Download - Contents Acknowledgement ... Replacement of conventional single blast cupola with divided blast cupola furnace.

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Contents

Acknowledgement ............................................................................................................................................ i

Abbreviations .................................................................................................................................................. ii

Executive Summary ...................................................................................................................................... iv

CHAPTER 1: Introduction ............................................................................................................................ 1

1.1 Background of the project ......................................................................................................................... 1

1.2 Scoping study objective .............................................................................................................................. 2

1.3 Methodology .................................................................................................................................................... 3

1.4 Summary of secondary literature survey ............................................................................................ 3

CHAPTER 2: The Ludhiana-Batala-Jalandhar Forging & Casting cluster overview ................ 5

2.1 Cluster Profile ................................................................................................................................................. 5

2.1.1 Ludhiana – Batala – Jalandhar Forging cluster profile……………………………….. 5

2.1.2 Ludhiana – Batala – Jalandhar Casting cluster profile………………………………… 7

2.2 The Process ................................................................................................................................................... 11

2.2.1 Forging process…………………………………………………………………………………….. 11

2.2.2 Foundry or Casting Process: .............................................................................................. 12

2.3 Fuel use ........................................................................................................................................................... 14

2.3.1 Ludhiana – Batala – Jalandhar Forging cluster………………………………………………..14

2.3.2 Ludhiana – Batala – Jalandhar Casting cluster…………………………………………. 14

2.4 Major energy consuming facility .......................................................................................................... 15

2.4.1 Ludhiana – Batala – Jalandhar Forging cluster………………………………………… 15

2.4.2 Ludhiana – Batala – Jalandhar Foundry (Casting) cluster………………………… 17

2.5 Validation of information of earlier BEE -SME Program ........................................................... 19

2.6 Energy Saving Scope ................................................................................................................................. 20

2.6.1 Technologies identified for Forging Industries ......................................................... 20

2.6.2 Technologies developed for Casting Industries ........................................................ 25

2.7 Past Experience with EE interventions ............................................................................................. 29

2.8 Financing needs of industries ............................................................................................................... 29

2.9 Major Barriers ............................................................................................................................................. 29

2.10 Mitigation measures for eliminating barriers ................................................................................ 30

2.11 Aspirations and willingness of Associations/ Units .................................................................... 31

2.12 Road map for implementation .............................................................................................................. 31

2.13 Conclusion ..................................................................................................................................................... 33

Annexure 1: List of units studied under the Ludhiana-Batala-Jalandhar scoping study

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List of Tables

Table A: Energy and GHG emission saving potential ......................................................................................... v

Table 2.1: Fuel wise break up ................................................................................................................................... 14

Table 2.2: Fuel wise break up ................................................................................................................................... 14

Table 2.3: Specific Fuel consumption of furnace oil based batch type re-heating furnace ............. 16

Table 2.4: Specific power consumption of conventional type turning machine ................................. 16

Table 2.5: Specific Fuel consumption of coal based cupola furnace ......................................................... 18

Table 2.6 Cost benefit analysis of Induction heater ........................................................................................ 21

Table 2.7: Replication potential of Induction heater technology .............................................................. 22

Table 2.8 Cost benefit analysis of Special purpose machine ....................................................................... 23

Table 2.9: Replication potential of Special purpose machine ..................................................................... 25

Table 2.10 Cost benefit analysis of Divided blast cupola furnace ............................................................. 26

Table 2.11: Replication potential of divided blast cupola............................................................................. 27

Table 2.12: Cost benefit analysis for IGBT based induction furnace ........................................................ 28

Table 2.13: Replication potential of IGBT based induction furnace ......................................................... 29

Table 2.14: Steps for implementation of project .............................................................................................. 31

List of Figures Figure 1.1: Meeting with Association Representatives..................................................................................... 3

Figure 2.1: Market -share .............................................................................................................................................. 6

Figure 2.2: Type of units based on furnace type .................................................................................................. 8

Figure 2.3: Market -share .............................................................................................................................................. 9

Figure 2.4: Maps showing the geographical location of cluster cities ..................................................... 10

Figure 2.5: Flow chart of forging process ............................................................................................................ 11

Figure 2.6: Process flow diagram of foundry process .................................................................................... 12

Figure 2.7: Furnace oil fired batch type furnace ............................................................................................... 15

Figure 2.8: Conventional lathe machine............................................................................................................... 16

Figure 2.9: Single Blast copula furnace................................................................................................................. 17

Figure 2.10: Induction furnace ................................................................................................................................. 18

Figure 2.11: Induction heater ................................................................................................................................... 21

Figure 2.12: Special Purpose Machine .................................................................................................................. 23

Figure 2.13: Divided blast furnace ......................................................................................................................... 25

Figure 2.14: Induction furnace ................................................................................................................................. 27

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Acknowledgement

InsPIRE Network for Environment, New Delhi wishes to place on record its sincere gratitude

towards United Nations Industrial Development Organization, New Delhi for entrusting the

prestigious assignment of carrying out a scoping study for Ludhiana-Batala-Jalandhar Forging &

Casting cluster under the project titled ”Promoting Market Transformation for Energy Efficiency in

MSMEs”.

We extend our sincere gratitude to Mr. Debajit Das, National Project Coordinator for the project

titled “Promoting Market Transformation for Energy Efficiency in MSMEs”, for coordination,

support, valuable inputs, and guidance for the project.

We are also thankful to S. Gurpargat Singh Kahlon, President, Autoparts Manufacturers

Association of Punjab, S. Gurpreet Singh Kahlon, MD, Bharat International, Ludhiana, S.

Narinderpal Singh, MD, Global Exports, Jalandhar & Mr. Vinesh Shukla, Ex-Chairman, The Institute

of Indian Foundrymen & President, Laghu Udyog Bharti, Batala for their valuable inputs and

support during the course of this study.

We thank all forging and casting industry members who helped us at various points of time during

this study.

InsPIRE Team

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Abbreviations

APFC

APMA

AC

BEE

BJL

Automatic Power Factor Controller

Auto Parts Manufacturers Association

Alternating Current

Bureau of Energy Efficiency

Batala Jalandhar Ludhiana Cluster

CO

DBC

DG

EET

EESL

FO

Carbon Mono-oxide

Divided Blast Cupola

Diesel Generator

Energy Efficient Technology

Energy Efficiency Services Limited

Furnace Oil

GEF

GoI

GHG

GDP

Global Environment Facility

Government of India

Greenhouse Gas

Gross Domestic Product

HP

IF

Horse Power

Induction Furnace

kcal Kilo Calories

kg Kilogram

kVA Kilo Volt Ampere

kW Kilo Watts

kWh

LPG

LDO

LSD

Kilo Watt Hour

Liquefied Petroleum Gas

Light Diesel Oil

Low Sulfur Diesel

MSME

MT

Micro Small and Medium Enterprises

Metric Ton

MS

OEM

PI

Mild Steel

Original Equipment Manufacturers

Pig Iron

SPM Special Purpose Machine

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SEB State Electricity Board

SFC

SPC

SEC

TPM

Specific Fuel Consumption

Specific Power Consumption

Specific Energy Consumption

Ton Per Month

UNIDO

UCPMA

United Nations Industrial Development Organization

United Cycle Parts Manufacturers Association

VFD Variable Frequency Drive

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Executive Summary

UNIDO’s Project “Promoting Market Transformation for Energy Efficiency in MSMEs” aims to

promote the implementation of energy efficiency in the MSME sector; to create and sustain a

revolving fund mechanism to ensure replication of energy efficiency measures in the sector.

InsPIRE Network for Environment has been awarded with Scoping Study Project of Ludhiana,

Jalandhar, and Batala Forging and Casting Cluster.

A team of professionals from M/s. InsPIRE Network for Environment conducted the scoping

study. Meetings were held with various associations, industry owners at Ludhiana, Jalandhar

and Batala. A detailed survey was carried out to ascertain the type, nature of units in the cluster.

A. Cluster profile:-

The Batala, Ludhiana and Jalandhar forging & casting cluster comprises of around 2000 working

forging units and 500 casting units. The forging units’ manufacturer parts for industrial sectors

such as automobiles, bicycles, agricultural implements, fasteners etc. and are spread over

Ludhiana & Jalandhar cluster. The casting units manufacturer parts for industry such as

automobile, agricultural implements, hand tools etc. and are mainly concentrated in Jalandhar &

Batala cluster.

B. Energy efficient technologies:-

There are well established and proven energy efficient technologies that have been developed

and implemented in both casting and forging cluster. However, the penetrations of such

technologies are low. These technologies have a saving potential of around 15 to 20 % in

specific energy consumption. The energy efficient technologies with the highest potential for

energy saving and with highest replication potential have been identified under the assignment

and are listed below:

Forging sector:

Replacement of conventional fuel fired batch type re-heating furnace with induction

heater

Replacement of conventional lathe & drilling machines with special purpose machines

Casting sector:

Replacement of conventional single blast cupola with divided blast cupola furnace.

Replacement of oil fired rotary furnace with electric induction furnace.

C. Willingness for adaption of energy efficient technologies

The industries as well as the associations expressed that, there is a lack of adequate financing to

the units at affordable rates for up gradation and EE projects, the prevailing bank interest rates

are high for borrowing, and banks are not adequately informed to finance EE projects due to

perceived risks. The units seek low cost funding for EE projects, guaranteed energy & monetary

savings from the EE projects, financial incentives including subsidies, etc. The units have

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responded positively on availability of revolving fund for financing EE projects, welcomed it,

and provided affirmative views.

