GODREJ & BOYCE MANUFACTURING CO....

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First Prize

Manufactures of

BEE Star Labelled Appliances

(Refrigerator)

GODREJ & BOYCE MANUFACTURING CO. LTD. Pirojshanagar, Vikhroli (Maharashtra)

Unit Profile

Godrej group is one of the largest privately held diversified industrial Corporations in

India. The Company celebrated its centenary in 1997. Today Godrej Group is leading

into many manufacturing activities.

M/s Godrej & Boyce Mfg. Co. Ltd. (Appliance Div.) is a Flagship division of Godrej

Group.

State-of-the-art Plant at Shirwal

Presently the wing-Shirwal plant has an installed plant capacity of 9 Lakh

Refrigerators and 3 Lakh Washing machines per annum.

Company have set Missions to ensure continuous efforts for Energy Conservation:

• To reduce Specific Energy Consumption by 2% every year. • 25% of Total Energy Requirement to be fulfilled by Renewable Energy Resources

by 2016-17. • 30% of Total Energy Requirement to be fulfilled by Renewable Energy Resources

by 2020.

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Mohali Plant

Mohali is a green field project of Godrej commissioned in February / March 1996 to

manufacture refrigerators. This project came about as the Company was looking for

a North Indian site for setting up of a facility to increase the refrigerator

manufacturing capacity to meet the growing demand at 20% and above during 1992

-1994.

Presently the Mohali plant has an installed plant capacity of 18 Lakh Refrigerators /

year & 30 Lakh Compressors / year. The capacity is being enhanced with an

investment of Rs 50 Lakh for Refrigerators Plant line modification to enhance

capacity by 8%.

Energy saving projects implemented with respect to product

Use of HC Refrigerant (R600a):

As a part of the drive to save electrical energy, Godrej has specifically designed

cooling system for its refrigerator, which uses HC (Hydro-Carbon) refrigerant which

is not only energy efficient but also protects environment.

Salient Features of Isobutene (R600a) • Isobutene refrigerant is more efficient. • Lower working pressure leads to low vibrations, noise & less power consumption

during operation.

• Lower working temperatures leads to higher reliability & extended life. • Isobutene have better GWP & ODP properties. (ODP – 0, GWP -3)

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The compressor efficiency has been improved through efforts in electrical and

mechanical design. The EER has been improved from 5.1 to 5.8.

Use of DC Fan motor:

Godrej Frost free refrigerator uses DC powered fan motors which consume lesser

power compared to AC fan motor. These fan motors plays crucial role in forced cold

air circulation inside refrigerator.

Godrej Refrigerators have always led the way in introducing new technologies for

better efficiency and greater value for the consumer. There have been very

significant improvements in technology for our range of refrigerators.

The most significant improvements in company range of award winning refrigerators

are –

• Increase in foam thickness for better insulation

• HC refrigerant

• Higher efficiency motors

• Improvements in internal design of compressor components

• Improvements in lubrication system of compressors

• Suction line material has been changed from Aluminium to Copper.

In future Company is developing appliances which will be powered by variable speed

compressors, which clearly increases the system efficiency by around 10 – 15 %.

CARE 30 COMPRESSORS R600a COMPRESSORS

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Second Prize

Manufactures of


(Refrigerator)

HITACHI HOME & LIFE SOLUTIONS (INDIA) LIMITED

Kadi, Mehsana (Gujarat)

Unit Profile

Founded in Japan in 1910 by Namihei Odaira with the aim of promoting technology

developed in Japan, Hitachi is now one of the most respected Japanese business

powerhouses and a technology leader with well diversified activities worldwide in the

areas as diverse as consumer products, information system, electronics, power,

industrial system, materials, services etc. Hitachi Limited is ranked among top

companies in fortune 500 with a global turnover exceeding $100 Billion.

Hitachi Home & Life Solutions (India) Limited (HHLI), a subsidiary of Hitachi

Appliances Inc, Japan, is a listed company at BSE & NSE exchanges. HHLI came into

existence in 1984. Since its inception HHLI has focused on developing and supplying

high-quality products and technology that contribute to the overall prosperity of the

society.

