Cvbu lucknow 1 Category Excellent Energy Efficient Unit National Award In


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Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

1

Category

Excellent Energy Efficient Unit

National Award  In  

Excellence in Energy Management 2010

Unit

Tata Motors Limited ,

Tata Motors Limited ,

CVBU 

CVBU 

-

-

Lucknow

Lucknow

Sector  

Automobile 

Results 

Best in class 

– Sp. Energy consumption

- Sp. Water consumption &

- Sp. Fuel consumption 

Lake View  Within the Plant

Plant Greenery

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

2

National Award  In  

Excellence in Energy Management 2010

Tata Motors Limited 

Tata Motors Limited 

CVBU 

CVBU 

-

-

Lucknow

Lucknow

Presented By:-



Srinu Babu . Matta

Div Manager

Energy Auditor 

Nitansh . Kamboj

Manager


Energy Manager

Md. Amir

Manager


Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

3

v

Tata Motors Limited



is 

ØIndia’s largest automobile company,

Ø Consolidated revenues of 

Rs. 92,519.25  crore’s

in 

2009-10


.

(US $ 18.3 billion)

ØWe are the 

leader in commercial vehicles

in each segment, 

ØThe company is 

world’s 

fourth largest truck manufacturer

Ø



World’s 

second largest bus manufacturer.

TML - Lucknow

Lake View Within the Plant 

Plant Greenery

Company Profile:- Lucknow Plant

v

Tata Motors -



CVBU Lucknow

is

Ø



Established in 

1992


to meet the demand of Commercial

Vehicles in Indian & overseas market.

Ø

Specialized in the designing and manufacturing of a range  



of modern buses – Low floor, Ultra Low floor, CNG & 

RE Buses.

Ø

Prominent customers include DTC & STU.



Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

4

Lucknow Works

EASTERN COMPLEX LUCKNOW WORKS

Weld Shop 

Cowl & 

Cabin 

Vehicle 

Assembly

Paint Shop

TCF

Vehicle 

Factory

Transmission 

Factory

Integral Bus 

Factory

Frame 

Cowl

Vehicle 

Assembly

Machining

Heat 

Treatment

Module 

Assembly

Module 

Fabrication

Bus 

Focused 

ERC setup

Recon

FBV 

Head 

Quarter 

TMML

Service 

Training 

center

Facilities @ Lucknow

Who are we



Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

5

* Delhi Transport Corporation

**State Transport Unit

Plant  Process

SUPPLY 

CHAIN

Material 

from 

Vendor base -



Local, 

Pune & 


Jamshedpur

Vehicle Assembly Line 

Western Complex

Bus Assembly Line 

TMML

Vehicle Assembly Line 

Eastern Complex

Engine 

Assembly

Transmission 

Assembly

Axle

Assembly

Chassis


Assembly

Cowl


Assembly

BIW 


Shop

Paint 


Shop

DISPATCH

DTC*

Private 

Operator

STU**

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

6

Plant Energy Policy

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

7

We have Energy Management Cell in our 

Plant, Which initiates & Manages all sorts 

of Energy Conservation measures across 

the Plant. The structure of the Energy 

Management Cell is, 

Energy Management Cell

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

8

ENCON Summary

Low Investment < Rs 10,000/-

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

9

ENCON Projects

2006-2007

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2006-2007

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2006-2007

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2006-2007

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2006-2007

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2006-2007

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2006-2007

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2007-2008

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2007-2008

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2007-2008

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2007-2008

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2007-2008

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2007-2008

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2007-2008

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2007-2008

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2008-2009

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2009-2010

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2009-2010

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2009-2010

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2009-2010

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2009-2010

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2009-2010

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

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ENCON Projects

2009-2010

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

48

ENCON Projects

2009-2010

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

49

Burner

SEALER OVEN

Air

Blower

Burner

Air

Blower

Burner

Air

Blower

Burner

Temp 150 

0



Blower

No Flame


Air

Blower

Burner

Air

Blower

Burner

SEALER OVEN

Before: Top mounted three burners oven maintains inside oven temperature i.e. 150 

0

C for full baking of Cowl 



body.

After:

After Consultation with OEM and Internal Quality controller, we found baking of Cowl after sealant paint at 110 

0

C at its pregel stage, which fulfills the requirement. Accordingly one Burner out of three Burners has been 



stopped.

Optimisation of Sealer Oven- Cowl Baking in Paint Shop

Temp 110 

0

After CED process , Seam Sealant and Under body sealant is applied on body. After Sealant application it goes 

for baking in sealant Oven at 150° C. After Baking body goes for sanding , top coat application and again baking 

up to 150°C. So sealant gets baked twice in one cycle.