D. Energy and GHG emission saving potential:

The technologies listed for both the sectors are well proven with significant energy saving and

GHG reduction potential. These technologies also have an attractive payback period. The table

below summarizes the energy saving potential for the proposed technologies, its investment

and pay back periods:

Table A: Energy and GHG emission saving potential

SN Base line Scenario

Energy Efficient technology

Potential units for

replication in the

cluster (Nos)

Annual energy savings

potential from a typical

forging unit (toe/year)*

Annual GHG emission saving potential from

a typcial forging unit

(tCO2/annum)

Overall energy saving

potential from the cluster (toe / year)

Annual GHG emission

saving potential from the cluster

(tCO2/annum)

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Furnace oil fired re heating furnace

Reheating furnace replaced with Induction Heater

1105 21.88 71.16 24177.40 78631.80

2 Turning lathe machine

Conversion of conventional lathe machines to Special purpose machines

1275 1.48 15.47 1884.65 19723.05

3 Convectional Cupola Furnace

Conversion of conventional Cupola furnace with Special purpose machines

30 4.50 32.03 134.91 960.80

4 Convectional Inductiion furnace

Conversion of conventional induction furnace with IGBT based induction furnace

35 3.87 40.50 135.43 1417.50

Total 2445 26332.39 100733.15

* for the number of units already implemented, refer chapter 2

Assumption / conversion factors:

Specific gross calorific value of FO has been considered as 9,600 kcal /kg

Specific gross calorific value of Coal has been considered as 3,600 Kcal/kg

Emission factor FO has been considered as 77.8 t CO 2 per TJ (as per IPCC guideline)

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Emission factor Coal has been considered as 94.30 t CO 2 per TJ (as per IPCC guideline)

The annual production capacity has been considered as 75,000 MT (similar to small capacity

units)

E. Major Barriers for implementation:

The major barriers for penetration of EE technologies in the cluster has been identified as (1)

Lack of information, awareness, and knowledge on part of the unit owners on EE technologies

and its overall benefits; (2) lack of technical knowledge for implementation; (3) lack of

dissemination of the results of the successfully implemented EE projects in the cluster; (4) poor

after-sales service by the EE equipment or other machinery suppliers; (5) lack of confidence on

EE technology suppliers due to large variation of budgeted cost and actual expenses; high

perceived risks; (6) lack of affordable financing for investing in EE technologies and banks’

reluctance for funding EE projects.

F. Mitigation measures for eliminating the barriers:

Brainstorming meetings with stakeholders should be conducted in cluster-level on the

proposed project strategy. This should be supplemented by the feedback received from the

industry counter-parts. The implementation should have adequate numbers of demonstration/

pilot projects wherein the perceived risk should be mitigated; this can follow with large scale

upscaling and replication of the proven technologies; well-structured and effective technical

assistance component should be made available for implementation of EE projects; technical

capacity building and training of the technicians should be done; capacity of EE equipment

should be carried out in cluster level. Although successful demonstration of some of the

technologies has already been done in the cluster; there is a need for conducting detailed study

freshly to identify new and potential technologies. Based on the identified technology, necessary

decisions may be taken on piloting technologies which has not been implemented as of date.

The technology identification study and conduction of energy audit should be a pre-activity

prior to the roll-out of the implementation phase of the project.

G. Road Map: Considering the energy saving potential and success of the proposed EE technologies, the

following road map is being proposed for the implementation of the project:

Brainstorming Meetings: Brainstorming meetings needs to be conducted in each of the

clusters to disseminate the proposed project strategy and also to get inputs/feedback from

industries.

Energy audits: Energy audits need to be conducted in the selected units for establishing the

baseline scenario of the units and for identifying energy saving potential with cost-benefit

analysis. This is required as need of each industry is different.

Strengthening of Local service providers: The cluster lacks good local service providers.

By strengthening the local service providers the proposed technologies can be easily

implemented and technical issues while erection and maintenance issues can be easily

addressed.

Implementation of technologies: To start with pilot demonstration projects needs to be

implemented for all the identified technologies which can be further upscaled.

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Dissemination of success stories: Audio and video documentation of the success stories

and case studies needs to be developed. This is required for wider penetration of the EE

technologies in the cluster.

Training programmes: Skill development of workers needs to be taken up, as most of the

units are lacking on skilled labour.

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CHAPTER 1: Introduction

1.1 Background of the Project

Micro, small and medium enterprises (MSME) sector has emerged as a highly vibrant

and dynamic sector of the Indian economy over the last five decades. MSMEs not only

play crucial role in providing large employment opportunities at comparatively lower

capital cost than large industries but also help in industrialization of rural and backward

areas, thereby reducing regional imbalances assuring more equitable distribution of

national income and wealth. The sector consists of over 36 million units, as of today,

provides employment to over 80 million persons. The sector through more than 6,000

varied products contributes around 8% of GDP; 45% of the total manufacturing output

and 40% of the total exports from the country. The MSME sector has the potential to

spread industrial growth across the country and can be a major partner in the process of

inclusive growth.

Amidst the positive statistics, the MSME sector today is facing extreme challenges in the

form of rising competitive market; increasing production cost and thinner profit margin.

Energy forms a significant portion of the production cost in MSME units catering to 30-

40% of the average production cost. The rising energy costs in recent years have been a

matter for concern for the sector. Efficient utilization of energy and raw materials

becomes imperative for the sustenance of the sector as they work on low-profit margins.

The inefficient utilization and excessive use of raw materials, fuels, and energy lead to

exceeding levels of energy intensity and environmental pollution. The excessive

utilization of energy resources also impacts the regional energy balance and energy

security. Further, it impedes the productivity of enterprises and economic development

of communities at large.

It has been established over the years that the major barriers towards penetration of

energy efficiency in the MSME sector has been low awareness and incapability to

finance. Also, the MSME sector to a large extent requires external support for

technological upgrdation and process improvisation.

Under the above scenario, United Nations Industrial Development Organization

(UNIDO) in association with Ministry of MSME, Government of India with funding

support from Global Environmental Facility (GEF) has launched a national level project

titled “Promoting Market Transformation for Energy Efficiency in MSMEs”.

The project aims to promote the implementation of energy efficiency in the MSME

sector; to create and sustain a revolving fund mechanism to ensure replication of energy

efficiency measures in the sector; and to address the identified barriers for scaling-up

energy efficiency measures and consequently promote a cleaner and more competitive

MSME industry in India. The project has the following objectives:

Promote implementation of energy efficiency in the MSME sector, particularly

targeting the micro unit that constitutes more than 90% and need support for

technology induction;

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Create and sustain a mechanism that would ensure replication of energy efficiency

measures in the sector;

Create a revolving fund by apportioning a part of the revenues from the aggregator

(EESL) that would sustain the activities beyond the life of this project; and

Address the identified barriers for scaling-up energy efficiency measures and

consequently promote a cleaner and more competitive MSME industry in India.

The project is built around four substantive components, and these are:

Component 1: Program to identify energy intensive clusters and replicable

technologies

Component 2: Implementation of technology demonstration projects

Component 3: Aggregation of demand for demonstrated technologies in the clusters

Component 4: Financial models to support replication of energy efficiency projects

in MSMEs

1.2 Scoping Study Objective

The project has identified five clusters initially for commissioning of the project; the

Ludhiana-Batala-Jalandhar Forging & Casting cluster being one of them. Prior to the

actual field implementation, the project seeks to engage a technically qualified and

competent consulting firm for conducting a short scoping study related to energy

efficiency in specified cluster. M/s InsPIRE Network for Environment has been

entrusted with the task of carrying out the scoping study for the Ludhiana-Batala-

Jalandhar Forging & Casting cluster. The scope of work includes conducting preliminary

baseline study adequately addressing the technical, economic and financial issues to

develop a feasibility study for commissioning the identified sites. The competency

scoping study also includes establishment of the present level of energy consumption

and identification of potential areas for improvement of energy efficiency. The scope of

work for the assignment includes:

Profiling of the cluster including the number, categories, classification, and product

produced capacities, locations etc., no. of employees, business volumes, market

scenarios, sustainability scenario success factors etc.

Profiling of fuel used, the type of fuel used, facility wise quantum of use,

consumption per ton.

Identification and profiling of major energy consuming facilities

Validation of information of earlier BEE-SME projects.

Energy saving scope, past experience of EE interventions.

Financing needs of the industries, major barriers; mitigation measures

Documenting aspirations and willingness of associations / units

Developing a roadmap for implementation.

Providing concluding remarks.

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1.3 Methodology

A diversified approach was adopted for conducting the study which included secondary

data research, interactions with industry owners at their premises, meetings with

industry associations’ representatives, interaction with MSME officials, walk through

audits at few selected units, collecting data through questionnaire, analysis of outcome

and documenting key findings. The list of units studied under the assignment is placed

at Annexure A.

The InsPIRE team carried out a detailed secondary literature research of the forging &

casting cluster of Ludhiana-Batala-Jalandhar to understand the process and profile of

the industry in the cluster. The team subsequently visited industries in the cluster to get

firsthand information of prevailing on-ground situation. Meeting with unit owners who

had already implemented energy saving measures under BEE scheme viz. Ms. Bharat

International, M/s. N.N. Forging, M/s. Global Exports were carried out. The team also

visited the non-intervened industries in all the three clusters to understand the

potential of energy savings. Baseline energy audits were carried out in some industries

to determine the existing energy level. Team from InsPIRE along with officials from

UNIDO, EESL & DC-MSME office also conducted brainstorming meetings with the

industry associations’ representatives at Ludhiana, Jalandhar & Batala. These meetings

were held between January 23-25, 2017. The participants were briefed about the UNIDO

initiative for promoting energy efficiency in forging industry including the proposed

methodology, financial and technical intricacies of the project. The data gathered as

above was compiled, analyzed critically, and the scoping study report was prepared and

has been presented in the sections below.

Figure 1.1: Meeting with Association Representatives

1.4 Summary of secondary literature survey

A detailed secondary research was carried out, as part of the assignment, from various

relevant sources, including available literatures on forging and casting sector; web-

portals and publications on the specified cluster. A list of publications and portals

referred to, during the assignment has been listed in Annexure B. The outcomes of the

secondary data research have been summarized below:

The Ludhiana- Jalandhar cluster forms a significant portion of the country’s

forging industry comprising of a large numbers of micro, small and medium

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enterprises. The cluster is of prime importance both historically and strategically

based on the variety of products manufactured and industrial sectors which is

catered to by these units. A large quantum of the industries present here is also

engaged in export. The detailed profile of the cluster is provided in subsequent

sections.