Headquartered in Ahmedabad, Gujarat, the company's manufacturing facility at

Kadi, Gujarat, is among the ten Hitachi air conditioner facilities worldwide. With a

total installed capacity of 400,000 units a year HHLI is amongst the top air-

conditioning companies in India. HHLI offers the most sophisticated and advanced

air conditioning products designed and engineered especially for the diverse Indian

climate of high ambient temperatures. The Indian plant also exports Hitachi room air

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conditioners to the SAARC, Middle East and other tropical countries in addition to

catering to the Indian market.

HHLI has a wide range of products which include Room air-conditioners (Window &

Split type), Ductable air-conditioners, Telecom segment cooling solutions, Rooftops,

Chillers, SET FREE (Variable Refrigerator flow) Systems and Refrigerators.

HITACHI’S I-CLEAN 5 STAR AIR CONDITIONER WITH R410A REFRIGERANT

HITACHI’S I-CLEAN R410A 5 STAR MACHINE HAS THE FOLLOWING TECHNICAL

SPECIFICATIONS.

Unit Model Number RAU514ITDA RAU518ITDA

IDU Model Number RAS514ITDA RAS518ITDA

ODU Model Number RAC514ITDA RAC518ITDA

Compressor Type ROTARY ROTARY

Rated Cooling

Capacity BTU/Hr 13820 18000

Rated Cooling

Capacity Watts 4050 5274

Star Rating No of BEE Stars 5 5

Rated Power Supply Volts/Hz/Phase 230/50/1 230/50/1

Total Power Input Watts 1125 1524

COP

Rated Cooling

Capacity (Watts) /

Power Input

(Watts)

3.60 3.46

A perfect air conditioner is meant to keep you comfortable and your life

uninterrupted all the time. And that’s what Hitachi air conditioner with the

revolutionary I-clean technology is all about. It automatically cleans the filter of your

air conditioner whiteout you even realizing it and makes you enjoy life, nonstop.

Effect of filter cleaning on performance

1) If the filter is not cleaned for a period of 30 days then its cooling capacity drops

down from 100% to 93% and the Star rating of the unit drop from 5 Star to 3

Star.

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2) In the same way if filter is not cleaned for a period of 120 days then the cooling

capacity drops from 100% to 69% ( means a 1.5tr machine becomes 1.0tr) and

star rating from 5 star to non star rated machine. See below graph.

Due to regular filter cleaning, Hitachi’s I-CLEAN always cools in 100% capacity with

5 Star performances forever.

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First Prize Manufactures of


(Air Conditioners)

LG ELECTRONICS INDIA Greater Noida (Uttar Pradesh)

Unit Profile

LG Electronics India is one of the largest Consumer Electronics and Home appliances

with two manufacturing facility in India, one at Greater Noida and another unit at

Ranjangoan Pune.

LG-India is one of the company which leads market in terms innovation and product

development, LG develop eco friendly designs and improve the product to suit

Indian usage conditions.

LG AC’s history is very dynamics in terms of improvements, LG enter in premium

segment and open up whole new factory at Ranjangaon pune in 2004 & established

new product range in premium segment. At present LG is producing units from both

locations.

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NEW 2014 TECHNOLOGIES

The new range of LG Air Conditioners comes with upgraded 2014 Star rating norms

for higher efficiency. They are powered by latest technologies such as Himalaya Cool

and Monsoon Comfort to maximize comfort and furthermore enhance the efficiency.

LG Air Conditioners are designed to meet the needs of Indian consumers.

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Energy Improvement Projects

LG always works on innovative solutions to lead the market with Star rating. As BEE

upgraded the energy scheme second time in 2014, In lieu of this LG has initiated

and implemented following projects in 2013 ~ 14.

2014: Energy improvement as compare to 2013

• High Efficiency Multi flow condenser

• High star rated models designed with brushless DC motor in indoor units

• High COP compressors

• Cycle optimization through designing optimized evaporator pass

• Controls ( PCB & Airflow ) Optimization

• Energy Efficient Refrigerants

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First Prize

Manufactures of


(Distribution Transformer)

TOSHIBA TRANSMISSIONS AND DISTRIBUTION

SYSTEMS (INDIA) PRIVATE LIMITED

Medak (Telangana)

Unit Profile

“Toshiba Transmission & Distribution Systems (India) Private Limited” (TTDI) is a

wholly owned subsidiary of Toshiba Corporation, Japan.