Make:Maxon-Oven Pak400

Thermal O/p-426 KW

Vol-60,000 M3/Hr

ENCON Projects

Zero Investment

Total Investment



0 Lakh

Total Savings



43.84 T CO

2

/annum

Payback


:

Immediate

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

50

In Phase 1 : 2008-09 : The compressed air pr. of 6.2 bar was under usage earlier. The 

Line pressure of the Compressed air reduced to 5.9 bar with no effect on the pressure 

delivered at the end user.

In Phase 2 :2009-10:  After detailed study and agreement from end user, further  

reduced the pressure setting optimally at 5.7 bar. 



Before Condition

Phase 1 

Total Investment



0 Lakh

Total Savings



0.92 Lakh/annum

Payback


:

Immediate

Optimizing the Compressor Pressure

ENCON Projects

Zero Investment

Compressor House

Phase 2 

6.2 bar

5.9 bar

5.7 bar

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

51

After :

Process improvement-Removed one motor after evaluate the 

prime mover capacity to operate the roller bed conveyor

In Paint shop, after Top Coat & Sealer Oven ,cowl passes through the cooling Zone on roller bed conveyor for 

cooling the cowl body by forced draft blower

.

Before

:

Roller bed conveyor operates with three motor which connected with 

roller operated conveyor belt.

3 Motors 

Long belt

Optimisation of Cooling Zone- Roller Belt operation in Paint Shop

Cooling Zone

M1

M3

Sensor

Cooling Zone

M1

M3

M2

Sensor

L1

L2

L1

ENCON Projects

Low Investment

Total Investment



0 Lakh

Total Savings



1,085 KWH/annum

Payback


:

5 Months

Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

52

Energy Conservation Achievements

Innovative approach

with  Zero & Low Investment

Ø

Total ENCONs in last 4 years: 331



71

38

222

Total ENCONS 

Zero Investments ENCONs

Low Investment ENCONs

21

48

6

Total ENCONs 

Zero Investments ENCONs 

Low Investment ENCONs

ØTotal Low Investment ENCONs : 71

Ø Total Savings: Rs. 72.734  Million

Ø Total zero investment ENCONs : 38

Ø Total Savings thru. Zero investment  

ENCONs : Rs. 6.32 Millions

Ø Total Savings thru. Low Investment 

ENCONs : Rs. 21.22  Million

ØLow Investments mean < Rs. 10,000 /- of investment

Ø

ENCON’s

Ø

Savings


Sohrabji Godrej Green Business Centre

- CVBU LUCKNOW

53

Specific Energy Consumption

Year


Electrical 

KWH / Ton 

or unit of 

prodn


Thermal 

tons or kL 

per ton or 

unit of 


prodn

Electrical 

Thermal

KWH * 


Million

Rs Million

Type of 

fuel


Tons/KL   

(KL)


Rs Million

Eq. Veh.


KWH/Eq.Veh

.

KL/Eq.Veh.



% redn.

% redn.


2005–06

13.81

55.45

HSD

600

 - -

        31,049 

445

0.0193

 - -

 - -

2006–07


15.52

62.49

HSD

720

24.85

        43,073 

360

0.0167

18.962

13.498

2007–08


15.77

64.30

HSD

768

25.52

        46,725 

337

0.0164

6.343

1.670

2008–09


12.02

50.64

HSD

612

20.31

        33,366 

359

0.0183

-6.379

-11.593

2009–10


14.27

60.93

HSD

715

27.30

        65,495 

218

0.0109

39.276

40.451

(April 


− 

March)


Annual Energy consumption

Prodn. in 

tons or any 

other unit of 

prodn. 

Specific Energy 



Consumption

Redn. in Specific Energy 

consn. Over previous year          

**

Electrical



Thermal

Best in Class

Copper 


Text ile 

Ceramic 


- kJ / kg

Fertilizer 

Foundry 

Sugar 


Power Plant 

 

     S pecific  energy consumpt ion during 2007 - 08 = (B)



- kWh/Tone of Cane & % of Steam on 

     Reduct ion in Sp. Energy Consumption =  B – A x 100   = %

- % Aux iliary power consumption & Heat Rate (kCals/kWh)

** Specific energy  cons umption during 2008 - 09 = (A)



Exa mple

- G Cal / Ton

- kWh /  kg

- G Cal / Ton

- kWh/MT & KL or MT/MT of Product

200

300

400

500

600

20

03

–0

4

20

04

–0

5

20

05

–0

6

20

06

–0

7

20

07

–08

2008

–0

9

20

09

–1

0

TML-LKO

Specific Energy Consumption per Equivalent Vehicle produced

Ø

The Energy conservation measures resulted in managing the 



Sp Energy consumption at 218 

KWH/Eq Vehicle. This is National 

& International Bench mark across the class.

Ø


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