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Energy and water savings at DD Motors in Mayapuri Industrial Area, Delhi

Introduction:

Development in India is shaped by an advancing industrialisation. The risks associated with industrial development include increasing pollution levels, overuse of natural resources, and increasing amounts of waste and wastewater, that could lead to endangerment of ecosystems.                             

The objective of the “Sustainable and Environment-friendly Industrial Production (SEIP)” project of the Indo-German Development Cooperation is that private and public sector actors jointly implement strategies to achieve an efficient, environment- and climate-friendly industrial development. The implementation of the SEIP project works along three fields of action, which are:

  • Environmentally oriented modernisation of industrial areas.
  • Creation of enabling framework conditions.
  • Knowledge management and dissemination.

The Targeted Area: Mayapuri Industrial Area, Delhi

The Mayapuri Industrial Area of the Delhi State Infrastructure & Industrial Development Corporation (DSIIDC) is situated in the South West District of the National Capital Territory of Delhi. It is one of the three industrial areas in Delhi selected to showcase concrete solutions of how industrial water pollution can be reduced. The industrial area covers an area of 188 ha housing about 9,361 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 by the Central Pollution Control Board (CPCB). The manufacturing industries are from a wide range of sectors including engineering/fabrication, electroplating, pickling, metal finishing, plastic recycling, moulding, oil processing as well as offset printing.

Case Study: DD Motors - Resource Efficiency

DD Motors, a four-wheeler service station which is located in the Mayapuri Industrial Area of Delhi took initiative to make its operations more sustainable by increasing its energy and resource efficiency. With the support of an Indo-German expert team, an assessment of their current resource and energy usage has been undertaken in order to identify existing efficiency gaps.

Problems identified

Measures (Solutions) 

Costs

Results

Water Efficiency:

Water wastage due to leakages in water pipelines and at taps

Fix all water leakages

 No cost

Water savings of 26,000 litres per annum, translating into monetary savings of around INR 3,700

Energy Efficiency:

Electricity wastage because of LED tubelights being switched on during daytime in the shop floor & during no occupancy in the paint booth

Switch off lights during daytime and no occupancy

 No cost

Electricity saving of around 670 kWh per year, leading to annual monetary savings of around INR 15,897 

Energy Efficiency:



Electricity wastage due to air leakages in the compressed air network and low utilization rate of 30 hp air compressor causing higher power consumption than required

 Arrest the air leakages in the compressed air network and replace 30 hp compressor with existing small capacity screw compressor (15 hp) which is already available as standby

 No cost  Savings in electricity are estimated to be 25,083 kWh per year leading to annual monetary savings of around INR 200,667 

Total costs:

Negligible

Total monetary savings:

INR 2,20,264 saved per annum + light replacement less frequently

Estimated payback period:

0 Months    

Measure 1

After an Indo-German expert team conducted a comprehensive RECP audit at DD Motors, a high level of water wastage due to leakages in water pipelines and taps was identified. Only by fixing the water leakages at the shop floor DD Motors is able to save up to 60,000 litres of fresh water per year, this reduction in resource consumption translates into direct annual economic benefits of around 39,000 INR. Furthermore, the amount of wastewater is reduced significantly and by minimizing water leakages, spillages are avoided leading to improved housekeeping at the shop floor.

Measure 2

The consultants also identified opportunities in the plant that allow for the realization of energy saving measures. Firstly, the team found out that there were 12 LED tube lights kept ON during the daytime at the shop floor. In addition, about 36 tube lights each of 40 W was switched ON even when no car was inside the paint booth. Only by switching OFF the lights during daytime and non-operating hours, electricity savings of estimated 670 kWh per year translating into INR 15,897 could be achieved. This intervention not only comes along with the aforementioned economic benefits but it also contributes to waste reduction what impacts positively the environment. As light fixtures are switched on less frequently, their working expands and therefore tube lights will have to be purchased at less frequent intervals.

Measure 3

As the company is a four-wheeler service station, it is having a major electrical load of air compressors. DD motors has installed 4 air compressors (2 nos. of 10 horsepower (hp) each, one of 15 hp and one of 30 hp) of which 30 hp was running at the time of detailed assessment.  It was further observed that the present 30 hp compressor was having the high idle running time of about 49%, consuming power during idle running. The team identified the low utilization rate of the 30 hp air compressor (~35%) against the ideal value of around 70%. This was also resulting in higher power consumption against the required. On the shop floor, various air leakage points were identified in the compressed air network.

It was recommended to arrest the air leakages in the compressed air network and reduce the idle time of the screw compressor by replacing the 30 hp compressor with a small capacity screw compressor (15 hp) which was already available in the company as standby. By simply exchanging the two compressors the same outcome could be achieved with a lower energy input.  These changes allowed the company to make electricity savings of around 25,083 kWh per year, which translate into monetary savings of around INR 200,667 per year. Apart from electricity saving, this intervention also resulted in an improved work environment because of a reduced noise level in the factory.

Lesson Learned

Despite the openness of DD Motors towards environmental improvements in their operation, there was scope of amelioration regarding saving potentials within the company. Energy and water wastage occurred largely because of a lack of knowledge and awareness, and not because of the absence of highly complex technology. Only by information given by the Indo-German expert team about low/no cost saving measures DD Motors could achieve notable energy, water and consequently cost savings. 

Because of the benefits achieved with the measures DD Motors was encouraged to undertake further interventions, such as installing air guns in place of open hose, replacing coloured transparent sheets with polycarbonate sheets, installing trans vector nozzles in the compressed air guns as well as using air blowers in place of compressed air for car cleaning

The management, as next steps, has planned optimizing compressor usage and implementing water saving measures.

The fact that cleaner production is not merely a good deed for the environment but also helps to increase operational efficiency leading to cost-savings and increased competitiveness, is being vividly demonstrated by the implementation of these simple yet effective changes, further contributing to a change in perception regarding environment-friendly production, paving the way for further, more large-scale, interventions.

RECP initatives undertaken @ DD Motors, Wazirpur

Testimonial

“Following the proposals of the expert team and implementing the recommended measures allowed for substantial energy and water savings in our company. We are proud to help protecting the environment and at the same time realize cost savings. Under guidance of the experts, we made a change towards more sustainability in our operations. The knowledge disseminated in the workshops helped to raise awareness for environment related topics and measures amongst our employees.”

 

Pic 1: Measure 1: 'After' Fixed leakages

 

Pic 2: Measure 2: 'After' Standby compressor

 

Pic 3: Measure 3: 'After' Paint booth with lights off during no occupancy  

 
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