The Jalandhar – Batala cluster has being long known for its casting (foundry)

sector and a large number of units’ produces casts to cater to a variety of

industries like automobiles, agriculture, machine tools etc. A large portion of the

industry in Batala is also involved in hand tool manufacturing.

Both forging and foundry sector are highly energy intensive with majority of the

energy used in the form of thermal energy. A large variety of fossil fuel including

coal, coke, furnace oil, diesel, HDD etc. is used by using. Electrical energy is also

used by these industries.

The only intervention made till date was through the BEE-SME program in 2003

and 2013. In 2003, the Ludhiana-Jalandhar-Batala foundry cluster was studied and

energy efficient technologies related to the same were identified. Later in 2013,

under BEE-SME program Ludhiana forging cluster was taken for intervention

wherein 20 units were supported for pilot demonstration of energy efficient

technologies.

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CHAPTER 2: The Ludhiana-Batala-Jalandhar Forging &

Casting cluster overview

2.1 Cluster Profile

The following section has detailed out the cluster profile separately for the Ludhiana –

Batala-Jalandhar forging and foundry (casting) cluster.

2.1.1 Ludhiana – Batala – Jalandhar Forging cluster profile

The Indian forging industry has emerged as a major contributor to the manufacturing

sector of the Indian Economy. It is a key element in the growth of the Indian automobile

industry as well as other industries such as general engineering, construction

equipment, oil, gas and power. The Indian forging industry is well recognized globally

for its technical capabilities. With an installed capacity of around 37.7 lakh MT, Indian

forging industry has a capability to forge variety of raw materials like carbon steel, alloy

steel, stainless steel, super alloy, titanium, aluminum, etc.

The Ludhiana –Jalandhar forging cluster comprises of around 2000 registered units

scattered across different industrial and commercial areas. Over and above these 2000

units, there are numerous very small capacity forging units who are not registered and

work in clusters mainly relying on job-works. There are approximately 2000 forging

units in the cluster mainly located in and around the cities of Ludhiana and Jalandhar.

The cumulative production capacity of the cluster is approximately 17.5 million tonnes.

These units are categorized as Large, Medium, Small, and Micro units.

Categories:

The forging units in Ludhiana-Batala-Jalandhar can be categorized into Large, Medium,

Small and Micro units, depending on their production capacity. In Ludhiana and

Jalandhar, over 95% of the units fall under MSME sector. The categorization of the units

based on the production capacity has been summarized below:

Very large (capacity above 75,000 MT),

Large (capacity above 30,000 to 75,000 MT),

Medium (capacity above 12,500 to 30,000 MT),

Small (capacity above 5,000 to 12,500 MT) and

Very small (capacity up to 5,000 MT).

Classification:

Forging units cater to a wide number of industries like automobiles, bicycle, fasteners,

agriculture etc. The classification of the forging units can be done based on the product

manufactured and the end sector it caters to. The classification and share of the units

based on the product manufactured has been detailed out in the figure below:

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Figure 2.1: Market -share

Products:

The forging clusters in Ludhiana & Jalandhar manufacturers a wide variety of products

depending on the needs of the end-user. Almost 50% of the products are used for the

Automobile industry including the Bicycle manufacturing sector. The forged products

are processed and finished as per the requirement of clients. The forging industry

manufactures close to 300 different variety of products some of which are crank-shafts,

washers, flanges, shafts, brackets, load bearing hooks, garden tools, hammers,

manufacturing gears, rollers , die blocks, rings etc.

Production Capacity:

The MSME forging cluster consists of units with a wide range of forging capacity ranging

from 30 tons to 1500 tons per month. While the larger units are mostly automated using

latest machinery, the micro and smaller units are still heavily dependent on manual

labor and age-old machine tools. There are many industries in the cluster that carry out

production based on job-work assigned by larger units. Jalandhar mainly has hand tools

and garden/agricultural implements in forging industry. There are about 350 units in

this area.

Locations:

Both Ludhiana and Jalandhar houses densely populated forging industry. Around 1500

forging units exit in Ludhiana. Most of the micro industries in Ludhiana are located in

the Shimla Puri Areas. The small and medium scale industry is spread over Industrial

Estate and Focal Point areas. The forging industry in Jalandhar is concentrated in Focal

Point area. Most of the industries are small scale to medium scale industries. They

manufacture gardening tools, scaffoldings, hand tools etc.

Employees:

A typical forging industry works mainly with outsourced/ contractual labors. Typical

forging units consist of management group; followed by supervisor and outsourced

semi-skilled and un-skilled laborers. The larger units consist of a foreman who is in

charge of the entire production units. A typical forging unit employs around 10 to 50

37%

13%20%

13%

10%7%

Market-share

Auto Parts

Bicylce

Fasteners

Handtools

Agriculture

Others

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personal. Thus, the Ludhiana-Jalandhar cluster in total employs close to 80,000

personal. Almost 3/4th of the employees are un-skilled laborers.

Market scenario:

Current share of auto sector is about 50% of total forging production in the cluster while

the rest is with the non-auto sector. Changes in Indian automobile industry directly

impact forging industry, because the forging components form the backbone of the

Indian automobile industry. Since the automobile industry is the main customer for

forgings the industry’s continuous efforts in upgrading technologies and diversifying

product range has enabled it to expand its base of customers to foreign markets. The

industry operates for 300 to 330 days to meet the market demand. Most of the units are

operating in single 10-12 hours shift.

The Ludhiana-Jalandhar forging cluster has made rapid strides and currently, not only

meets domestic demand, but has also emerged as a large exporter of forgings. The

industry is increasingly addressing opportunities arising out of the growing trend

among global automotive OEM’s (Original Equipment Manufacturers) to outsource

components from manufacturers in low-cost countries. As a result, the industry has

been making significant contributions to country’s growing exports.

Sustainability Scenario:

The units have been in operation since independence and have a good market standing

of their own. With the younger generation taking up the mantle of industry, there is shift

in paradigm towards more energy efficient socially responsible production. The younger

generation knows that in order to compete on World level they need to upgrade which

they are ready to do with some help from government sector. The Punjab Forging

Association which was the representative body of forging cluster is now a defunct unit.

Other representative industry associations include Auto Parts Manufacturers

Association, Chamber of Industrial Commercial Undertaking, United Cycle Parts

Manufacturers Association.

Success Factors:

Ludhiana & Jalandhar is known for its immense skill and low cost production. The

industry here is quite sustainable because of reasons such as flexibility in operations,

large variety of products, economic production, availability of raw material including

alloy steel and a large market for automotive machine parts.

2.1.2 Ludhiana – Batala – Jalandhar Casting cluster profile

There are more than 5,000 foundry units in India, having an installed capacity of

approximately 7.5 million tonnes per annum. The majority (nearly 95%) of the foundry

units in India falls under the category of small-scale industry. The foundry industry is an

important employment provider and provides direct employment to about half a million

people. A peculiarity of the foundry industry in India is its geographical clustering.

Typically, each foundry cluster is known for catering to some specific end-use markets.

For example, the Coimbatore cluster is famous for pump-sets castings, the Kolhapur and

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the Belagum clusters for automotive castings and the Rajkot cluster for diesel engine

castings.

The Ludhiana-Batala-Jalandhar casting (foundry) cluster with an overall production

capacity of 0.36 million tonnes, located in the state of Punjab, are important foundry

clusters in Northern India. Out of the total production, almost 72% of the units with a

production capacity of 0.26 million tonnes approximately fall under the MSME segment.

The majority of the foundry units is in the small-scale and produces grey iron castings.

About 15% of the foundry units are also exporting their products. The foundry units at

Batala and Jalandhar are predominantly making machinery parts and agricultural

implements. The cluster houses approximately 600 casting (foundry) units out of which

around 200 units are engaged in cast iron and rest 400 units cast special grade material.

The cast iron manufactures normally use cupola furnace for casting whereas the others

use oil fired rotary furnace or induction melting furnace. However, in recent past, most

of the units engaged in special grade casting have switched over to induction melting

furnace. The figure shows the unit types based on fuel usage:

Figure 2.2: Type of units based on furnace type

Categories:

Broadly, foundry units are classified with respect to production capacity:

Large Scale Units: These units are having annual Casting production above 1500

Metric Tonnes. There are around 50 such units in BJL Foundry Cluster.

Medium Scale Units: These units have annual Casting production in the range of 250

-1500 Metric Tonnes and there are around 200 units of medium scale size.

Small Scale Units: These units are having annual Casting production up to 250

Metric Tonnes. There are around 250 such units in BJL Cluster.

Classification:

Foundry units in Jalandhar & Batala mainly cater to the automobile machinery parts and

agricultural implements. The classification of the forging units can be done based on the

product manufactured and the end sector it caters to. The classification and share of the

units based on the product manufactured has been detailed out in the figure below:

200

350

50

Type of units

Cupola furnace based units

Induction furnce based units

Oil fired rotary furnacebased units

9 9

Figure 2.3: Market -share

Products:

The foundry (casting) clusters in Ludhiana, Batala & Jalandhar manufacturers a wide

variety of products depending on the needs of the end-user. Majority of the products

include automobile parts, agricultural implements, machine tools, diesel engine

components, manhole covers, sewing machine stands, pump-sets, decorative gates and

valves. Majority of the units used industry grey casting process for manufacturing the

foundry parts. Units in Batala are in operation since last 40 – 45 years manufacturing

lathe machines, milling/ pantograph, fan bodies, pump bodies etc.

Production Capacity:

Most of the units in Batala are using Cupola for melting as the normal production

capacity of the units in Batala is 150 to 200 tpm, whereas only some units are having

capacity of 100 to 150 tpm. Availability of Electricity in Batala – across Dhir Road, GT

Road is an issue; power is available from the grid for maximum 12/14 hours a day. Most

of the units in Jalandhar and Ludhiana are having induction furnace in the range of 500

kg to 1 ton capacity whereas few units which are using local scrap as well as have high

melting temperatures are having cupola and rotary furnace and has a capacity of

minimum 5 ton per day.

Total production capacity in BJL cluster can be estimated approx. 237500 T/yr.

