Which of the Bureau of Energy Efficiency Morbi ceramic reports pays back fastest, and which saves the most rupees?

In the Bureau of Energy Efficiency (BEE) Morbi ceramic reports, leaving out cogeneration, an agitator on and off timer pays back in 0.05 years and roller kiln heat recovery in 0.80. The largest yearly saving, rupees (Rs) 36.10 lakh, is the briquette hot air generator at 1.47. Efficient agitator motors are slowest at 3.4.

Twelve projects, fastest payback first

Each line gives project cost, yearly saving, both in Rs lakh, and payback in years, as the report's own summary table prints them.

• Agitator on and off timer: 0.22, 4.26, 0.05.
• Roller kiln heat recovery (a recuperator): 8.46, 10.44, 0.80.
• Dryer on a tunnel kiln, fed with cooling air: 6.64, 6.50, 1.00.
• Power factor panel: 2.31, 2.00, 1.2.
• Polishing line motors: 25.79, 20.37, 1.26.
• Briquette fired hot air generator: 53.01, 36.10, 1.47.
• Variable frequency drive (VFD) on a grinding machine: 4.64, 2.541, 1.82.
• Kiln insulation: 15.58, 8.4, 1.85.
• Variable frequency drives on agitators: 3.99, 2.13, 1.87.
• Variable frequency drive on a hydraulic press: 3.64, 1.56, 2.33.
• Low thermal mass kiln car: 21.96, 7.51, 2.92.
• Efficient motors on agitators: 2.01, 0.59, 3.4.

Gas, power, or neither

Five reports save gas and pay back in 0.80, 1.00, 1.47, 1.85 and 2.92 years. Six save power and pay back in 0.05, 1.26, 1.82, 1.87, 2.33 and 3.4 years. The power factor panel saves neither fuel nor units, only a rebate on the bill. The three kiln reports we checked price gas at Rs 15 a standard cubic metre (scm), which is a 2010 figure.

Where a report disagrees with its own workings

• Power factor: the summary says Rs 2.31 lakh, the cost table totals Rs 2.42 lakh although its lines add to 2.37, and the paragraph's items add to 2.30. Payback is 1.2 years on either.
• Roller kiln heat recovery: the before and after lines (9,540 and 9,236 scm a day) differ by 304, while the saving line says 295. The annexure's 108,350 kilocalories an hour recovered gives 295 at the 8,800 kilocalories per scm the other kiln reports use. The 9 scm a day gap is not explained. The summary also labels the 69,620 scm saved as kilowatt hours (kWh) a year. On the printed cost and saving, 8.46 divided by 10.44 gives 0.81 years, against 0.80 printed.
• Dryer on a tunnel kiln: 6.64 divided by 6.50 is 1.02; the report prints 1.00.
• Kiln insulation: the summary says Rs 15.345 lakh and 1.8 years, while the cost table and payback section say Rs 15.58 lakh and 1.85 years. The ranking uses the latter.

Files in the public report list that repeat

The list shows 15 Morbi files. Three pairs are word for word the same: the two hot air generator files, the two polishing files, and the two agitation files. The cogeneration reports are left out of the table, as they cost Rs 899 lakh and 1,904 lakh and have their own page.

Yearly saving for each rupee spent, from the printed figures

• Agitator timer: 4.26 / 0.22 = Rs 19.36 saved a year per Rs 1
• Roller kiln heat recovery: 10.44 / 8.46 = Rs 1.23
• Dryer on tunnel kiln: 6.50 / 6.64 = Rs 0.98
• Polishing motors: 20.37 / 25.79 = Rs 0.79
• Hot air generator: 36.10 / 53.01 = Rs 0.68
• Low thermal mass kiln car: 7.51 / 21.96 = Rs 0.34

Figures are the reports' own, at 2010 prices.

What Senseible does here

Senseible reads fuel invoices and electricity bills into monthly records, so a unit's gas and power bills are on file to test any of these savings against its own use.

• Slip agitation: three options
• Dryer on a tunnel kiln
• Variable frequency drive on a grinding machine
• Variable frequency drive on a hydraulic press
• Morbi power factor report

Sources: BEE, Detailed project report: briquette fired hot air generator, Morbi ceramic cluster (SAMEEEKSHA), BEE, Detailed project report: energy conservation in polishing section, Morbi ceramic cluster (SAMEEEKSHA), BEE, Detailed project report: use of low thermal mass car in tunnel kiln, Morbi ceramic cluster (SAMEEEKSHA), BEE, Detailed project report: waste heat recovery in roller kiln, Morbi ceramic cluster (SAMEEEKSHA), BEE, Detailed project report: kiln insulation improvement, Morbi ceramic cluster (SAMEEEKSHA)

Last reviewed 2026-11-04. Figures are from BEE's Small and Medium Enterprises (SME) programme project reports; costs, tariffs and paybacks are at the report year's prices. Check today's gas and power prices and a current quote before you rely on any payback.