Toshiba Corporation, Japan acquired the businesses of Power Transformers,

Distribution Transformers and Switchgears from M/s Vijai Electricals Limited,

Hyderabad in December 2013, and established Toshiba Transmission & Distribution

Systems (India) Private Limited (TTDI) and also integrated its state of the art

Manufacturing & design technologies for T&D systems. TTDI is a leading

manufacturer of Power and Distribution Transformers from 5 KVA to 1000 MVA,

1200 kV class.

At TTDI, Hyderabad are also in process of setting up most modern, state of Art

manufacturing facilities for Solid &Gas Insulated Switchgears under collaboration &

support of Toshiba Corporation, Japan.

Toshiba Transmission & Distribution Systems group is a world leader in the supply of

integrated solutions for energy Transmission & Distribution. Our systems effectively

control Transmission & Distribution in order to deliver reliable electricity from Power

Plants to Factories, Transportation Systems and even Our Homes.

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TTDI will emerge as the global production hub of Toshiba Corporation to cater Power

Transmission and Distribution Equipment and component requirements across the

world.

Annual Installed Capacity of TTDI: 34800 MVA

• 12800 MVA-- Distribution Transformers

• 22000 MVA -- EHV/UHV Power Transformers

TTDI has sophisticated ultra - modern manufacturing facilities and state - of - art

Testing &Manufacturing Equipment for fabrication / assembly and testing of

Transformers with total quality control process mechanisms meeting International

Quality Standards. All Testing facilities are accredited by National Accredited Board

for Testing & Calibration Laboratories (NABL) as per ISO/IEC 17025:2005 to conduct

various tests and certify the quality of the product. Apart from that section testing of

components and sub-assemblies, each Transformer is being tested online in the

manufacturing stage. This ensures a defect free product which is perfectly reliable

and gives the customer a trouble free operation.

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TTDI product portfolio includes CRGO and Amorphous Distribution Transformers, Dry

Type Cast Resin Transformers, Power and Ultra High Voltage Transformers and

Reactors, Gas Insulated Switchgear, Air Insulated Switchgear, Solid Insulated

Switchgear, Surge Arrestors, Instrument Transformers, Control and Relay Panels,

Indoor and Outdoor Type Vacuum Circuit Breakers, SF6 Circuit Breakers, Vacuum

Interrupters, Compact Substations andNetwork control system.

TTDI has taken up the following measures to reduce Greenhouse gas emissions and

encourage clean Energy.

TTDI has taken up Bio-Mass Gasification plant which is used to produce producer

gas. The producer gas will be used for thermal applications. This producer gas will

replace the conventional fuel LPG which is used for Ovens of painting section. Apart

from the above, the producer gas will be used to replace the wood of canteen which

is used for cooking application.

TTDI has taken initiative to set up 500KW Roof Top Solar power plant and is

expected to generate about 7.4 Lakh units per annum. This green energy power

plant will be commissioned by end of this financial year (2014-15).

TTDI has always been in the forefront for promoting energy efficiency and analysis of equipment on the Life Cycle Cost basis. TTDI is all set and poised to bring - in a revolution in the field of making more and more Energy Efficient Transformers by usage of most advanced Materials. Driven by the ambition to meet the ever - changing requirements of the market, TTDI intends to reinforce its dedicated base of Research & Development to launch newer & improved versions of Transformers,

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which will prove to be economical in terms of cost and energy and provide total satisfaction to the end users.

TTDI is one of the transformer manufacturers in India, welcomed the energy

efficiency labelling scheme developed by the Bureau of Energy Efficiency (BEE),

Ministry of Power, Govt. of India and got registered with BEE for certain models in

the year 2008 itself, under voluntary scheme during that period. Supplied more than

1 lakh BEE labelled energy efficient distribution transformers across India since 2010

under mandatory labelling scheme and supplied even more (approximately 3 lakh)

high energy efficient distribution transformers in India, since inception of the

company. All these transformers are part of the distribution networks of various

State Electricity Boards (SEBs) and have yielding cumulative energy savings

throughout its life.

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Second Prize

Manufactures of


(Distribution Transformer)

SHIRDI SAI ELECTRICALS LIMITED

Kadapa (Andhra Pradesh)

Unit Profile

Shirdi Sai Electricals Limited (SSE) is a pioneer in the power segment was

established in 1994 at Kadapa, Andhra Pradesh State of India. SSE is one of the

largest manufacturer and supplier of Power and Distribution Transformers in India

and is also a leading provider of solutions for power transmission and distribution

systems in the country through its turnkey projects division.

