PCRA

1. BEE SME PROGRAMME MACHINE TOOLS PCRA

2. CLUSTER BACKGROUND Global Machine Tools Market : •Total world market size; USD 65.3 bn •World leader Japan has USD 10.5 bn ;has 16% market share Indian Machine Tools Industry •Domestic Market Size : USD 620 mn ( consumption) •Ranks 19th in overall world machine tools production •Contributes 0.5% to overall world production •Exports : USD 11 mn •Exports mainly to developed countries   Manufacturers are geographically dispersed •Top 10 producers account for 70% of the output in India •Around 70% of the players are in the small & medium scale sector •Hubs of manufacturing centres located near the raw material industry or user industries

3. CLUSTER BACKGROUND Machine Tool hubs in India •Mumbai and Pune in Maharashtra; •Batala, Jalandhar and Ludhiana in Punjab; •Ahmedabad, Baroda, Rajkot Jamnagar, and Surendranagar in Gujarat; •Coimbatore and Chennai in Tamil Nadu; •Bangalore in Karnataka. India enjoys several advantages for the growth of machine tool industry •Design Skills •Lower cost of manufacture •Availability of raw materials •Availability of skilled manpower •Presence of support industries (like foundry) •Growth in end user industries

4. Total no .of Machine Tool Units identified for the project are 62 Total no. of Energy Audits to be conducted are 30 (21 nos. Preliminary Energy Audits and 9 nos. Detailed Energy Audits) Preliminary Audits of 21 Units have been completed till now. Reports for 6 nos. of these Preliminary Energy audits have been prepared and sent to BEE. Reports for other Preliminary Energy Audits are being prepared and shall be sent to BEE by the end of this month. The Progress is ahead of Schedule as per Project Work Plan PROGRESS ON SME MACHINE TOOL CLSTER

5. PROGRESS ON SME MACHINE TOOL CLSTER • 12 Units for the Preliminary Energy Audits were taken from the Units suggested in Situation Analysis. • However, further, there was no response from other SME Units specified in the list. Some units were even closed. • Data for other SME units have been collected from Industrial Associations. (Bangalore Machine Tool Association and Peenya Industrial Association) • Rest of the Preliminary Audits (9nos) were completed in consultation with these Industrial Associations.

6. PROGRESS ON SME MACHINETOOL CLUSTER • Seminar on Energy Efficiency Measures in SME Machine Tool Cluster was conducted on 7.10.09 to familiarize the objectives of the Project with Entrepreneurs. • 45 participants from different SME Machine Tool Units involving Entrepreneurs, Managers ,Engineers, LSPs attended the Seminar. • Ex- CMTI Scientists covered topics on Energy Efficiency Measures in Machine Tool Units and EE measures in Hydraulic and Pneumatic systems of Machine Tools • Energy Efficient Motors were covered by Siemens Engineer and external Faculty of PCRA • Bio Gassifier and Solar energy as Fuel Substitution was dealt by Enzen Global Pvt. Ltd • Process changes/ up gradations that eventually result in energy savings, being identified by Key Technical Persons. • DPR preparation shall be initiated after identifying these Technologies and completion of Detailed Audits.

7. No finished Product of two different companies is identical so far. Some of the finished products include the following Armature winding machines Spindles, Centre Grinding Machine, ID Grinding Machine Self Centering Steady Rest Bar Feeding Attachment CNC machine Enclosures Sound Proofs Aerospace Parts Fixtures & Modules Special Purpose Machines Coordinate Measuring Machines Rotary Tables Index Tables to Rotary self centres FINDINGS FROM PRELIMINARY ENERGY AUDIT

8. FINDINGS FROM PRELIMINARY ENERGY AUDIT • Raw Material for these industries is Steel • Typically, these Machine Tool units Perform operations such as • Milling • Turning • Grinding • Cutting • Heat Treatment • Hobbing • All these operations are driven by Electricity. • Capacity of these motors range from 1 HP to maximum of 20KW. • Contract Demand of these units vary from 30KW (LT connection ) to 150KVA. • Some of the industries have taken HT connection, though others have drawn LT supply.

9. FINDINGS FROM PRELIMINARY ENERGY AUDIT • Apparently, it is seen in preliminary audits that there is scope for saving electrical energy as these units mostly have taken Higher contract demand than required anticipating future expansion. • Perceivable Scope of Energy Saving Measures: • Under sizing of the motors • Replacement by EE motors • Employment of VFDs • Adopting latest technologies by replacing conventional machines etc. • Improvement of Power factor • Reduction in Demand,.

10. ENERGY EFFICIENCY OPTIONS • Usage of Del-star converters for under loaded motors • Regulation of supply voltage for illumination could be considered • Use of Renewable energy Sources like Bio– mass Gasification, Solar energy etc. • Replacement of existing Compressors by Screw compressors , arresting compressed air leak etc • However, Actual Potential of Energy performance could be assessed during the course of detailed energy audit .

11. PRE ENERGY USE AND TECHNOLOGY PHASE • SEC has been calculated for individual units. • However, it can not be used as an index for comparison because the final product for each unit is different. • Though it is unfair to compare the Specific Energy Consumption of different machine tool units as they are manufacturing products of different requirements and sizes, it is observed that SEC varies from 0.13 Gcal / unit to 1.5 Gcal/ unit

12. PRE ENERGY USE AND TECHNOLOGY PHASE • The machine tool cluster is not energy intensive as there are only superficial changes made on the job piece. • Most of the conventional machines are second hand ones and imported as the cost of the new machines is very high and are not made in India. • The only energy intensive stage in the machine tool cluster is ‘Heat treatment’ which is generally outsourced.

13. PRE ENERGY USE AND TECHNOLOGY PHASE • Lighting & Air-conditioning loads are low as there is adequate natural light during the day time and the weather condition is cooler in general. • Most of the industries have a turn-over of less than Rs. 2 crores • Generally, the machines/components are not dismantled as they are bought as a single package and apprehensions about the impact on performance.

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