However, the capacity utilization factor is very less. This is mainly because most of the

units in BJL cluster operate for 1 – 4 days/month. The main reason behind this is,

demand pattern and also power situation. Many units have closed down their

production recently.

Locations:

The major locations wherein the casting units are spread are G.T. Road, Industrial area,

Focal Point in Batala. In Jalandhar. Dada Colony Industrial Area, Focal point, Focal Point

Extn, Udyog Nagar, I.D.C, Kapurthala Road & Preet Nagar. In Ludhiana Focal Point Phase

5 to 8, Janta Nagar, Bhagwan Chowk Area & Industrial area – A/B.

33%

35%

10%

10%6%

10%

Machine Parts

AgriculturalimplementsPumps / Fans

Automotive /Oil EnginesTractor Parts

Others

10 10

Employees:

A typical casting industry works mainly with outsourced/ contractual labors. Typical

casting units consist of management group; followed by supervisor and outsourced

semi-skilled and un-skilled laborers. The larger units consist of a foreman who is in

charge of the entire production units. A typical forging unit employs around 10 to 50

personal. Thus, the Ludhiana-Jalandhar cluster in total employs close to 80,000

personal. Almost 3/4th of the employees are un-skilled laborers.

Market scenario:

The Casting units are spread over Batala & Jalander region and most of the units are

meeting the domestical demand. Most of the units in Batala are not in operation

currently due to financial crises and also due it’s to remote location.

Sustainability Scenario:

The units have been in operation since independence and have a good market standing

of their own. With the younger generation taking up the mantle of industry, there is shift

in paradigm towards more energy efficient socially responsible production. The younger

generation knows that in order to compete on World level they need to upgrade which

they are ready to do with some help from government sector

Success Factors:

Batala, Jalander & Ludhiana casting cluster is very old cluster in India. As the cluster is

uniquely placed based on its products and quality, the cluster has a potential for revival

& success

Figure 2.4: Maps showing the geographical location of cluster cities

11 11

2.2 The Process

To understand the fuel use, energy intensity and energy saving potential for the forging and

casting (foundry) cluster, it is important to under the process of manufacturing for

both forging and casting cluster.

2.2.1 Forging process

A typical forging process has been shown in the process flow diagram below. The

different steps involved in the forging process have been separately described.

Figure 2.5: Flow chart of forging process

In the process, the raw material i.e. Mild Steel or Alloy Steel is usually treated with acid

bath & wash to remove surface impurities. This is followed by hot drawing operations,

where cross-sectional area of the material is reduced to the required size. The metal

bars are cut to pieces as per requirement and are ready for forging operations. The

forging process usually involves feeding the metal bar into a batch type furnace (FO or

LPG Fired) on an Electric Induction heater, to raise its temperature to the forging

Raw Material

Cutting metal bars in to

Acid bath + Wash

Drawing

Heating metal pieces @ 1200 –

1250 deg. C

Forging

Trimming

FO Fired Re-

heating Furnace

(open type)

Threading

Heat Treatment (Hardening)

Tempering

Galvanizing and

Final Product

12 12

temperature which in case of mild steel is 1150 – 12000C. This is followed by processing

the heated bar in between the forging die, using a free hammer. The hammer impact

causes the metal bar to attain required size of the die. Once cooled, the material is

machine processed through turning, facing and trimming operations. Subsequently,

threading and drilling is carried out, as per the need. A number of heat treatment

processes are carried out before the material is ready for dispatch.

The major energy guzzler in the forging process is the batch type re-heating (forging

furnace), where material or charge is heated to a temperature of 1150-1200 0C. Furnace

oil is the most commonly used fuel for firing of the re-heating furnace. A significant

amount of energy is spent in the process. The other process where the thermal energy is

used is in a annealing furnace used for heat treatment of the forged bars. An annealing

furnace is also fired by furnace oil most commonly. The respect of the process is driven

by electrical motors ranging from 2 HP to 15 HP. Electrical energy driven machines are

used for machining purposes like trimming, grinding, drilling, threading etc.

2.2.2. Foundry or Casting Process:

The process flow of a typical foundry process has been shown in the figure below. The

different steps involved in the forging process have been separately described.

Figure 2.6: Process flow diagram of foundry process

Pattern

Moulding

Repair and Paint Coating

Mould Closing

Pouring

Cooling

Knock-out

Shot Blasting

Fettling

Inspection

Dispatch

Cupola Melting

Sand

Raw Material

Cooling and mixing

13 13

The major manufacturing processes involved in a foundry process are:

Melting Section:

The raw material is melted in melting furnace. The melting furnace can be an induction

furnace or rotary or arc furnace or cupola furnace. Molten metal from the melting

furnace is tapped in Ladles and then transferred to the holding furnaces. Typically the

holding furnaces are induction furnaces. The holding furnace is used to maintain the

required molten metal temperature and also acts as a buffer for storing molten metal for

casting process. The molten metal is tapped from the holding furnace whenever it is

required for casting process.

Sand Plant:

Green sand preparation is done in the sand plant. Return sand from the moulding

section is also utilized again after the reclamation process. Sand Mullers are used for

green sand preparation. In the sand mullers, green sand, additives and water are mixed

in appropriate proportion. Then the prepared sand is stored in bunkers for making

moulds.

Pattern Making:

Patterns are the exact facsimile of the final product produces. Generally these master

patterns are made of aluminum or wood. Using the patterns the sand moulds are

prepared.

Mould Preparation:

In small-scale industries still the moulds are handmade. Modern plants are utilizing

pneumatic or hydraulically operated automatic moulding machines for preparing the

moulds. After the moulding process if required the cores are placed at the appropriate

position in the moulds. Then the moulds are kept ready for pouring the molten metal.

Casting:

The molten metal tapped from the holding furnace is poured into the moulds. The

molten metal is allowed to cool in the moulds for the required period of time and the

castings are produced. The moulds are then broken in the shake out for removing the

sand and the used sand is sent back to the sand plant for reclamation and reuse. The

castings produced are sent to fettling section for further operations such as shot

blasting, heat treatment etc. depending upon the customer requirements.

In a foundry unit, the melting process is the main energy guzzler. Some of the units in

the Ludhiana-Batala-Jalandhar cluster are still using single blast cupola furnace for

melting purpose, even after the penetration of double blast cupola furnace in the cluster.

Some units also use furnace oil fired rotary furnace or induction furnace for the

melting purpose.

14 14

2.3 Fuel use

2.3.1 Ludhiana – Batala – Jalandhar Forging cluster

The fuel used in industry is mainly furnace oil are used (50-60% of units are based on

this). Some 10-15% units are using LPG for heating, 8-10% units are using LDO/LSD and

5-7% is using coal. Induction heating is a recent introduction and is being used by only

10-15% of the units.

Table 2.1: Fuel wise break up

Fuel Type % age of units

Induction 15%

LPG 15%

Coal 5%

LDO/LSD 10%

Furnace Oil/ used oil 55%

Thermal energy is used in heating (forging furnace) and annealing furnace in a typical

forging unit. The other processes like forging, machining and finishing is carried out by

electrical energy.

2.3.2 Ludhiana – Batala – Jalandhar Casting cluster

Major energy sources being used in foundry cluster are electricity and fuels such as Coal,

Furnace Oil, and Diesel. This depends on application of technology, process requirement,

availability, and economic and safety point of view. The two forms of energy being used

in foundry sector in typical foundry unit are electrical energy and thermal energy.

Electrical energy is being used in melting of iron in induction furnaces, operation of

electrical utilities and thermal energy is being used in cupola furnaces operation.

Availability and consumption of various fuels in typical foundry unit is mentioned in

below sections. The fuel wise break-up of the type of units are shown below:

Table 2.2: Fuel wise break up

Fuel Type % age of units

Coal 33.33 %

Furnace Oil 8.33 %

Electricity 58.33 %

Coal used in foundry cluster is of different grade and is available with local dealers also.

Furnace oil prices are highly market dependent. SEB is the main source of electricity

supply. However availability of electricity is one of the key issues.

15 15

2.4 Major energy consuming facility

2.4.1 Ludhiana – Batala – Jalandhar Forging cluster

The major energy consumption in a forging unit is in heating of the raw material.

Around 70-80% of the total energy is used here. The remaining 20 % is electrical energy

used for lathe machines to obtain turning, facing, threading operations.

A. Batch type re- heating furnace:

Furnace Oil (FO) fired (or) LPG based batch type re-heating furnace is used to heat the

metal pieces for forging. In a batch type re-heating furnace, the metal pieces are kept

inside the furnace and heated for a period of 30 – 45 mins, depending upon the

size/shape of the metal piece and final product to be formed. The metal piece to be

forged is heated to a temperature of 1150~1200 0 C. After the heating process, the red

hot metal piece is kept on the forging die (using a tong) having the cavity of the product

to be formed. The hot metal piece is forged using a free hammer on the forging press and

the metal piece attains the required shape of the die. The re-heating furnace used in the

sector is mostly old having conventional design

with manual control option for fuel firing. A large

quantity of heat penetrates from the furnace

opening. Thus, the efficiency of such furnaces are

low. Further, the flame of the furnace directly

touches the surface of the metal leading to high

burning loss and scale formation due to oxidation

ultimately leading to material/ production loss. In

addition, the atomic/grain structure of the metal is

deteriorated by this process.

Figure 2.7: Furnace oil fired batch type furnace

The batch type re- heating furnace has several disadvantages which are highlighted

below:

Conventional Technology

Material deterioration

High energy consumption

Low production rate

Environmental and health Issues

Ideal running of forging press

Choking at blower suction end

Base line specific energy consumption scenario:

The table below summarizes the base line specific energy consumption figures of a

typical furnace oil based batch type re-heating furnace:-

16 16

Table 2.3: Specific Fuel consumption of furnace oil based batch type re-heating

furnace

Parameter Unit Value

Furnace oil consumption on re-heating furnace Ltr/hr 7.00

Productivity in terms of Kg kg/hour 36.00

Specific energy consumption on FO based re-heating furnace

kg/kg 0.18

Specific fuel consumption in terms of kcal kcal/kg 1773.33

B. Conventional lathe machines:

Conventional machines are used in forging units for various component machining job

work like turning, undercut, threading, threading etc. These machine runs on electrical

motors having the capacity varying from 3 hp to 15 hp with production/ machining of

1000- 2000 pcs/day. Since these machines are manually operated, the process through

which components are manufactured is very slow

and time consuming. Apart from the slow process,

the components manufactured are not very precise

and of high quality. Sometimes the machine keeps on

running even there is no component on the machine

or the operator is busy in some other work. All these

factors lead to the loss of energy and production of

low quality components.

