1 ID: 97 Title of measure Sector: Tyre Industry

2 Survey Year: 2006 Energy Efficient Temperature Control Technology: Control Systems
3 Name of the Company : Apollo Tyres Ltd., Kerala, INDIA
4 Agency that executed the project : In-house
5 Year of Implementation : 2005
6 Unit Profile:
Apollo Tyres Ltd., is a US$ 1.07 billion annual turnover company with its manufacturing plants at
Perambra & Kalamassery in Kerala, Vadodara in Gujarat and Pune in Maharashtra. Apollo Tyres is
engaged in production of Bias and Radial tyres for all types of vehicles.
7 Description of Energy Conservation Measure:-
Tyre industry uses a large number of temperature control units (TCU's) for maintaining constant
temperature in its machinery. In the original system, tempered water at controlled temperature is
circulated through the machinery using a pump. This water is heated using steam and cooled using
cold water in heat exchanger as and when required, by using a single point pneumatic temperature
control.
The plant has developed an innovative energy efficient temperature control unit, which incorporates a
compact energy efficient TCU which uses electricity for heating and radiator for cooling. Since the unit
is very small it can be placed very close to the machine saving in pumping energy and reduced
radiation losses. Heating and cooling controls made through electronic controllers avoid the valves
and pneumatic systems making it accurate and energy efficient.
8 Picture Before Modification Picture After Modification

Steam
Electric
Heat Pump Heater
Pump

Load Cold Water Load

Radiator
Heat

9 Total investment per unit: 1,250 US$

10 First year energy cost savings: per unit 17,500 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual electricity consumption before, MWh 63
13 Annual electricity consumption after, MWh 27
14 First year electricity savings, MWh 36
15 Annual oil consumption before, kl 30
16 Annual oil consumption after, kl 0
17 First year oil savings, kl 30
18 First year tons of CO2 mitigated 126
19 Assumed sustainability, years 10
20 Expected tons of CO2 mitigated throughout life cycle 1,260

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 1 ID: 98 Title of measure Sector: Tyre Industry
2 Survey Year: 2006 Plant Lighting Technology: Lighting System
3 Name of the Company : Apollo Tyres Ltd., Perambra, Kerala, INDIA
4 Agency that executed the project : In-house
5 Year of Implementation : 2004
6 Unit Profile:
Perambra plant is known as the mother plant of Apollo tyres Ltd., and was incorporated in 1975. The
product range of this plant includes bias tyres for trucks, light commercial vehicles, passenger cars,
front & rear tyres for tractors and radial tyres for various farm sizes.
7 Description of Energy Conservation Measure:-
The shop-floor was illuminated with 3500 Nos. of 40 watts twin tube lights (each consuming 106
watts) with electromagnetic ballasts. This has been replaced with
1) 1500 twin tube sets with electronic ballast and T8 tube lights (each consuming 80 watts) and
aluminum reflectors.
2) 1800 single tube sets of 28 W T5 lamps with electronic ballast (each consuming 28 watts).

8 Picture Before Modification Picture After Modification

3500 tube light set with 2X40 watts T13 lamps 1500 nos of 2X40 watts T8 tube lights
with electromagnetic ballasts with electronic ballasts

1800 nos of 28 W, T5 tube lights

9 Total investment: 62,500 US$

10 First year energy cost savings: 147,500 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual electricity consumption before, MWh 3,200
13 Annual electricity consumption after, MWh 1,500
14 First year electricity savings, MWh 1,700
15 First year tons of CO2 mitigated 1,700
16 Assumed sustainability, years 3
17 Expected tons of CO2 mitigated throughout life cycle 5,100

112
1 ID: 99 Title of measure Sector: Tyre Industry

2 Survey Year: 2006 Replacement of reciprocating Technology: Chillers

compressors with screw compressor
in chillers
3 Name of the Company : Apollo Tyres Ltd., Perambr, Kerala, INDIA
4 Agency that executed the project : In-house
5 Year of Implementation : 2005
6 Unit Profile:
Perambra plant is known as the mother plant of Apollo tyres Ltd., and was incorporated in 1975. The
product range of this plant includes bias tyres for trucks, light commercial vehicles, passenger cars,
front & rear tyres for tractors and radial tyres for various farm sizes.
7 Description of Energy Conservation Measure:-
Chilled water at a temperature of 14 degrees Celsius was used in the process of tyre production
4Nos. of 120 ton reciprocating compressor chillers were installed in 1990 and had an efficiency of
0.8 kWh/ton of refrigeration. This has been replaced with 2 Nos. of 215 ton screw type chillers with
an efficiency of 0.45 kWh/tons of refrigeration.
8 Apollo Tyres Limited Picture After Modification

screw compressor chillers

9 Total investment: 125,000 US$

10 First year energy cost savings: 78,750 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual electricity consumption before, MWh 2,800
13 Annual electricity consumption after, MWh 1,900
14 First year electricity savings, MWh 900
15 First year tons of CO2 mitigated 900
16 Assumed sustainability, years 10
17 Expected tons of CO2 mitigated throughout life cycle 9,000

113
 1 ID: 100 Title of measure Sector: Tyre Industry
2 Survey Year: 2007 Optimization of Energy on Technology: Cooling Towers
Cooling towers
3 Name of the Company : M/s J K Tyre & Industry Ltd., Rajasthan, INDIA
4 Agency that executed the project : In-house
5 Year of Implementation : 2006-07
6 Unit Profile:
J K Tyre & Industry Ltd. (Formerly known as J K Industries Limited), is the flagship company under the
umbrella of JK Organization. J K Tyre manufactures entire range of tyres for all four-wheeler vehicles
being manufactured in India. J K Tyres have pioneered Radial tyre technology in India in 1977 and still
has largest market share. J KTyre has largest share of business with Maruti and Tata Motors, the
largest vehicle manufacturers in India.
J K Tyre also provides compete range of technical services for tyre care. The annual turnover of the
unit for the year 2006-07 is US$ 0.25 billion.
7 Description of Energy Conservation Measure:-
In tyre plants CT are used to remove process heat. In the original system, the unit 's two different plants
sections in the same premises, were having separate cooling towers for catering to the process
cooling demand. Both these CT's were under-utilized. The process heat was required to be removed
at particular pressure & flow.
This is an innovative idea of the in-house team to optimize the plants energy consumption. In this
regard, pressure of one of cooling tower water was measured near another plant. Based upon study,
one inline pump was incorporated to increase the pumps pressure, so that same cooling tower could also
cater another plants. This measure resulted in elimination of cooling towers.

8 Picture/ sketch/ drawing Before Modification Picture/ sketch/ drawing After Modification

9 Total investment: 2,500 US$

10 First year energy cost savings: 162,910 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual energy consumption before, MWh 3,411
13 Annual energy consumption after, MWh 1,899
14 First year electricity savings, MWh 1,512
15 First year tons of CO2 mitigated 1,512
16 Assumed sustainability, years 10
17 Expected tons of CO2 mitigated throughout life cycle 15,120

114