The organization has been growing at phenomenal pace with its firm commitment to

Quality, Delivery & meeting customized design requirements. Today SSEL has

reached a turnover of Rs. 340 Crs during the financial year 2013-2014 and the

group turnover of Rs. 500 Crs.

Transformer Division

SSE designs, manufactures and supplies eco-friendly distribution and power

transformers adopting a green technology. SSE offers variety of transformers to the

Electrical Utilities of the Government segment and in the Private sector enterprises

within the country and abroad. These transformers conform to IEC60076 / BS171 /

ANSI C 57.12 / IS 2026 / IS1186 and other National and International Standards

and Customers’ specifications.

The following is the product range offered by SSEL’s Transformer Division.

• Conventional type Oil immersed Distribution Transformers with CRGO and

Amorphous Metal Core up to 33kV voltage class

o 3-Ф – up to 3000 kVA o 1-Ф – up to 167 kVA

• Completely self protected type Oil Immersed Distribution Transformers with

CRGO and Amorphous Metal Core up to 11kV voltage class

o 3-Ф – up to 315 kVA o 1-Ф – up to 167 kVA

• Oil immersed Transformers for special applications up to 33kV voltage class

o Wind Energy segment

o Solar Energy Segment o Oil & Gas Segment o Industrial Segment And Other need based applications viz., o Earthing duty o Convertor duty

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• Oil immersed Transformers with corrugated fin walls

o Up to 1500 kVA, 33kV voltage class

• Power Transformers both 3-Ф & 1-Ф up to 20000 kVA and 66kV voltage class.

We are the largest and leading manufacturer and supplier of 5 Star Rated

Distribution Transformers in India.

SSE has committed itself to the cause of energy savings and has invested

substantial amount in its infrastructure for the production of amorphous metal core

(AMC) distribution transformers, under the technology licence of Metglas Inc., of

USA (a subsidiary of Hitachi Metals Ltd., Japan) for the manufacture of amorphous

metal core loops. Amorphous metal cores are manufactured from low loss Metglas

2605SA1 & 2605HB1M core alloys. These low loss and high permeability alloys have

excellent magnetic properties and offer very low no-load losses as compared to the

transformers with conventional CRGO cores (approximately 30%) and hence the

transformers with these cores are quire vividly used in the distribution systems for

the cause of energy savings. Further, the transformers made out of these cores have

the following advantages.

• Save significant amount of energy and reduce green house gases

• Excellent option to reduce distribution losses and improve efficiency

• Superior electrical performance under harmonic conditions. Potential to

improve power quality and mitigate harmonics.

• Lower temperature rise, slower deterioration of insulations result in longer life

of the transformer.

• Key to improve utility economics and enhancing energy conservation efforts.

Responsive to the demands and technological advancements, SSE has created a

world class state of the art modern plant for the manufacture of these transformers

Turkey Projects Division

SSEL has executed turnkey projects with its world class technology and qualified, trained and experienced and skilled work force. The division undertakes design, engineering, supply, erection, testing and commissioning of

• EHV Sub Stations up to and including 132KV

• Transmission Line erection works • Distribution System Projects - APDRP and HVDS.

Energy Conservation Promotional activities

SSE is continuously promoting Star-5 Distribution transformers even though BEE’s

Basic level starts from Star-3. We got succeeded and have been supplying Star-5

Distribution transformers to all the DISCOMS of Andhra Pradesh and Telangana

states.

Apart from the Electricity Boards, we are promoting Low Loss Distribution

transformers for Agriculture and all industry applications also.

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SSE is making the Power transformers also with Amorphous Metal Core, since there

is a energy saving due to reduction of No Load Losses (75 % Lesser than CRGO Core

transformers) and to reduce environmental impact based on suppressing power loss

during operation to minimize CO2 emissions and contribute to the prevention of

global warming.

Energy Management Policy

SSE committed to conserve energy in the Electrical Network and to minimise

damage to the environment. We will promote the energy conservation by the use of

best practices, the latest engineering solutions by supplying the eco friendly energy

efficient Transformers. We will try to achieve the same in the next 5 years.