Figure 2.8: Conventional lathe machine

Since these lathe machines are manually operated, the process through which

components are manufactured is very slow and time consuming. Apart from the slow

process, the components manufactured are very precise and of high quality. It is often

observed that the machine operate ideally (without any component loaded on to the

machines) and the operator is busy in doing some other work/activity. All these factors

lead to valuable resource; energy, manpower, time and money.

In the Ludhiana & Jalander 80 to 90 % of the units are using conventional lathe

machines.


The table below summarizes the base line specific energy consumption figures of

conventional turning machine:-

Table 2.4: Specific power consumption of conventional type turning machine


Power consumed in conventional system (say 2 turning machine of 2 hp each and one threading machine of 1 hp)

kW 2.98

Productivity on conventional turning machine Pcs/hr 50

Hourly productivity in terms of kg (assuming one piece of 2 kg) kg/kr 100

Specific power consumption on conventional machine kWh/kg 0.03

17 17

2.4.2 Ludhiana – Batala – Jalandhar Foundry (Casting) cluster

The major energy consumption in a foundry unit is thermal energy that is for melting of

raw material using blast cupola furnace & induction furnace around 80 to 90 % of

energy used for this process rest 10 % for electrical energy

A. Single Blast Copula Furnace

The cupola furnace is a shaft melting furnace, it is

filled with fuel (coke), metal charge (pig iron,

circulation material, scrap steel) and slag-

forming additives (limestone) from the top. In the

bottom part of the furnace, combustion air (blast)

compacted by a blower is fed into the furnace shaft

by nozzles. During this process, the counter flow

principle is used to transfer heat from the

combustion gases to the charge until it is melted.

Thus, the required energy is generated in the

cupola itself, i.e. without any transfer, and it is

used at the site of generation. The quality of the

fuel and the combustion process itself must be

reproducible since all fluctuations have an impact

on the melting process.

Figure 2.9: Single Blast copula furnace

Preparing the hearth bottom with layers of coke is the first step in the operation cycle of

a Cupola. Wood is used for initial ignition to start the coke burning. Subsequently, air is

introduced through the ports in the sides called tuyeres. Once the coke bed is ignited

and of the required height, alternate layers of metal, flux and coke are added until the

level reaches the charged doors. The metal charge would typically consist of pig iron,

scrap steel and domestic returns. The air reacts chemically with the carbonaceous fuel

thus producing heat of combustion. Soon after the blast is turned on, molten metal

collects on the hearth bottom where it eventually tapped out into a waiting ladle or

receiver. As the metal is melted and fuel consumed, additional charges are added to

maintain a level at the charging door and provide a continuous supply of molten iron.

Then charging is stopped but the air blast is maintained until all of the metal is melted

and tapped off. The air is then turned off and the bottom doors opened allowing the

residual charge material to be dumped.

The Cupola furnace has several disadvantages which are highlighted below

Incorrect blast rate

Lower blast air pressure

Incorrect distribution of air between the top and lower tuyeres

Turbulent (non-linear) entry of air into the cupola

Incorrect sizing of cupola parameters such as tuyere area, well depth,

and stack height among others

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http://www.giessereilexikon.com/en/foundry-lexicon/?tx_contagged%5Bsource%5D=default&tx_contagged%5Buid%5D=3807&tx_contagged%5BbackPid%5D=3&cHash=bb3b0804610204566dec57670c2a8c28

http://www.giessereilexikon.com/en/foundry-lexicon/?tx_contagged%5Bsource%5D=default&tx_contagged%5Buid%5D=4336&tx_contagged%5BbackPid%5D=3&cHash=359ab2783cc5f021904f68030652c795

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http://www.giessereilexikon.com/en/foundry-lexicon/?tx_contagged%5Bsource%5D=default&tx_contagged%5Buid%5D=4768&tx_contagged%5BbackPid%5D=3&cHash=729fd2fcd2261325e03b00f204d0d100

http://www.giessereilexikon.com/en/foundry-lexicon/?tx_contagged%5Bsource%5D=default&tx_contagged%5Buid%5D=3872&tx_contagged%5BbackPid%5D=3&cHash=c4d77d5760c53d80de7c2d56fc7b62b6

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https://en.wikipedia.org/wiki/Tuyeres

18 18

Poor operating and maintenance practices

Poor control of feed materials (shape, size, weight, sequence).


The table below summarizes the base line specific energy consumption figures of a

Cupola furnace

Table 2.5: Specific Fuel consumption of coal based cupola furnace


Casting material tons/day 10

Coal Consumption tons/day 2.5

Specific fuel consumption of coal in cupola furnace t/t 0.25

B. Electric Induction Melting furnace

Almost 350 units in Ludhiana – Jalandhar – Batala cluster uses electric induction furnace

for melting of casting material. An induction furnace is an electrical furnace in which the

heat is applied by induction heating of metal. Induction furnace capacities range from

less than one kilogram to one hundred tonnes capacity and are used to melt iron and

steel, copper, aluminum and precious

metals. The advantage of the induction

furnace is a clean, energy-efficient and

well-controllable melting process

compared to most other means of metal

melting. Most modern foundries use this

type of furnace, and now also more iron

foundries are replacing cupolas with

induction furnaces to melt cast iron, as the

former emit lots of dust and other

pollutants.

Figure 2.10: Induction furnace

An induction furnace consists of a nonconductive crucible holding the charge of metal to

be melted, surrounded by a coil of copper wire. A powerful alternating current flows

through the wire. The coil creates a rapidly reversing magnetic field that penetrates the

metal. The magnetic field induces eddy currents, circular electric currents, inside the

metal, by electromagnetic induction. The eddy currents, flowing through the electrical

resistance of the bulk metal, heat it by Joule heating. In ferromagnetic materials like

iron, the material may also be heated by magnetic hysteresis, the reversal of the

molecular magnetic dipoles in the metal. Once melted, the eddy currents cause vigorous

stirring of the melt, assuring good mixing. An advantage of induction heating is that the

heat is generated within the furnace's charge itself rather than applied by a burning fuel

or other external heat source, which can be important in applications where

contamination is an issue.

19 19

Induction furnace has been the mode of steel and other metal melting for ages. With

development, the furnace has also gone through changes, with more energy efficient

versions available. These furnaces are manufactured in India by indigenous technology

supplier. Only a handful number of such furnace suppliers exist who caters to the need

of the induction furnace across various sectors, across the country.

Base line specific energy consumption scenario: The table below summarizes the base line specific energy consumption figures in an

electric melting furnace:

Table 2.5: Specific Fuel consumption of electric induction furnace


Production capacity per day tons/day 8

Total energy consumption per day kWh/day 4800

Specific energy consumption in induction furnace kWh/t 600

2.5 Validation of information of earlier BEE -SME Program

The “BEE SME Program” was implemented in the Forging & Casting Cluster during the

year 2009-10.

DPR‘s were developed on energy efficient technologies on casting units namely

Replacement of Single Blast Copula with Divided Blast Copula

Replace Oil-fired Rotary furnace to Induction furnace

Installation of APFC

Providing insulation to the Cupola furnaces

Use of Energy Efficient correct size motor

Installation of Energy efficient lighting systems

However, most of the DPRs are not relevant in the present scenario significantly due to

the change in the price of fuel, better technologies available in market, implementation

of some technologies by the units and cost benefit due to changed market scenario. Most

of units in the cluster who are involved in special grade casting have replaced the

conventional oil fired rotary furnace with induction furnace. Latest design of induction

furnace has evolved in market in recent past, which is more energy efficient than the

earlier version. However, detailed project report related to the same needs to be

prepared. Similarly, divided blast cupola has already been adopted by most of the grey

casting units. Fresh study needs to be conducted for possibility of further saving.

Later in 2014, BEE-SME Program for Ludhiana forging cluster was been initiated. 20

units’ were enrolled under the project out of which 9 units successfully implemented the

following two technologies:

Induction Heater

Special purpose machine

20 20

The energy saving potential in the cluster is huge as the BEE- SME program has only

touched 1% of the total industries. Out of the 2000 active forging units in the cluster, the

BEE-SME project has directly intervened only 20 units, out of which only 7 units have

successfully implemented the technologies. However, a large section of units exist using

conventional technology, which needs to adopt energy efficiency technology. The

following observations were made pertaining to BEE SME program and present

scenario:

Lack of awareness about the EE technologies in the market. It was observed that

instead of the BEE-SME program, most of the units are still not aware of the energy

efficient technologies. A significant move in this regard has already been taken by

BEE by conducting 5 numbers of dissemination workshops in the cluster.

However, these workshops were attended by around 100 units which work out to

be 5% of the total population. Thus, a lot more capacity building program and

hand-holding needs to be conducted in the sector for large scale penetration of the

technologies.

Dynamic changes in fuel cost. It was observed that although the technology has

been successfully demonstrated; the economics has been changing with varied

price of furnace oil over the years. Cost-feasibility of these machines needs to re-

check during the period of implementation.

Lack of skill man power in operation of special purpose machines. Although many

of the units are convinced about the technologies, the lack of skilled manpower in

the cluster is a case of concern. So, it is important to consider capacity building

exercise of the workers in addition to the technology implementation.

Cost of equipment is too high. High capital investment required is a major barrier

towards higher penetration of these EE technologies in the sector. In such case,

capital subsidy or financial incentive may upscale the penetrations.

Most of the units are running with partial process. All EE technologies are not

applicable for all units. Under such conditions, individual energy audit or walk-

through audit is required.

