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Energy Efficient Lighting brings cost savings for Mallika Enterprise, New Delhi

Pic: M/s Malika Enterprise

Summary of the success

A consortium of experts in the field of resource, energy and water efficiency in industrial processes, led by the German consultancy, Adelphi, visited 20 companies in the Mayapuri Industrial Area in Delhi to undertake rapid assessments of their production facilities. Twenty companies interested in increasing resource efficiency and reducing pollution levels caused by the production processes were selected for a more detailed assessment, based on the fact that potential for the implementation of efficiency measures existed. Malika Enterprise, involved in the washing of denim, located in Mayapuri Industrial Area, Delhi was amongst the companies chosen for a detailed assessment. The company was keen to have the expert group conduct a comprehensive RECP study at their site in order to identify energy and water saving potentials.

Whilst the detailing of measures is currently still ongoing, some energy and, hence, electricity cost savings have already been realised through the implementation of simple and low-cost measures.

About the problem

Mayapuri Industrial Estate of the Delhi State Industrial Development Corporation (DSIIDC) is situated in the South West District of the National Capital Territory of Delhi. The estate covers an area of 188 ha housing about 9361 commercial units of different sizes and sectors. About 2,800 of them are micro-, small, and medium-sized manufacturing industries. 51 of them are classified as seriously polluting. The manufacturing industries are from a wide range of sectors including engineering/fabrication, electroplating, pickling, metal finishing, plastic recycling, moulding, oil processing, offset printing, and so on.

In general, the companies in the estate do not have environmental management systems in place. Waste and wastewater generated are often not adequately treated, and raw materials, water, and energy are consumed inefficiently further leading to avoidable waste and environmental pollution. Companies lack the technical data as well as the knowledge about Best Available Techniques and Technologies in the Indian or international context. 

Actions initiated

To systematically improve the situation, Mayapuri Industrial estate in Delhi was included as a project site under the “Sustainable and Environment-friendly Industrial Production (SEIP)” project of the Indo-German Development Cooperation. Jointly with DSIIDC, a public agency responsible for infrastructure in the industrial estates, the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH has been implementing the SEIP Project since 2016.

Under SEIP, a German consultancy (Adelphi) was hired to audit and assess the potential of environmental improvements in companies directly. On the one hand, end-of-pipe solutions, i.e. an improvement in the treatment of wastewater and waste are being considered. On the other, however, the main focus lies on increasing resource, water, and energy efficiency in the companies’ processes since tackling pollution at the source is generally a more economical solution. The objective is to reduce environmental impacts of industrial operations at the same time also to reduce costs of waste treatment and disposal.

The approach is to target technological modifications as well as changes in techniques applied, and optimisation of manufacturing processes. The latter two usually do not require large investments, but rather entail changes in the production steps, change of input materials, or the training of workers. These measures tend to build the trust of companies in the viability of efficiency measure and lay the basis for larger interventions requiring substantial investments.

During the Rapid Assessments (RA) the industries’ resource efficiency and cleaner production performance was assessed across the categories 1) Energy Management and Optimal Use, 2) Water Management and Optimal Use, 3) Material Use Management, 4) Technology, Processes, and Data Control, 5) Good Housekeeping and Good Maintenance, as well as 6) Waste Management incl. Wastewater Management. Already the RA phase showed significant room for improvement across all six performance areas in most companies.

The most prevalent issues discovered were related to insufficient monitoring of resource consumption, leakages in equipment (e.g. conveyance systems for water and air pressure), wastage of water (translating into large potentials for water recovery and reuse), and a lack of training for employees to enhance their knowledge regarding production processes as well inefficient lighting systems (e.g. using a large number of tube lights or ineffectively exploiting daylight during production hours).

The companies chosen for RECP audits in Delhi are from the electroplating, service stations, washing units, textile, dyeing, and chemicals. 

Pic: Industries in DSIIDC’s industrial estate of Mayapuri 

Efficiency improvement

Malika Enterprise wanted the expert team to improve their energy and water efficiency performance. After conducting a comprehensive RECP audit, a high level of electricity consumption from inefficient lighting fixtures at electrical panels was found. These lights are operational for 24 hours per day.

The experts suggested to simply replace the existing incandescent and compact fluorescent light bulbs (CFL) with energy efficient LED lights in order to save on electricity consumption. Malika Enterprise followed this recommendation and replaced one CFL and two incandescent lights with LED lights. This simple and low-cost intervention cost only 200 INR and repaid itself within one month. Measured over a one year period, the company will save about 337 kWh of electricity translating in cost savings of INR 2,696 as a direct result. 

 

Problems identified

Solutions

Costs

Results

Inefficient lighting system using CFL and incandescent lights

Replace inefficient light bulbs with energy efficient LED lights

 INR 210

- Reduction in electricity consumption of 337 kWh per year.

- Reduced electricity consumption translates to cost savings of INR 2,696 per year. 

Total investments:

INR 210 

Total savings:

INR 2,696 per year

Estimated payback period:

1 months

Economic benefits

Environmental benefits

Energy cost savings of INR 2,696 per year

Reduction of energy    consumption by 337 kWh per year

“Before” (electrical panel with one CFL and two incandescent light bulbs)

“After” (Electrical panel with LED lights)

The success – The benefits

The implemented measure did not require sophisticated technology or large investment sum but led to significant energy and cost savings in the plant where they were implemented. Malika Enterprise is expected to save more than 12 times the investment cost for the LED light bulbs over a twelve-month period.

However, this is just the beginning. The positive experience with the improved lighting condition encouraged and motivated Malika Enterprise to also implement further measures that were suggested by the expert team. Possible interventions could be the insulation of the steam pipelines and the optimisation of the usage of the compressor. One could say that the small intervention of changing light bulbs opened the eyes of manager and technical personnel regarding the potential that lies in efficient and cleaner production opening the doors for further improvements in the company.

Mr. Keshav, Master, Malika Enterprise

Mr. Madhav, Master, Malika Enterprise

“We are a jeans washing unit. We, in our company, are mostly focused on achieving the production targets and quality of washing of jeans. The consultants explained us the areas where we can optimize resource saving. They explained simple measures to us to reduce energy. We have now started implementing the recommendations for optimizing lighting, the boiler and the compressor. The consultants have been very supportive to us in training and implementing recommendations.”

 

 
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