Customer Service

The organization has an exclusive Customer Service Wing manned by a team of

highly skilled Engineers and Technicians to provide prompt and efficient service to

the customers. Periodic analysis of the feedback is made and appropriate corrective

and preventive measures are taken to ensure not only quality but also reliability,

downtime reduction and life cycle extension. The CSW team remains in constant

touch with the customers and assures Total Customer Service through interaction,

prompt service and effective feedback system.

Future Plans

“SSE is all set to launch EHT Power Transformers up to 220 kV soon” Our Transformer Manufacturing Unit:

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First Prize

Manufactures of


(Pump Set)

AQUASUB ENGINEERING

Thudiyalur, Coimbatore (Tamil Nadu)

Unit Profile

AQUASUB ENGINEERING the Coimbatore based company is a part of AQUA GROUP

an ISO 9001 certified company with 50 years of experience in the pump industry.

The Group manufactures the entire range of water pumps under the brand name of

“TEXMO” and “AQUATEX”.

Aqua Group has 8 units in 3 locations with a manufacturing capacity of 2000 pump

sets a day. The group has two captive automated foundries for ferrous and non-

ferrous castings, a captive electrical lamination (stamping) unit, captive winding wire

manufacturing unit and manufacturing facilities of the highest standards with

Automatic coil winding machines, CNC work centres, over 150 CNC machines and

the latest laboratory instruments & testing facilities.

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ENERGY CONSERVATION MEASURES IN PUMPSETS

• Adapting the latest technologies in the design and development of pump sets to

enhance the efficiency at par with international standards

• Maintaining the consistency in the manufacturing by implementing stringent

quality strategies

• Latest foundry practices are implemented to produce smooth hydraulic profiles

of impellers and diffusers/bowls/volutes to reduce the frictional losses to achieve

higher efficiency level

• Advanced machineries are used for manufacturing the various parts of the pump

sets for attaining sustainable and consistent efficiency levels

• Usage of high quality in-house processed electrical laminations contributes less

wattage losses and energy efficient pump sets

• Better and optimum raw material usage to operate efficiently at wider voltage

bands

ENERGY SAVING PROJECTS UNDERTAKEN

• At present Aqua Group is supplying Star rated Energy Efficient Submersible

pump sets and mono blocks to Ag-DSM project in Malavalli, Mandya District of

Karnataka state in association with Power Grid Corporation of India Ltd, New

Delhi and Energy Efficiency Services Ltd (EESL, A Joint Venture of PSUs of

Ministry Power, Govt. of India).

• Supplied Star rated Energy Efficient Submersible pump sets and mono blocks to

ENZEN project at Karnataka state in the year 2013.

• Star rated Energy Efficient pump sets are supplied to CLDP & RWS Projects, and

all Municipalities in Andhra Pradesh

• Working along with various ESCO companies like EESL in selection, installation

and maintenance of Energy Efficient Pump sets for AgDSM in various states

• Pump sets for solar applications supplied and installed in various states

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ENERGY CONSERVATION BY MARKING STAR LABELED PUMPSETS

Aqua Group is committed to sustained Research & Development activities for the

design of new pumps and continuous improvement of the performance of the

existing product range. It contributes energy saving to the nation by introducing

energy efficient pump sets with star labelling year by year.

Equipped with the latest technology and a most favourable reputation in the

industry, AQUA GROUP is poised to meet new challenges and continue to achieve

standards of excellence.

0

20000

40000

60000

80000

100000

SUBMERSIBLE OPENWELL MONOBLOCK

2009-10 1332 0 0

2010-11 40125 21858 679

2011-12 46721 50345 2196

2012-13 70805 58898 2834

2013-14 87941 60319 3366

MW

h

ENERGY SAVINGS BY STAR LABELLED PUMPSETS

IN MEGAWATT HOUR

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Second Prize

Manufactures of


(Pump Set)

TEXMO INDUSTRIES

Coimbatore (Tamilnadu)

Unit Profile

Founded in 1956, Texmo Industries have been at the forefront and been the pace

setters in the electric motor and agricultural pump Industry since. Texmo, primarily

started to serve the nascent textile motor marker, and today has an annual

turnover of over eight and half billion INR, making it the market leader in India.