2.6 Energy Saving Scope

2.6.1 Technologies identified for Forging Industries

The EE technologies that have significant scope for reducing the energy consumption

and production costs in forging cluster are (I) Replacement of oil fired forging furnace

with induction heaters, (II) Replacement of conventional machines with special purpose

machine. These are explained below:

A. Replacement of oil fired forging furnace with induction heater

Induction heating is the process of heating an electrically conducting object by

electromagnetic induction, where eddy currents are generated within the metal and

resistance leads to Joule heating of the metal. So it is possible to heat a metal without

direct contact and without open flames or other heat sources (like IR). An induction

heater consists of an electromagnet (coil), through which a high-frequency alternating

current (AC) is passed. The frequency of AC used depends on the object size, material

21 21

type, coupling (between the work coil and the object to be heated) and the penetration

depth. An induction heating system is composed by an inductor (to generate the

magnetic field) and a converter (to supply the inductor with a time-varying electrical

current).

Hot forging is a process where the part is heated above the material recrystallization

temperature before forging, typically 1100°C (2012°F) for steel. Hot forging allows a

part to be formed with less pressure, creating finished parts with reduced residual

stress that are easier to machine or heat treat. Warm forging is forging a part below the

recrystallization temperature, typically

below 700°C (1292°F). As a superior

alternative to furnace heating,

induction heating provides faster,

more efficient heat in forging

applications. The process relies on

electrical currents to produce heat

within the part that remains confined

to precisely targeted areas. High

power density means extremely rapid

heating, with exacting control over the

heated area.

Figure 2.11: Induction heater

Recent advances in solid-state technology have made induction heating a remarkably

simple and cost-effective heating method. Benefits of using Induction heating for forging

are:

Rapid heating for improved productivity and higher volumes

Precise, even heating of all or only a portion of the part

A clean, non-contact method of heating

Safe and reliable – instant on, instant off heating

Cost-effective, reduces energy consumption compared to other heating methods

Easy to integrate into production cells

Reduced scaling

Energy Saving Potential:

The table below illustrates the saving potential of replacing furnace oil based re-heating

furnace with Induction heater

Table 2.6: Cost benefit analysis of Induction heater


Baseline scenario

Furnace oil consumption on re-heating furnace ltr/hr 7.00

Hourly productivity on re-heating furnace kg/hr 36.00

Specific energy consumption on FO based furnace kg/kg 0.18

Specific energy consumption in terms of kcal kcal/kg 1773.33

Cost of energy consumption Rs /kg 4.62

22 22


Annual Production (based on baseline productivity) kg/annum 86400.00

Post Implementation Scenario

Power consumed by induction heater kWh 28.01

Hourly productivity on induction heater kg/hr 65.00

Specific energy consumption on induction heater kWh/kg 0.43

Specific energy consumption in terms of kcal kcal/kg 370.59

Cost of energy consumption Rs/kg 3.02

Annual Production (based on post implementation productivity)

kg/annum 156000.00

Savings

Reduction in cost of energy Rs/kg 1.60

Reduction in specific energy consumption kcal/kg 1402.74

Annual cost savings (based on post implementation productivity)

Rs/annum 249848.67

Annual energy savings (based on post implementation productivity)

kcal/annum 218827360.00

Annual energy savings (in terms of toe) toe/annum 21.88

Annual energy savings (in terms of TJ) TJ/annum 0.91

Investment for 50 kW induction heater Rs 731745.00

Simple Pay-back years 2.93

Annual GHG emission savings tCO2/annum 71.16

* Emission factor of furnace oil taken from IPCC guideline as 77.8 tCO2/TJ

Based on the scoping study and survey the tentative implementation scenario and the

replication potential for this particular technology are tabulated below:

Table 2.7: Replication potential of Induction heater technology

S.

No

No. of

units in

the

cluster

No. of

units

using

forging

furnaces

Percentag

e of units

who has

converted

to

Induction

Heater

(%)

Potential

units for

replication

Annual

energy

savings

potential

from a

typical

forging unit

(toe/year)*

Annual GHG

emission

saving

potential

from a typical

forging unit

(tCO2/annum)

Overall

energy

saving

potential

from the

cluster

(toe /

year)

Annual GHG

emission

saving

potential

from the

cluster

(tCO2/annum

)

1 2000 1300 15 1105 21.88 71.16 24177.40 78631.80

*Refer Table 2.5 above

B. Special Purpose Machine

A Special Purpose Machine (SPM) is a kind of multi-tasking machine used for machining

purpose. A special purpose machine is used as a replacement to conventional machines

like lathe, drilling or trimming machine. A special purpose machine is designed based on

the customized requirement of a unit and may be used for one or multiple task as per

the design. For example, a conventional lathe machine takes 3 mins (say) to machine

(turn) a metal piece. Thereafter it is transferred to another machine for facing and

23 23

trimming operations. In some cases, a third machine is used for threading operations. A

special purpose machine specifically designed can replace all the three machines with a

single machine. The replaced special purpose machine can perform all the four activities

i.e. turning, facing, trimming, and threading on sequential manner. The sequence of

operation is pre-set using timers and sensors. The entire operation is maintained using

pneumatic and mechanical control. For ease of operation, each special purpose machine

is equipped with an automatic feeder.

Replacement of conventional machines with

special purpose machines usually increases

machine productivity by 5 times, easing the

life of the operators by avoiding manual

intervention during each operation. Since, a

number of conventional machines is

replaced with a special purpose machine, the

total electrical power of the equipment

reduces, this making it energy efficient.

Figure 2.12: Special Purpose Machine

A special purpose machine (SPM) is usually customized based on the specific

requirement of a unit. A SPM is used for multi-task operation, which are typically

performed in more than one conventional machine. The sequence of operation in a SPM

is pre-set using timers and sensors. Usually, a SPM is equipped with two or more

machine tools fitted in different axis. The operations are carried out in sequential

manner. The axial motion of the machine tool is usually powered by pneumatic controls,

whereas positioning of the tool is done using sensors. A particular operation e.g. turning

operation in a metal piece of 400 mm is pre-set using timers. Once the operation is over,

the sensor directs the next sequence of operations, which are also pre-fed programs in

the machine. Thus, manual intervention in each operation can be prevented. Also, two or

more operational can be performed simultaneously in a SPM. Similar is the case for

SPM-drilling machine, where the time taken in conventional drilling machine which

performs one drilling operation at a time, can be significant reduced by simultaneously

performing two or more drilling operations at a time.

Energy Savings Potential:

The table below illustrates the saving potential of converting conventional turning

machine with Special purpose machine.

Table 2.8: Cost benefit analysis of Special purpose machine


Baseline scenario

Power consumed in conventional system (say 2 turning machine of 2 hp each and one threading machine of 1 hp) Assuming the motors are running on 80% loading

kW 2.98

24 24


Hourly productivity on conventional machine in terms of pcs

pcs/hr 50.00

Hourly productivity in terms of kg (assuming one piece of 2 kg)

kg/hr 100.00

Specific energy consumption in terms of kWh/kg kWh/kg 0.03

Cost of energy consumption Rs /kg 0.21

Annual Production (based on baseline productivity)

kg/annum 240000.00

Post Implementation Scenario

Power consumed by special purpose machine (one spm of 3 hp replaces three conventional machines; runs at 80% loading)

kW 1.79

Hourly productivity on spm machine in terms of nos. of pcs.

pcs/hr 150.00

Hourly productivity in terms of kg (assuming one piece of 2 kg)

kg/hr 300.00

Specific energy consumption in terms of kWh/kg KWh/kg 0.0060

Cost of energy consumption Rs/kg 0.04

Annual Production (based on post implementation productivity)

kg/annum 720000.00

Savings

Reduction in cost of energy Rs/kg 0.17

Reduction in specific energy consumption kWh/kg 0.024

Annual cost savings (based on post implementation productivity)

Rs/annum 120314.88

Annual energy savings (based on post implementation productivity)

kcal/annum 14781542.40

Annual energy savings (in terms of toe) toe/annum 1.48

Annual energy savings (in terms of MWh) MWh/annum 17.19

Investment for SPM turning machine Rs 530250.00

Simple Pay-back years 4.41


*Emission factor of electricity taken as per IPCC guideline as 0.9 tCO2/MWh.



25 25

Table 2.9: Replication potential of Special purpose machine

S.No No. of

units in

the

cluster

(No.)

No. of

units

using

forging

furnaces

(No.)

Percentage

of units

who has

converted

to

Induction

Heater (%)

Potential

units

for

replication

(No.)

Annual

energy

savings

potential

from a

typical

forging

unit

(toe/year)*

Annual

GHG

emission

saving

potential

from a

typical

forging unit

(tCO2/annu

m)

Overall

energy

saving

potential

from the

cluster

(toe /

year)

Annual

GHG

emission

saving

potential

from the

cluster

(tCO2/annu

m)

1 2000 1500 10 1275 1.48 15.47 1884.65 19723.05

*Refer Table 2.5

2.6.2 Technologies developed for Casting Industries

The EE technologies that have significant scope for reducing the energy consumption

and production costs in casting cluster are (I) Replacement of oil fired forging furnace

with induction heaters, (II) Replacement of conventional machines with special purpose

machine. These are explained below:

A. Replacement of single blast cupola with divided blast furnace

Poorly designed cupolas lead to high consumption of coke resulting in increased input

costs of melting. A divided blast cupola (DBC) reduces carbon monoxide (CO) formation

by introducing a secondary air blast at the

level of the reduction zone. Thus the DBC has

two rows of tuyeres with the upper row

located at around 1m above lower row.

Dividing the blast air has benefits in terms of

energy savings. However, to realize the full

benefits of energy efficiency, optimal design

of the divided blast system is crucial. The

coke consumption in the DBC is reduced by

almost 35%. It increases tapping temperature

by about 50 0C and the melting rate is also

increased.

