Where does energy go in a plastic pipe unit in Ramnagar?
Into the extrusion line, run on grid electricity. TERI's profile of the Ramnagar plastics cluster puts its 20 pipe and fitting units at 1,755 of the cluster's 2,860 toe a year, over 60%. Power comes from PUVVNL, with diesel in DG sets through frequent power cuts.
Inside the line
- Barrel heaters: often ON-OFF controlled and poorly insulated, one of the largest users.
- Extruder screw motor, usually at constant speed through a gearbox.
- Vacuum sizing tank and cooling stages.
- Caterpillar haul-off and the cutter on a limit switch.
- Air compressors and process cooling.
Fuels besides the grid
Across the cluster, high speed diesel runs DG sets during power failures, and used engine oil and LPG are also burned. Electricity is about 84% of the cluster's energy.
How the bill is built
Most units take supply from PUVVNL under tariff HV-2, a two-part tariff billed on maximum demand and kVAh. TERI found power factor at the main incomer between 0.95 and 0.97; automatic power factor correction cuts kVAh billed for the same work.
What to fix first
- Radiant barrel heater bands: 20 to 30% of heating energy.
- VFD on the extruder motor: up to 20%.
- Air leaks, often above 20%, brought to about 5%.
- Replace motors rewound three or more times with IE3 motors.
An average pipe unit (estimate)
- 1,755 toe across 20 units = 87.75 toe per unit a year.
- If 84% is electricity, as for the cluster: 73.7 toe, about 857,700 kWh at the profile's 11,636 kWh per toe.
- 857,700 kWh x 0.675 kg CO2 (CEA, FY 2025-26) = about 579 tCO2 a year from grid power.
Averages from a 2016 cluster profile; your own bills give the real figure.
What Senseible does here
Senseible reads PUVVNL bills, using the printed kWh on kVAh bills, and DG diesel invoices into monthly CO2 for your unit, so you can see whether a heater or drive change moved it.
Sources: TERI and SAMEEEKSHA, Cluster profile: Ramnagar plastic industries, CEA CO2 Baseline Database for the Indian power sector, version 22.0
Last reviewed 2026-11-03.