How do I turn the Pune rubber profile's percent savings, such as 20 to 25 percent on roller mixers, into kilowatt-hours (kWh) and carbon dioxide (CO2) for my own unit?

Our reading: each percentage in the Pune rubber cluster profile applies to that machine's energy, not the whole bill: servo drives 20 to 30 percent, thyristor heater control 7 to 15, roller bearings 20 to 25, autoclave racks 5 to 15 of fuel. The profile does not state the base. Multiply by that machine's kWh or fuel, not your total.

The percentages the profile prints

• Injection moulding machines with servo drives, which cut idle motor running: 20 to 30 percent.
• Thyristor control of electrical heaters in place of on-off control: 7 to 15 percent, and longer coil life.
• Roller bearings in place of bush bearings on roller mixers, with new gearboxes: 20 to 25 percent.
• Stainless steel mesh in place of mild steel racks on autoclave and oven trolleys, where the racks are about 90 percent of the trolley structure weight: 5 to 15 percent of fuel.
• Among those with no percentage: variable frequency drives on roller mixers, energy efficient IE3 motors, boiler efficiency monitoring, oven loading, insulation of heated plates, compressor and chiller practice, solar and LED lighting, and compressor pressure cut from 8 to 11 bar down to 5 to 8 bar.

How to size one saving

1. Find the machine group's own kWh. If you have no sub-meters, take the rated kilowatts, running hours and a load factor you can defend, and say it is an estimate.
2. Multiply by the profile's percentage range, low and high.
3. Convert kWh at 0.675 kg CO2 a kWh, the Central Electricity Authority (CEA) grid factor for financial year (FY) 2025-26. For fuel, convert litres or kilograms with the factor for that fuel.
4. Keep the range. The profile gives no investment costs, machine baselines or paybacks, so do not turn the range into a single promised figure.

The fuel line

The racks saving applies to the fuel that heats the autoclave or oven, which in Pune is light diesel oil (LDO) in boilers for some units, thermic fluid heaters for autoclaves in some units (the profile does not state their fuel) and electricity in ovens for others. A unit that cures only in electric ovens sees it in kWh. Our reading of the profile's unit table is that medium units burn about 33,480 kg of LDO a year, not an hour; see the linked page for the check.

A medium unit using 2.4 million kWh and 33,480 kg of LDO a year (shares are examples)

• Roller mixers, example share 30 percent: 720,000 kWh. At 20 to 25 percent, 144,000 to 180,000 kWh, or 97.2 to 121.5 tonnes of CO2
• Injection moulding, example share 20 percent: 480,000 kWh. At servo 20 to 30 percent, 96,000 to 144,000 kWh, or 64.8 to 97.2 tonnes of CO2
• LDO racks, 5 to 15 percent of 33,480 kg: 1,674 to 5,022 kg, which at 3.186 kg of CO2 a kg, the Intergovernmental Panel on Climate Change (IPCC) 2006 default for gas or diesel oil, is 5.3 to 16.0 tonnes. Our reading: the IPCC does not name LDO, and we place it on that line

The machine shares are examples, not profile data. Use your own meter or load data.

What Senseible does here

Senseible reads fuel invoices and electricity bills into dated, fingerprinted records, so your kilowatt-hours and litres are on file by date. The standard product reads bills, not single machines. Machine-level meters and sensors are custom, on request.

• Pune rubber parts makers: energy for OEMs
• Pune rubber profile: fuel units do not tie
• Servo against hydraulic injection moulding
• Compressed air pressure cut: savings
• Your MSME carbon number

Sources: TERI, Energy profile: Pune rubber cluster (potential energy efficient technologies), IPCC 2006 Guidelines, Volume 2, Chapter 1: Introduction (Table 1.2 net calorific value, Table 1.4 CO2 emission factor, gas or diesel oil), CEA, CO2 Baseline Database for the Indian Power Sector (0.675 kg CO2 per kWh, FY 2025-26)

Last reviewed 2026-11-06. Percentages are the profile's own 2018 ranges, not guarantees. Get a quote and a measured baseline before you decide.