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Plastic Packaging ManufacturingManufacturing

Energy Audit & Electricity Cost Optimization for a Plastic Packaging Manufacturing Facility

A comprehensive energy audit of a plastic packaging manufacturing unit identified multiple electricity-saving opportunities across utilities and processing equipment, delivering over 20% reduction in electricity cost with a payback of just 14 months.

Energy Audit & Electricity Cost Optimization for a Plastic Packaging Manufacturing Facility
Savings
₹31.09 Lakh per year
Annually
Energy
3.10 lakh kWh/year
Reduction
ROI
14 months
Payback Period
Efficiency
26% to <5%
Improvement

Project Specs

Client
Industry
Plastic Packaging Manufacturing
Technologies
Energy AuditPlastic PackagingInjection MouldingChiller OptimizationIE5 MotorsServo MotorsCompressed Air OptimizationManufacturing Sustainability

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01

The Challenge

The manufacturing facility faced high electricity consumption due to: Oversized chiller operating at low load and high kW/TR Inadequate cooling tower capacity affecting condenser performance Belt-driven AHUs with low efficiency Significant compressed air leakages (~26%) Hydraulic-based injection moulding machines consuming excess power Multiple under loaded motors operating at poor efficiency High specific energy consumption (SEC) variability with production fluctuations These issues resulted in increased operating costs and underutilized energy-saving potential.
02

Our Solution

A detailed, equipment-level energy audit was carried out covering: Chiller plant, cooling towers, condenser and evaporator pumps Air compressors and compressed air distribution HVAC air handling units Injection moulding and CCM machines Material feeding and conveying systems Key solutions recommended: Addition of CTI-approved cooling tower and chiller controller Replacement of condenser and evaporator pumps with IE5 efficiency motors Upgrade of AHUs with plug fans and IE5 motors Implementation of a structured compressed air leakage management program Conversion of hydraulic injection moulding machines to servo-driven systems Replacement of multiple processing motors with IE5 motors and VFDs Centralized material conveying system for improved efficiency
03

The Results

  • Total annual electricity consumption: 16.25 lakh kWh

  • Electricity cost before audit: ₹1.51 crore/year

  • Electricity savings identified: ₹31.09 lakh/year

  • One-time investment required: ₹36.69 lakh

  • Overall electricity bill reduction: 20.5%

  • Simple payback period: 14 months

Major contributors to savings:

  • Chiller plant & cooling tower optimization

  • HVAC fan upgrades

  • Compressed air leakage reduction

  • Servo and IE5 motor retrofits in processing equipment

The audit delivered a clear implementation roadmap, enabling the plant to achieve fast savings while improving reliability, productivity, and sustainability.

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