kirloskar pneumatic company limited

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.
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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
Consumption
over 2013 - 14
6909
145 kWh/Cylinder
—
7664
139.9 kWh/Cylinder
3.52%
Cylinder
2013 - 14
Refrigeration
Compressor
2014 - 15
Refrigeration
Compressor
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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
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Use only 5 star rated air
conditioners
For new requirement of
lighting load, only LED based
lighting
For new project energy
efficient motors will be used
For flow regulation, variable
frequency drive will be used.
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For any new system, best
available energy efficient
system will be used.
Vacuum cleaning
Energy meters
Inverter based welding
machines
Air circulator
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
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Up gradation of SR furnace
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Oil metering unit at test bed
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AC drive at paint booth
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Water filtration unit
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Energy efficient electric screw
compressor
Energy efficient welding machine
Energy saver for air conditioners
LED based lighting system
Energy Policy
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