State-of-the-art Plant at Place

Some snapshots (featuring world-class manufacturing practices) of the manufacturing facility

• Fully Automation Foundry

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• Aluminium Die casting Machine

• Robotics in Assembly Line

• Submersible Motor Winding Machine

• Name Plate Details in Laser Marking in Shell

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• Production capacity per annum

Texmo Industries is supply wide verity of pump set to its market. It is having the

present manufacturing capacity of 7,50,000 pump sets per annum and also it is

having spare capacity of further 2,00,000 pump sets per annum.

• Company Product Offerings

Texmo Industries manufactures following products

• Monoset Pumps • Openwell Submersible Pumpset • Borewell Submersible Pumpset

• Domestic Pumpset • Induction Motors

Energy saving projects implemented in Company products

Texmo Industries is one of the largest agriculture pump set manufacturing industry

in India. It understands and owns the responsibility to improve energy efficiency in

the products it manufactures. Texmo Industries consciously and continuously

implementing the energy saving projects in manufacturing process and through its

product performance also.

Below table shows the developments made during year 2013

Sr. No Descriptions Models

1 Active energy labelled products till 2013 147

2 Products withdrawn due to less energy efficiency 0

3 Total active energy efficient products till Aug’2014 80

Providing Energy efficient products to comply with the changing market

scenario

Company’s vertical and horizontal products are energy efficient and star labelled.

This has given company a good mileage in the market, as customers are very

conscious of energy conservation, thanks to the awareness campaigns of BEE in the

media viz. electronic and print.

The market scenario is changing rapidly towards the use of high-energy efficiency

appliances due to growing awareness on energy conservation and to comply with the

new norms from BEE.

Texmo Industries is continuously improving its offering of energy efficient products

to customers to further strengthen its Market Leadership.

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First Prize

Manufactures of


(Ceiling Fan)

CROMPTON GREAVES LIMITED

FAN DIVISION

Ponda (Goa)

Unit Profile

Fans Division is very important part of Crompton’s consumer business. This division

has manufacturing units at Bethora and Kundaim in Goa and Baddi in Himachal

Pradesh, which supports the network of authorised dealers and retailers. We are also

leading fan exporter to countries like France, Italy, United Kingdom, Brazil,

Australia, China, USA, Middle East etc.

Fans Division manufactures fans like Ceiling Fans, Table fans, Wall-mounted fans,

Pedestal fans, Exhaust fans, Industrial fans and personal fans. Its range of Ceiling

fans is the largest in India and encompasses everything from under-light and

decorative fans to standard models in various colours, shapes, designs and

performances making each fan unique.

A world class factory with superior testing facility

Assembly Line

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Company Product Offerings

Ceiling Fans, Table fans, Wall-mounted fans, Pedestal fans, Domestic Exhaust fans,

Industrial fans and personal fans.


There are various projects and trials done for energy efficiency improvements.

Company use good quality steel with low watt loss rating, company have changed

copper gauges and stator slot profiles , brought automatic and auto layering winding

machines to reduce copper loss.

Below table shows the developments made during year 2013

1 Active energy labelled products till 2013 19 Nos.

2 Products withdrawn due to less energy efficiency None

3 Total active energy efficient products till Aug’2014 18 Nos.

Continuous improvement to make our product offerings energy efficient

We at Crompton Greaves ltd, Fans Division, believe in continuous improvements in

the products to comply with energy conservation norms. In the recent past, we

made the improvements in the following areas to comply with new energy norms.


scenario

Our vertical and horizontal products are energy efficient and star labelled. This has

given us a good mileage in the market, as customers are very conscious of energy

conservation, thanks to the awareness campaigns of BEE in the media viz. electronic

and print.


appliances due to growing awareness on energy conservation and to comply with the

new norms from BEE.

Crompton Greaves ltd, Fans Division, is continuously improving its offering of energy

efficient products to customers to further strengthen its Market Leadership.

Additionally company ensures the reduction of electric energy usage by providing

sufficient ventilation in the plant, introduced air ventilators for effective exhaust

system, usage of transparent sheets on the roof for proper sunlight.

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First Prize

Manufactures of


(Storage Water Heater)

RACOLD THERMO LIMITED

Chakan (Maharashtra)

Unit Profile

Racold is the largest manufacturer & seller of water heaters in India. Racold became

a 100 % subsidiary of MTS Group of Italy in 1999. It started as a joint venture

company in 1996 between Racold Electrical Appliances and Merloni Termo Sanitari

Spa, Italy with the MTS GROUP having 74% share. In April 2009, the company

changed the name from MTS India Ltd to Racold Thermo Ltd. The company also

exports to various countries like Italy, U.A.E., Singapore and Sri Lanka.