Figure 2.13: Divided blast furnace

Benefits of Divided Blast Cupola

Optimum blower specifications (quantity and pressure)

Optimum ratio of the air delivered to the top and bottom tuyeres

Minimum pressure drop and turbulence of the combustion air

Separate wind-belts for top and bottom tuyeres

Correct tuyere area, number of tuyeres, and distance between the two rows of

tuyeres

26 26

Optimum well capacity

Higher stack height

Mechanical charging system

Stringent material specifications


The table below illustrates the saving potential of converting conventional cupola with

divided blast Cupola furnace

Table 2.10: Cost benefit analysis of divided blast cupola furnace


Casting material tons/day 10.00

Coal consumption for 8 hour operation using conventional Cupola furnace

tons/day

2.50

Specific fuel consumption using conventional Cupola furnace

t/t 0.25

Coal consumption for 8 hour operation using Divided blast Cupola furnace

tons/day 2.00

Specific fuel consumption using Divided blast Cupola furnace

t/t 0.20

Savings after Implementation of DBC/ ton of molten material

t/t 0.05

Monetary Savings Rs/ton of molten metal Rs/t 750.00

Rejection of material In Conventional Cupola for 8 hour operation

tons/day 0.70

Rejection of material In Divided Blast Copula for 8 hour operation

tons/day 0.50

Savings of material after implementation of DBC for 8 hour operation

tons/day 0.20

Monetary Savings Rs/ton of molten metal Rs/t 40.00

Total monetary savings per tonne Rs/t 790.00

Annual production t/y 250.00

Annual monetary savings Rs in lakhs 1.98

Investment for Divide blast furnace Rs in lakhs 6.00

Payback period years 3.04


Annual energy savings toe/ annum 4.50

* Emission factor for coal considered as 98.06 tCO2/annum



27 27

Table 2.11: Replication potential of divided blast cupola

Sl .No No .of units in

the cluster

No. of units using

cupola

Percentage of units who

has converted to divided

blast cupola (%)

Potential units for

replication



casting unit (toe/year)*

Annual GHG emission

saving potential from

a typcial casting unit

(tCO2/annum)


potential from the

cluster (toe / year)

Annual GHG emission


the cluster (tCO2/annum)

1 600 200 85 30 4.50 32.03 134.91 960.80

*Refer energy saving calculations for the particular technology

B. Replacement of conventional Induction furnace with IGBT based induction furnace

An induction furnace consists of a nonconductive crucible holding the charge of metal to

be melted, surrounded by a coil of copper wire. A powerful alternating current flows

through the wire. The coil creates a rapidly reversing magnetic field that penetrates the

metal. The magnetic field induces eddy currents, circular electric currents, inside the

metal, by electromagnetic induction. The eddy currents, flowing through the electrical

resistance of the bulk metal, heat it by Joule heating.

The inverter based power supply is an important factor for the operation of the

induction furnace. More power can be fed into the induction furnace by increasing the

frequency. With increased power, the melting can be fast thus leading to reduction in

specific power consumption. With the development of insulated-gate bipolar transistor

(IGBT) based invertor, operating the furnace with higher frequency is possible. The

hybrid invertor design has advantages of both parallel and series invertor and utilizes

IGBT’s capabilities to better control inverter. The

power conversion efficiency of these technologies

is good compared to the earlier thyristor based

control. Also the power factor is maintained at a

good level at any load. In IGBT based equipment

the major benefit is of power factor which is 0.98

during complete melting also sintering cycle. Also

less input KVA required running the same

equipment which means we will get the same

liquid metal with lesser input KVA.

Figure 2.14: Induction furnace

Limitation:

Replacement of Thyristor based induction furnace with IGBT based induction furnace

requires huge capital investment. For e.g. a 350 kW / 500 x 2 IGBT based induction

furnace would cost around Rs 50 lakhs including auxiliaries. In such case, it is not

feasible to replace existing induction furnace with IGBT based induction furnace.

However, in those scenario, where the unit wants to increase their productivity and go

on for a new furnace, IGBT based induction furnace is the most suitable solution.

https://en.wikipedia.org/wiki/Alternating_current

https://en.wikipedia.org/wiki/Magnetic_field

https://en.wikipedia.org/wiki/Eddy_current

https://en.wikipedia.org/wiki/Electromagnetic_induction

https://en.wikipedia.org/wiki/Electrical_resistance

https://en.wikipedia.org/wiki/Electrical_resistance

https://en.wikipedia.org/wiki/Joule_heating

28 28

Keeping in mind, the low penetration level of such furnaces, the replication potential has

been accordingly worked out.

Benefits of Induction Technology

Low melting cost

Low rejection rates

Less pollution i.e. environment friendly

Cheaper scrap material can be used

Less burning losses of alloys & Pig Iron

Higher production

Better quality (malleability)


The table below illustrated energy saving potential by replacing a conventional

(Thyristor based) induction furnace with IGBT based induction furnace:

Table 2.12: Cost benefit analysis for IGBT based induction furnace


Productivity of induction furnace of 500 kg capacity

per day tons/day 5

Specific energy consumption for thyristor based

induction furnace per tonne kWh/t 600

Specific energy consumption for IGBT based induction

furnace per tonne kWh/t 570

Annual production (considering 250 days operation

per year) tons/year 2500

Annual energy savings kWh/y 75000

Annual monetary savings Rs in lakhs 3

Investment difference between IGBT based induction

furnace vis-à-vis thyristor based induction furnace Rs in lakhs 4

Simple Pay Back year 1

Annual energy savings (in terms of toe) toe/year 4

Annual GHG emission savings tCO2/year 41

*Emission factor of electricity has been taken from IPCC guidelines as 0.9 tCO2/MWh

**Cost of electricity taken as Rs 7 /kWh



29 29

Table 2.13: Replication potential of IGBT based induction furnace

S.No No .of units in

the cluster

No. of units using

induction furnace

Percentage of units who

has converted to IGBT based induction

furnace (%)

Potential units for

replication



casting unit (toe/year)*

Annual GHG emission


a typical casting unit

(tCO2/annum)


potential from the cluster (toe / year)

Annual GHG emission


the cluster (tCO2/annum)

1 600 350 10 35 3.87 40.50 135.43 1417.50

*Refer energy saving calculation for the particular technology

**Only units looking to increase productivity and wanting to go for new furnace would opt of IGBT based induction furnace.

2.7 Past Experience with EE interventions

The foundry and forging cluster are scattered across the cities of Ludhiana, Jalandhar

and Batala. A large number of initiative has been taken in the past in these cluster for

diffusion of energy efficient technologies including the initiatives taken by PCRA, BEE,

Local Pollution Control Board and the Industry Association. As a result, the scenario in

these clusters has vastly changed in the past few decades. Most of the cupola based

furnace has been replaced with divided blast cupola furnace. Also, furnace oil based

rotary furnace has completely been phased out by replacement with Induction furnace.

All the new units are now opting for IGBT based Induction Furnace. Similarly for Forging

cluster, the interventions has led to adoption of energy efficient technologies in the form

of Induction Melting units and Special purpose machines. The BEE-SME EE intervention

in Ludhiana and Jalandhar has resulted in nine units upgrading their facilities. They have

reported increased production levels with better products and reduction in their

specific energy consumption of 60 to 80 %. The balance units which did not complete

the project backed out due to financial problems and market slow down. Still a huge

potential exists in these cluster for large scale adoption of energy efficient technologies.

2.8 Financing needs of industries

One of the major barriers identified towards lack of penetration of energy efficient

technology in the cluster is lack of financial support to cater to the high CAPEX required

for implementation of these technologies. The past experience shows that

implementation of EE technologies has been motivated significantly with financial

support from Government or other organization. Under such scenario, introduction of a

suitable financing mechanism and kick-start large scale adoption of energy efficient

technologies in the cluster.

2.9 Major Barriers

The major barriers towards low penetration of EE technologies in the cluster, that have

been identified from the discussions and field , which can be categorized into financial,

technical, institutional, and legal/ regulatory, as given below:

Lack of information, awareness, and knowledge on part of the mill owners on EE

technologies and its overall benefits; majority of the mill owners doesn’t have

30 30

technical knowledge. In such scenario, introduction of large scale dissemination of

EE technology can boost higher penetration of EE technologies in the sector.

Lack of dissemination of the results of the successfully implemented EE projects in

the cluster; though some mills have successfully implemented EE technologies in

the cluster, there is no propagation or effective dissemination of information on

benefits achieved, investments, financing, etc. within the cluster. For e.g. the BEE-

SME program has been able to reach only 1% of the population of the forging units

in the cluster. In order to assure fast-track adoption of EE technologies, it is

important to have repeated and widely spread dissemination programs as part of

the project design.

Lack of technical capacity of mill owners for implementation EE technologies; also

their workforce is non-technical. This barrier mandates introduction of capacity

building program which is equally important as technology implementation.

Technology implementation should happen in parallel with capacity enhancement

of the man-power.

Unable to identify the vendors. Although some of units are aware of the benefits

envisaged by adoption of EE technologies, lack of local service providers (LSPs) to

cater to these technologies is an important concern.

Worry of poor after sales service. Linked with non-availability of adequate

numbers of LSPs in the cluster, comes the problem of poor after sales service. It is

important to develop the skills of the LSPs to cater to maintenance / overhauling

of the technologies being implemented.

Worry of technical risk involved. Units here fall under different category and sizes.

Pilot demonstration of technologies under varied capacity of units may boost large

scale adoption and replication of the potential EE technologies.

Lack of adequate finances for up gradation. Finance is an important barrier

towards upscaling of the technologies. In such case, introduction of some suitable

financial support may boost implementation.

2.10 Mitigation measures for eliminating barriers

The following measures could help in mitigating the barriers:

Holding of awareness cum dissemination workshop. The step one of the project

designs aimed to upscale energy efficient measures in the sector, should look into

designing a suitable strategy to reach to each of the units. Holding of frequent

awareness and dissemination workshops across sectors can motivate units for fast

tracking energy efficiency in the sector.

Providing technical support to identify the technology suited to the unit. The

implementation of energy efficient technologies cannot be standardized due to the

varied production capacity and product range. More numbers of energy audits

should be conducted to develop customized requirement for each type of units.

Helping in finding local vendors for EE products. It is important to develop LSPs

for fast tracking the implementation of energy efficient measures. Identification

and capacity enhancement of LSPs should be taken up as a pre-requisite activity to

upscale energy efficiency.

