division has undertaken prestigious Projects in India & countries like Oman, Thailand & Egypt. Company has successfully completed large orders for Indian Navy, Reliance Industries Ltd., IOCL, Gujarat Adani, ONGC, SHELL etc. Today Company has over 26,000 compressors working in the field in India and Abroad (over 30 countries) for more than 15 applications. Applications include food and beverage, Fruits and vegetables preservation, Potato cold store, Dairy, Ice Cream, beverages, Breweries, Fisheries, Meat processing, ice plants (block, flake, tube), Pharmaceuticals, Chemicals, Air-conditioning, other process cooling applications. Energy Consumption Energy Consumption (Lacs kWh/year) 2013-14 2014-15 Purchased Electricity (Lacs kWh / year) 11.78 12.66 Through DG sets (Lacs kWh / year) 0.41 0.43 Total consumption of electricity 12.19 13.08 Energy consumed is being monitored on daily basis including shop wise energy consumption along with MSEDCL meter reading. Specific energy consumption for Saswad plant operation is calculated on daily basis and performance is being monitored and shared with all departmental, divisional heads. At KPCL – Saswad plant, total 13 nos. of energy meters are installed for the verification of shop wise energy consumption. Company has dedicated software (GAGEtrak 6.70 Build 038) for the monitoring on calibration frequency for measuring & monitoring instruments wherein we can schedule calibration requirements and alert is generated before due date. All the energy meters are calibrated once in three years. For any organization, control of energy and fuel can be achieved by starting consumption monitoring. KPCL- Saswad plant has started monitoring of energy, water and oil by installation of meters and systems. After installation of meters, we started to monitor the consumption pattern on daily basis and reports are being circulated to all department head including top management. Energy Conservation Year Product Production in Specific Energy % Reduction Cylinder Consumption over 2013 - 14 2013 - 14 Refrigeration 6909 145 kWh/Cylinder — Compressor 2014 - 15 Refrigeration 7664 139.9 kWh/Cylinder 3.52% Compressor 201 Energy Conservation Projects implemented in year 2014-15 25 Nos. Annual Electricity Saving - Lacs kWh/ Year 4.29 Annual Cost Saving - Rs. Lacs / Year 53.55 Investment – Rs. Lacs/ Year 12.88 Payback Period – Months 3.00 Energy consumption reduction programs are part of integrated management system where in monitoring of programs is done and measurements are recorded in M & M plan. Through internal auditing the progress is being monitored. Also during MRM review concerns and progress of management programs are reviewed. Below are the benchmarks, which KPCL follows Use only 5 star rated air For any new system, best conditioners available energy efficient For new requirement of system will be used. lighting load, only LED based Vacuum cleaning lighting Energy meters For new project energy Inverter based welding efficient motors will be used machines For flow regulation, variable Air circulator frequency drive will be used. Day light sheets All in one desktop Area wise energy consumption analysis for ACR-equipment operation is carried out. Below chart shows the shop wise energy consumption pattern. Implemented projects LED lamps at shop floor area Energy efficient electric screw Up gradation of SR furnace compressor Oil metering unit at test bed Energy efficient welding machine AC drive at paint booth Energy saver for air conditioners Water filtration unit LED based lighting system 202 Energy Policy 203.
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