The company has a pan India presence with over 9,000 retail outlets and 175

service centres. It has redefined industry standards and set new benchmarks in

water heating by enhancing the aesthetics, quality, durability, safety and

performance of the product. The continuous focus on innovation and R&D has

established Racold as the pioneer in technology. It has also been the first to obtain

quality and performance certifications as per IEC, CE and other similar International

standards.

State-of-the-art Plant at Chakan

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Racold has its manufacturing plant at Chakan, Pune. The plant capacity is in excess

of 5 Lakhs storage water heaters per annum. It has a full-fledged manufacturing and

testing setup for water heaters. The lab is equipped to carry out all the tests as per

BIS & IEC Specifications. The company is ISO 9001:2008 certified and

implementation of ISO/IEC 17025 for product testing and laboratory is in process.


In May 2014, company applied for revised star ratings for 59 models as per new

norms of BEE (schedule 10). These product developments were validated through

3rd party verification. Production for these models started from July 2014.

Below table shows the developments made during year 2013.

1. Active energy labelled products till 2013 96

2. Products withdrawn due to less energy efficiency 37

3. Total active energy efficient products till Aug’2014 65

Energy Savings increase over a period

Continuous improvement to make our product offerings energy efficient

i) Racold believe in continuous improvements in the products to comply with

energy conservation norms. In the recent past, it made the improvements in the

following areas to comply with new energy norms.

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a. Keeping PUF thickness same, increase the density to reduce overall heat

loss

b. Possible air pockets / gaps filled with additional glass wool to avoid heat

loss

c. Glass wool thickness increased, at Heating Element flange, this eliminates

the heat loss from heating element flange

d. Introduced SMART electronic program to capture the consumer usage habit

and tune the water heater according to the use. This reduces the energy

consumption during unused condition.

ii) From 2013 onwards, company have started using Thermal image analysis to

check the heat loss areas ensuring quick decision to improve in the design

wherever required. Thus all the products manufactured are guaranteed for

energy efficiency and sustainability.


scenario


appliances due to growing awareness on energy conservation. And to comply with

the new norms from BEE, Racold is continuously improving its offering of energy

efficient products to customers to further strengthen its Market Leadership.

Additional initiatives to conform to the standards of the new BEE norms -

a) Development of different kind of thermal insulating materials that can give high

heat retention.

b) Special coating on the tank with higher thermal insulation is under verification.

c) Special efforts being made to design and develop the non-metallic Water tank

These developments will ensure the fulfilment of new norms from BEE, which are

going to be introduced in near future.

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Second Prize

Manufactures of


(Storage Water Heater)

BAJAJ ELECTRICALS LIMITED

Mumbai (Maharashtra)

Unit Profile

Bajaj Electricals Limited is one of the 25 group companies of BAJAJ group.

Company has its headquarters in Mumbai with several Sales and Marketing offices

spread across the country.

Bajaj is one of the oldest business conglomerates in India – Incepted about 76 years

ago in 1938.The turn-over for financial year 2013-14 was over � 4000 crores.

Expected turn-over for the current financial year (2014-15) is approximately � 4700

crores, a growth of ~ 16-17%.Bajaj employs around 2000 employees nation-wide.

COMPANY VISION

Enhancing quality of life and bringing happiness with sustainability.

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Energy saving projects implemented with respect to the product

Bajaj Electricals Ltd. has undertaken several technical assessments over the last 2-3

years to improve on the energy savings of Electrical Storage Water Heater. Following

are the brief of some –

1) Thermal analysis simulation of heat dissipation in a water heater thereby

knowing the pattern and magnitude of heat loss over the entire body.

2) Rigorous testing of water heaters to assess the impact of heating element

design, heating element wattage etc. on the heat gain and heat loss.

3) Experimenting with different PUF chemical compositions to evaluate the best

composition / grade for effective thermal insulation.

4) Undertake testing with different PUF thickness and establish the optimum

thickness for different water heater capacities.

