How much power does an efficient pump save on a 150 kg jet dyeing machine?

About 1.47 kW per machine in BEE's Surat report: a 65% efficient circulation pump replacing a 51% one on a 150 kg jet, running round the clock, saves 12,348 kWh a year. Five machines save 61,740 kWh and about 42 t CO2. Cost Rs 4.40 lakh, saving Rs 3.46 lakh, payback 1.27 years.

Why the old pumps waste power

Surat's units have about 4,200 circulation pumps on jet machines, mostly locally made. BEE's tests found them 40 to 60% efficient, from poor impeller and casing design and pumps picked for the wrong duty. A new pump with the same flow and head, a stainless impeller and better casing runs above 65%.

The report's numbers

• Old pump: 6.8 kW on a 10 HP motor at 51% efficiency, 150 kg jet, about 750 kg a day, 24 hours for 350 days.
• New pump at 65%: 6.8 x 51 / 65 = 5.33 kW, so 1.47 kW saved.
• Per machine: 1.47 x 24 x 350 = 12,348 kWh, Rs 0.69 lakh at Rs 5.60 a kWh.
• Five machines: 61,740 kWh, Rs 3.46 lakh a year. Cost Rs 4.15 lakh for five pumps and motors plus Rs 0.25 lakh wiring, Rs 4.40 lakh. Payback 4.40 / 3.46 = 1.27 years, about 15 months.
• One day of downtime per machine.

Your pump's efficiency decides the saving

• New kW = present kW x present efficiency / 65.
• One audited pump: 136 kWh a day (5.67 kW) at 42.5% falls to 3.71 kW. Saving about 16,500 kWh a year.
• Another: 112 kWh a day (4.67 kW) at 58% falls to 4.17 kW. Saving about 4,200 kWh a year.
• Have the supplier measure flow, head and power on your pump first. Replace the worst ones first.

Five jets, one year (estimate)

• Saved: 12,348 kWh x 5 = 61,740 kWh
• CO2: 61,740 x 0.675 = 41.7 t
• Per machine: 8.3 t
• The report's 52 t uses an older grid factor of about 0.84

CO2 at CEA's FY 2025-26 grid factor of 0.675 kg per kWh.

What Senseible does here

Senseible reads monthly electricity bills into kWh and CO2 records tied to each bill, so the drop after the pumps change is on file for a lender or a buyer's questionnaire. For finance on the pumps, the green loan check lists what to prepare.

• Green loan readiness check
• Surat process houses: buyer carbon data
• Dyeing effluent heat recovery
• Online flue gas analyser on a coal boiler

Sources: BEE, Detailed project report: energy efficient pump for jet machine (150 kg), Surat textile cluster (SAMEEEKSHA), CEA CO2 Baseline Database, version 22.0

Last reviewed 2026-11-01. Report figures are from a BEE SME programme project report; costs and paybacks are at the report year's prices. Check today's tariff and a current pump quote.