Energy Audit Report at S. S.

Polymers, Kanpur

ENERGY AUDIT AT

S.S.POLYMERS
17-W BLOCK M.I.G. P.O. JUHI

KANPUR-208014
M/s S.S. Polymers, Kanpur was established in the year 2011. It is engaged in the
manufacturing of PVC conduits used in electrical wiring purposes. The present
average daily production rate is nearly 1000Kg/day. The plant operates in all three
shifts and about 300days per annum. The main raw material used is compounded PVC
resins (resin powder). Product is sold in Kanpur and whole of Uttar Pradesh.
Electrical energy is received by the plant at 415Volts. The contracted maximum
demand (Sanctioned Load) of the plant is 45kVA. Average monthly electrical energy
consumption of the plant is 25000kWh (units). The Corresponding energy bill remains
around Rs 1.25 Lac per month.
Conduit manufacturing is done through extrusion process. PVC is one of the few
polymers which can be processed thermo-plastically and by means of pastes.
Thermoplastic processes take place primarily on extruders or so-called screw presses.
The final product is pipes. The process is energy intensive as a lot of electrical energy
is consumed in its manufacturing. The raw material (PVC resin) is injected in the
mould at a pre-determined flow rate and varied pressure. The power consumed in
injection moulding process depends on the pressure and flow rate of the material
which in turn depends upon the size of the conduit to be manufactured.
The various process steps involved in the manufacture of conduits/pipes are extrusion,
sizing, traction and cutting.
Since inception, the plant was operating with a conventional old technology extrusion
machine. The older screw extruder machine had only one screw and its maximum
production output was limited to 60Kg/hr. The old machine was equipped with a
standard 25kW DC motor without any speed control device.
The progressive management of M/s S.S. Polymers has taken several steps to bring
down its electrical energy consumption. In an endeavour to reduce energy
consumption the plant management has procured a new and state of art energy
efficient technology extrusion machine of 170Kg/hr capacity. The machine has been
procured from KABRA Extrusion Technik, Andheri(W) Mumbai.
In order to bring down its electrical energy consumption, the plant has installed a new
machine for production process. The new energy efficient technology KOLSITE
BATTENFELD EXTRUSION LINE (Make:KABRA Extrusion Technik) machine for
National Productivity Council, Kanpur

Page 1

Energy Audit Report at S. S. Polymers, Kanpur

the production of rigid PVC pipes/conduits was installed in the year 2013. The
machine being twin screw extruder, the production capacity of the new machine is just
double than the old machine. The production capacity of the new machine is 120130Kg/hr. The maximum output of the machine 170Kg/hr. Output of the machine
depends on compound, the product dimensions and quality of the pipe to be
manufactured. Pipe sizes from 20mm-110mm outside diameter can be manufactured
with the new machine.
Model No of various components of the new energy efficient technology KOLSITE
BATTENFELD EXTRUSION LINE machine is as follows: Extruder: BEX 2-5225V/4, Die head PVC 75/250, Vacuum calibrator V-125-6.0W, Electronic haul off: R
110 SEV/800-20, Cutting Saw SPR 110R, Spiral Hopper Loader 5Mtr. L.
During energy audit it has been found that the new extrusion machine is consists of
two numbers of major motors (i) Main Drive Motor of 15kW capacity (ii) Spray pump
motor of 5.5kW capacity. These motors are attached with AC drive. AC drive helps to
control the speed, which in turn results in energy savings. Besides, a few very small
capacity motors are attached with the machine. The small capacity motors remain idle
most of the time. The small/low capacity motors operate intermittently, i.e. depending
on the command/signal the motors performs its function and stops. As measured
during energy audit the total load of the new machine, when under production remains
less than 25kW.
As mentioned in previous paragraphs, the main motor of 15kW is equipped with a
2.2kW AC drive for controlling the speed of the motor. Depending upon the process
requirement the motor speed (RPM) is varied with the AC drive. The drive allows a
maximum speed of 52RPM. However, under normal production process speed of the
motor remains in the range of 20-28RPM. The feeder (which feeds the resin in the
extruder is also provided with a 1.5kW AC drive. The AC drive by controlling motor
speed brings down the energy consumption.
Moreover, the extruder is equipped with heating load. The connected electrical load
for heating purposes is 18.20kW. The heating elements are fixed at different zones of
the extruder and die head. There are five zones in each Extruder & Die head. Each
zone is fitted with an electrical heater. All the heaters consist of PID temperature
controllers. The PID provides precise temperature control and once set temperature is
reached the controller switches of the electrical element. PID temperature controllers
had resulted in substantial electrical energy. The set temperatures are either, 215 oC,
210oC or 175oC.
A comparison has been made with the machine parameters of the old extrusion
machine and the newly installed energy efficient technology KOLSITE
National Productivity Council, Kanpur

Page 2

Energy Audit Report at S. S. Polymers, Kanpur

BATTENFELD EXTRUSION LINE (Make:KABRA Extrusion Technik). The

following table represents the comparison.
SPEED
FOR ALL RPM

SPEED
28 RPM
40 RPM

PARAMETERS OF OLD EXTRUSION MACHINE

VOLTAGE CURRENT (A)
POWER FACTOR
415
35
0.95

LOAD (KW)
23.9

PARAMETERS OF NEW EXTRUSION MACHINE

VOLTAGE CURRENT (A)
POWER FACTOR
LOAD (KW)
415
14
0.95
9.6
415
17
0.97
11.9

The above table depicts that with the installation of new machine the operating load of
the extrusion machine has reduced by 50% i.e. (23.9kW-11.9kW)/23.9kW. It indicates
a 50% reduction in electrical energy consumption.
In addition with the new machine the productivity has improved by 50%. The
production capacity of the old extrusion machine was 60Kg/hr whereas the production
capacity of the new machine is 120Kg/hr. It implies that within same time period the
new machine gives double production than the old machine.
It may be noted that PID temperature control device helps to maintain precise
temperature and eliminates any unnecessary operation of heaters and therefore
prevents any wasteful energy consumption by heaters.
From the above energy audit, it has been concluded that with the installation of new
Energy Efficient Technology- KOLSITE BATTENFELD EXTRUSION LINE
(Make:KABRA Extrusion Technik) provided with fully automatic AC drive and PID
temperature control, the company has been able to garner an energy savings of 50%.
Besides, the productivity of the company has also improved significantly.

Besides small motors are as follows:

National Productivity Council, Kanpur

Page 3

Energy Audit Report at S. S. Polymers, Kanpur

(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)

Feeder Drive: 1.5kW

Vacuum Pump: 0.75kW & 2.25kW
Oil Pump: 0.75kW
Barrel cooling blower:0.50kW
Longitudinal Movement motor: 0.37kW
AC geared motor: 2x1.1kW (2.2kW)
AC drive: 2.2kW
Cutting Saw AC motor: 1.5kW
Swarf extraction Blower: 0.75kW

National Productivity Council, Kanpur

Page 4