Based on above similar trials, Bajaj has been able to design ‘smart’ water heaters

with an objective of energy savings. As a result, even with the new stringent norms

of BEE, majority of the best-selling models of Bajaj are with 5 star energy rating.

Find below an extract of the thermal analysis conducted for an Electrical water

heater to assess the heat dissipation pattern in heating mode and idle mode.

To better the energy savings of its water heaters, Bajaj has already implemented

the new specification of PUF injection by “fine-tuning” the PUF density, the PUF

thickness and the PUF chemical composition. The first series of water heaters with

this “improved” parameters is already introduced in the market. The second series

will be introduced shortly this year.

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What made this product so efficient-

Being a dominant player in Indian market for consumer durable products for the last

few decades, Bajaj has been able to clearly understand the Indian consumer needs

and has reflected this by developing and delivering products for the “mass market”.

As the Indian consumer is “sensitive” on the “running cost” of any product, Bajaj has

accordingly designed and manufactured Water heaters with the minimum possible

“running cost”. This is achieved by improving the thermal insulation of the water

heater.

100% of water heaters manufactured by Bajaj for the trade has INJECTED PUF as

thermal insulation as against modular PUF and Glasswool / Rockwool still used by

many manufacturers in India. Apart from delivering better energy savings, injected

PUF is also environment friendly as Bajaj uses only CFC free PUF chemicals.

Technically, INJECTED PUF insulates almost every nook and corner of the inner tank

outer surface, thereby eliminating heat losses – largely by conduction.

More importantly, based on the various analysis and experiments carried out in the

last 2-3 years, Bajaj has set certain design parameters which will assist in

developing the best thermal insulation for any capacity and for a range of different

product designs.

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Certificate of Merit

Manufactures of

BEE Star Labelled Appliances (Storage Water Heater)

AO SMITH INDIA WATER PRODUCT

PRIVATE LIMITED

Bangalore (Karnataka)

Unit Profile

A. O. Smith India Water Products Private

Limited (“A. O. Smith India”) was

established in 2006 as a wholly owned

subsidiary of A. O. Smith. Since this time,

the A. O. Smith India team has conducted

numerous focus group studies and spent an

endless number of research hours

determining what India wanted in a water

heater. Backed by 75 years of proven

technological advances, A. O. Smith India

has created a stylish design with features

demanded by the Indian consumer.

State-of-the-art Plant at Place

The A. O. Smith plant started with manufacturing facilities in the KIADB Industrial

Area, Harohalli. The India operation is the 16th A. O. Smith manufacturing facility

worldwide. A. O. Smith is the first manufacturer to invest in and produce glass lined

water heaters in India. Today, A. O. Smith Corporation is one of the largest water

heater manufacturers in the world and is a global leader in innovative technology

and energy efficient solutions.

Company Product Offerings

A. O. Smith’s Water Heater Products Range – HSE-SAS, HSE-SDS, HSE-SES, HSE-

SBS, HSE-SFS, HSE-VAS, EWSH, EWSH PLUS, CEWHR

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(BEE Labelled products Available in 6, 10, 15, 25, 35, 70 Litre capacities)

The company started with manufacturing of the vertical water heater which includes

the EWS series with BEE 4 star rating then A. O. Smith India Water Products Private

Limited, moved into manufacturing of wide range of vertical mounted product range

with BEE 5 star rating and horizontal mounted products with BEE 4 star rating.

Energy saving projects implemented in products

Injected PUF (poly urethane foam) insulation:

To increase thermal insulation capability in A. O. Smith water heater, company have

phased out from pre-moulded PUF insulation to in-site injected PUF Insulation.

1 Active energy labelled products till 2013 39

2 Products withdrawn due to less energy efficiency EWS, EWP,

EWJ series

3 Total active energy efficient products till Aug’2014 41

Continuous improvement to make company product offerings energy

efficient -

Electronics features to improve energy efficiency

a. Electronic Timers

Timers are provided in select electronic models to enable customers to use

the water heaters at a pre-defined time of the day. Timers can be set to

match off-peak electricity demand timings thus reducing the load on the

power grid.

b. Energy meter

Energy meter feature in select electronic models enable the customers to

get an indication on usage of electricity and alter the usage pattern to

minimize the energy costs.

Company vertical and horizontal products are energy efficient and star labelled.

GODREJ & BOYCE MANUFACTURING CO....

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