Do pipe and fittings makers in Balasore use most of the cluster's energy?

Over 60% of it, but only because they make most of the tonnes. Six pipe and fittings units use 1,755 of the cluster's 2,860 toe a year for 39,000 of its 62,600 t. Per tonne they are no hungrier than sack or household makers, about 0.045 toe each.

The cluster by product

• Pipes and fittings: 6 units, 39,000 t, 1,755 toe.
• Poly bags and sacks: 13 units, 10,500 t, 450 toe.
• Household items: 4 units, 4,800 t, 220 toe.
• Others: 16 units, 8,300 t, 435 toe.

Per tonne, the products are close

Pipes come to 0.045 toe per tonne, sacks 0.043 and household goods 0.046; the mixed others 0.052. The pipe units lead the cluster because they run big HT extrusion lines of 400 kVA or more, not because each tonne is harder to make. If a buyer compares your pipe with another supplier's, compare kWh per tonne, not the cluster share.

Where an extrusion line loses power

• Barrel heaters on on-off control with poor insulation: radiant heater bands with thyristor control save 20 to 30%.
• Extruder screw at constant speed: a variable frequency drive saves up to 20%.
• Process cooling: staging chillers, cooling towers and efficient pumps save 10 to 25% of cooling cost.
• Compressed air: leaks often above 20% can be brought near 5%; one bar lower pressure saves about 6%.
• Injection moulding: all-electric machines use 50 to 80% less, servo-driven hydraulics about 30% less.

What to send a pipe buyer

1. Kg CO2 per tonne of pipe from your kWh and generator diesel, with the months covered.
2. Tonnes despatched, matched to invoices.
3. Resin type and supplier for each grade; ask the resin supplier for its own figure, because making the polymer is outside your bills.

One tonne of pipe (estimate)

• Pipe units' share: 1,755 / 2,860 toe = 61% of the cluster's energy
• At the cluster's fuel mix: 61% x 20,070 t CO2 = about 12,300 t
• Per tonne: 12,300 t / 39,000 t = about 0.32 t CO2
• Sacks: 450 toe = 16% = about 3,160 t on 10,500 t = 0.30 t per tonne

Energy and output from TERI's Balasore plastics profile. The profile does not split fuels by product, so these lines assume the cluster's mix (20,070 t CO2 at the CEA FY 2025-26 grid factor and IPCC 2006 fuel defaults).

What Senseible does here

Senseible reads power bills, generator diesel slips and LPG invoices into a monthly record and keeps a supplier evidence trail, so the per tonne figure you send a buyer traces to your own bills.

• Supplier evidence for buyers
• Balasore: grid share and CO2
• Plastic moulding per kg

Sources: TERI, Cluster profile: Balasore plastic industries (SAMEEEKSHA), CEA, CO2 Baseline Database for the Indian Power Sector, version 22.0, IPCC 2006 Guidelines, Volume 2 Energy

Last reviewed 2026-10-31.