31 31

Providing training to staff and unit owners. In addition to the capacity building

programs for the LSPs, skill enhancement training programs should be also

conducted for the shop-floor level personal so that they are well aware of the

technologies and acquainted with the skills to operate these latest technologies.

Setting up pilot units to spread awareness. In some cases setting up of pilot

projects will stimulate the process of implementation. Pilot demonstration should

be taken up across sector and with varied capacity. Each category of units should

be facilitated with a demonstration unit; aimed to remove their technical hinge for

implementation.

2.11 Aspirations and willingness of Associations/ Units

The associations and units have expressed their complete willingness to participate in

the project during the kick off meeting.

2.12 Road map for implementation

The road map for successful implementation of the project has been illustrated below:

The section below elaborates the steps suggested for successful implementation of

market transformation project in the MSME cluster of Ludhiana-Batala-Jalandhar:

Table 2.14: Steps for implementation of project

Step Specific Outcome Envisaged

Details of activities suggested Status

1 Overview of the cluster; cluster profiling in terms of no. of units, categories, energy usage, rough estimate of the baseline scenario; identification of most replicable energy efficient technologies; estimated energy saving and GHG emission reduction from the cluster

Field study; secondary data research; stakeholders consultation; baseline evaluation; walk-through audits in sample units; awareness cum dissemination workshop; brainstorming session

Completed

2 Induction of cluster level implementation agency; Target setting; identification

Hiring of agency to carry forward the cluster specific work for implementation;

To be initiated

Basic scoping study Finalization of technologies

Carrying out energy audits in certain units to devlop feasibility of

all technologies

Determining the base energy consumption of

the sector and identified targets

Technical Implementattion

towards implementation

Post implementation and extablish

32 32

Step Specific Outcome Envisaged

Details of activities suggested Status

of units; launching of financial mechanism

Based on the overall project objective, setting specific energy saving targets for the cluster; drawing and implementing measures for selection of units for pilot demonstration / replication; finalizing financial support mechanism

3 Energy audits to identify customized solutions; Establishment of unit specific baseline energy consumption; Drawing implementation plan for each unit

Conducting detailed energy audit in each of the units enrolled; Providing document on energy saving potential and implementation plan

To be initiated

4 Identification; capacity building of LSPs

Listing of LSPs. Providing training to enhance capacity of LSPs to meet local needs.; enrollment of LSPs to cater to local needs; tender for large scale procurement

To be initiated

5 Technical assistance towards implementation

Day to day monitoring; supervising implementation activities including procurement, delivery, erection and commissioning; setting up norms for entire process

To be initiated

6 Financial support mechanism

Effective implementation of the financial support mechanism; coordination with banks for timely disbursement; monitoring effective utilization of funds

To be initiated

7 Establishing results Carrying of post implementation studies to establish actual results; comparing with targets; documenting results/ achievements

To be initiated

8 Capacity building programs To carry out parallel activities on capacity building of LSPs, shop-floor workers and management

To be initiated

9 Dissemination of lesson-learnt / achievement

Proper documentation of results; holding of dissemination workshop

To be initiated

10 Development of project exit strategy

Development of measure for sustainable implementation of the project initiative; ensuring take up of the model by industry association; banks in future

To be initiated.

33 33

2.13 Conclusion

With the serval interaction and meeting with units and association it’s clearly states that

the cluster is in need for energy efficiency intervention as the cluster has a significance

scope of around 10 to 15 % of reduction in the energy consumption and the potential of

the technologies that are developed in the various energy efficient programmes. The

need of energy efficiency in the cluster is summarized in the following paragraphs:

Cluster potential: as the cluster comprises of around 2000 forging and 500 casting

units ranging from small to medium units. As per the study it was been observed

that only 5 to 6% of the units were upgraded to energy efficiency technologies.

Energy efficient technologies available: They are well established technologies

that are can be replicated in the units in the cluster. Each of the technology has a

potential of 15 to 20 % of energy saving in specific energy consumption.

Willingness for adoption energy efficient technologies: As per the outcome

study, it has been established that there is a necessity for the industries to adopt the

energy efficient technologies as the cost of production of raw material is increasing

and there is a growing competitive nature of the business. The technologies are well

accepted due to its lower pay-back and can be implemented with some financial

assistance.

Energy & GHG saving potential: It is estimated that if around 200 forging units

and 200 casting units from the cluster adopt energy efficient technologies, it can lead

to an energy saving to the tune of 1060 TJ/year which implies reduction of GHG

emission by approx. 80,000 t CO2/year.

Major barriers: Lack of awareness about energy efficiency and lack of adequate

finance for implementation were identifies as the major barriers for the

implementation.

Road Map for future: The road map for future is suggested to start with small

group meetings and awareness workshops; this need to be followed up by energy

audits of individual plants since the technical requirement for each plant is different.

The recommendation of the energy audits can be taken up as implementation of

technologies. To boost the confidence of the units, implementation should be done in

two phases, phase-1 comprising of pilot demonstration followed by large scale

upscaling of technologies in other units. This can be supplemented by strengthening

of local service providers, documentation of success stories and capacity building of

stake holders.

34 34

Annexure 1

List of units studied under the Ludhiana-Batala-

Jalandhar scoping study

SN. Name of Industry Contact Person Contact No. Email

1 N N Products, Ludhiana Nitin Sharma 9417019692

2 Nicks India Tools, Ludhiana Surinder Mahendru

9872200000 [email protected]

3 Ranson Exports, Jalandhar Davinder S Kalsi 9317655101 [email protected]

4 Goyal International, Jalandhar Ashok Goyal 7087412900 [email protected]

5 Unison Lawn Equipments, Jalandhar

Raj Karan Singh 9915200085 [email protected]

6 Hind Metal & Allied Inds, Batala Vinesh Shukla 9814220418 [email protected]

7 Bravo Industries, Batala Ravinder Handa 9417168784 [email protected]

8 Shubham Industries, Jalandhar Suresh Kumar Agarwal

9316678485

9 National Corporate, Jalandhar Sanjay Gupta 9463217325

10 TMT Machine Tools, Jalandhar Baljit Singh 9357256005 [email protected]

11 Mitter Engineering Works, Jalandhar

Mukhvinder Singh 9417187713 [email protected]

12 Humma Tools, Jalandhar Surinder Singh 9814037276 [email protected]

13 Pilot India, Jalandhar Simranjeet Singh 9815200250 [email protected]

14 JSR International, Jalandhar Ankur Goyal 7087412800 [email protected]

15 Global Exports, Jalandhar Narinder Pal Singh 9814061278 [email protected]

16 Star Metal Industries, Jalandhar Varinder Mahindru

9463760899

17 Rava Engg. Corporation, Jalandhar

Vinod Sharma 7814099001 [email protected]

18 A.G.Steel Corporation, Jalandhar

Amrik Singh 9417506725 [email protected]

19 Syntech International, Jalandhar

Brij Mohan 9915600784

20 Northpole Industries, Jalandhar Satish Jagota 9815077994 info@northpole_industries.com

21 Vaishnav Engg. Works, Jalandhar

Harsimran Singh 9814218125 [email protected]

22 Clusson Engg. Industries, Jalandhar

Kulbir Singh 9814100078 [email protected]

23 Denmark Hydraulics, Jalandhar Jaswinder Singh Nagi


24 JST International, Jalandhar Mohan Singh sangha


25 Victor Tools, Jalandhar 2224001

26 HR Tools, Jalandhar Suresh Sharma 2432101 [email protected]

27 Prabhat Forgings, Ludhiana H.S. Khurana 9814020073 [email protected]

mailto:[email protected]


















mailto:info@northpole_industries.com

mailto:info@northpole_industries.com









35 35

SN. Name of Industry Contact Person Contact No. Email

28 Munish Manufacturing Corp. Ludhiana

Davinder Bhasin 9814024000 [email protected]

29 Manav Tools India Ludhiana D.P.Aggarwal 9814060390 [email protected]

30 Kay Jay Forgings P Ltd., Ludhiana

Gopi Kothari 9814000007 [email protected]

31 Kundi Brothers, Ludhiana B.D. Sharma 9915400305 [email protected]

32 M.R. Steel Forgings, Ludhiana Sat Paul Bhumbla 9814025377 [email protected]

33 Sunder Forgings, Ludhiana S.S. Anand 9888024855 [email protected]

34 Shiv Durga Engg. Works, Ludhiana

Mukesh Ghai 9814023070 [email protected]

35 United Tools & Steels Forgings, Ldh

G.S. Sekhon 9915877777 [email protected]

36 Harpreet Industries, Ludhiana G.S. Anand 9876080009 [email protected]

37 J.K.Cycles, Ludhiana Rajan Gupta 9872983800 [email protected]

38 Sandhu Forgings, Ludhiana Preet Pal Singh Sandhu


39 R.N.Gupta, Ludhiana Avinash Gupta 9815000338 [email protected]

40 Happy Machine Tools, Ludhiana

Vicky Goel 9814123215 [email protected]

41 Emson Tools Mfg Corp., Ludhiana

Amarjeet Dhall 9814021610 [email protected]

42 Kwality Forge, Ludhiana Sanjeev Garg 2534426

43 S.R. Forgings Sumeet Kapoor 9815615656 [email protected]

44 Sekhon Forgings, Ludhiana Gurdev Singh Sekhon


45 Rachna Fasteners, Ludhiana Taranjit Lal 9814047000 [email protected]

46 United Nut Bolt, Ludhiana Naval Kumar 9815082450

47 Udhera Mechanical Works, Ludhiana

Mangal Sain 9501023700 [email protected]

48 Souviner International, Ludhiana

Ravinder Kumar Gupta


49 Shine Industrial corp., Ludhiana Harpreet Singh Chadha


50 Satnam Steels, Ludhiana Gurdial Singh 9814025764 [email protected]

51 Nexo Industries, Ludhiana Rajinder Singh 2532331 [email protected]

52 Morning Star Inds., Ludhiana Rachpal Singh Bhamra


























