National Award on Energy Conservation

Mahindra & Mahindra Limited

Top Rank Award in Automobile Manufacturing Sector

Location

Zaheerabad,
Medak District
(Andhra Pradesh)

USD 16.2 billion multinational group

based in Mumbai, India

Employs more than 155,000 people in

over 100 countries

Power Mobility

Enhance Urban
lifestyles

Priorities
Increase business
efficiency

Drive rural
prosperity

Pillars of guidance
Accept No
limit

Alternative
Thinking

Driving Positive
change in everything

About the Zaheerabad factory

ISO 14001:2004
(Environmental Management)

OHSAS 18001:2007
(Occupational Health and Safety Management)

ISO 27001:2005
(Information Security Management System)

2500
Employees

Products
UVs

3 Wheelers
LCVs

Buses

Water Conservation Measures

Rain-Water Harvesting

ETP & STP

Green Belts Development

Bio-Filter Treatment

Absolute Power Consumption (Lakh units)

97.9

0.85 %

97.07

2011-12

2012-13

Specific Electrical Consumption (Kwh/ Eq. Veh)

95.72

2011-12

18.2 %

78.32

2012-13

Energy Conservation Ideas

1st Idea
Energy conservation by Optimal use of space

Initial Situation

Processing of sheet metal body

Cargo

Cabin

Skid

4 Skids used
for processing
4 BMT trucks

After Improvement

3 Skids used to process 4 BMT trucks

Savings
No. of kWh Saved
Thermal Savings
Savings per annum
Investment

: 1.42 Lakhs kWh

: 210 M k Cal
: Rs. 23.82 Lakhs
: Rs. 0.8 Lakhs

2nd Idea
Energy conservation by new lighting systems

Old systems replaced by

more effective and efficient
40W-T8
250 W MV/SV
250 W MV/SV
150 W MV/SV

28 W-T5
150 W SV/MV
45 W CFL
43 W LED

Savings
No. of kWh Saved
: 1.78 Lakhs kWh
Savings per annum : Rs. 17.21 Lakhs
Investment
: Rs. 9.45 Lakhs

3rd Idea
Energy conservation by changing a method of
cleaning

Paint Booth grills cleaning

Before
High pressure Water Jet system used to clean Paint Booth Grills
Physical forces produced by 110kW Motor
After
Chemicals used to remove paint from booth grills
The chemicals used are environment friendly
No compromise on quality
Chemical reactions are self-sustaining and do not require any
power source

Savings
No. of kWh Saved
Savings per annum
Investment

: 1.50 Lakhs kWh

: Rs. 14.51 Lakhs
: Rs.7.2 Lakhs

4th Idea
Choosing the equipment
according to requirement

Retro fitment of screw chilling compressor in

place of reciprocating compressor
Before
98 TR air cooled reciprocating chilling compressor
110 KW motor along with forced draft cooling tower
Water circulation pump in throttled condition

After
Replaced reciprocating compressor with 125 TR screw compressor (75 kW
motor)
Natural draft cooling tower & VFD controlled water circulation pump

Savings
No. of kWh Saved
Savings per annum
Investment

: 1.02 Lakhs kWh

: Rs. 9.91 Lakhs
: Rs. 14.9 Lakhs

Enhancing Energy Efficiency ENCON Cell

Suggestion Schemes
Small Group Activities
Total Productive Maintenance
Low Cost and No Cost automation Techniques

2013-14 Targets
Anticipated Investment Rs. 58 lakhs
Targeted Savings Rs. 64 lakhs