Page 11 - Arebian

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5 Summary of Energy Saving Opportunities In The Plant

The plant is found to be taking continuous actions to optimize the energy consumption as well
as adopting new technologies.

This energy Audit is one of the parts of the energy conservation initiatives taken by the
plant wherein efforts are taken to measure the efficiencies of energy-intensive equipment,
establishing specific energy consumption benchmarks and remedial actions for optimization of
energy costs (Both Fuel and Electricity).

Observations and recommendations are given below.

1. Arabian Flexible Packaging uses electricity + Diesel as the main energy source for the
production.
2. Electrical energy consumption per month of the plant is approximately 488663.5kWh
which cost approximately 185692 AED Per Month at 0.38 AED /KWH. (Ref. Table No. 2)

3. The Supply Electricity Board have implemented Cost Reflective Tariff Structure which has
resulted in a rise in electricity bill.
4. Total average Diesel (fuel) consumption is 11000 liter per month for Boilers. This is
considerable Energy use (Equivalent to 115,500,000 Kcal or 134302 KWH).
5. Fuel consumption data needs to be further clear i.e. clear figures in terms of Consumption
in gallons / liters per month.
6. The linear relation between Energy Consumption and production in the period of Jan-18 to
Dec-18 y= 28.16x + 458254 (Refer Figure-2). which means the variable component of
energy (Varying with respect to production is very small as compared to the fixed one.
Fixed component is almost 85% of the total energy consumption.
7. The scatter on the graph shows that there is not control on Energy Vs. Production.

8. Feb-2018 was the best energy performance month of the plant where Energy Performance
was i.e. 340 KWH / MT and August 2018 was the worst energy performance month with
figure of 535 KWH / MT. Of course this has weather impact, however, considering the low
or almost similar ambient temperatures in Month of January, February, March,
considerable deviation is seen in the SEC.
9. The plant would have saved almost 1.32 Million KWH Units (App. 0.5 Million AED)
statistically if the plant energy performance would have been at par to the best one (340
KWH/MT). Though this data is statistical, but is a fact and should be considered as bench

mark for the factory. This also indicates the need of keen monitoring of SEC Per Month, Per
Hour, Per Day, Per Shift with the help of a precise Energy Monitoring system.
10. This can be achieved in steps but the company management needs to make proper
synchronization of Production>>Planning & Energy / Maintenance Department for daily