Why does the Bureau of Energy Efficiency (BEE) Surat report for a 250 kilogram jet machine pump pay back in 0.99 years when the 150 kilogram one takes 1.27?

BEE's Surat reports swap five jet machine circulation pumps for 65% efficient ones. The 150 kilogram report costs rupees (Rs) 4.40 lakh and saves 61,740 kilowatt hours (kWh) a year; the 250 kilogram one costs Rs 4.78 lakh and saves 86,100. Payback is 1.27 and 0.99 years.

The two reports side by side

• The reports cover jet machines of 150 and 250 kilograms (kg) capacity. Both specify a new pump of 50 cubic metres an hour at 30 metres head and 65% efficiency; the 250 kg report lists it at 7.5 kilowatts (kW). The old pumps sit on 10 horsepower motors. Both work on five machines, 24 hours a day, 350 days, at Rs 5.60 a kWh.
• 150 kg report: old pump 6.8 kW at 51%. New 6.8 x 51 / 65 = 5.33 kW, so 1.47 kW saved: 12,348 kWh a machine, 61,740 for five, Rs 3.46 lakh. Cost Rs 4.15 lakh for pumps and motors plus Rs 0.25 lakh wiring: Rs 4.40 lakh. Payback 1.27 years.
• 250 kg report: old pump 7.00 kW at 46%. New 7.00 x 46 / 65 = 4.95 kW, so 2.05 kW saved: 17,220 kWh a machine, 86,100 for five, Rs 4.82 lakh. Cost Rs 4.53 lakh plus Rs 0.25 lakh: Rs 4.78 lakh. Payback 0.99 years.
• Printed indicators, 150 kg against 250 kg: internal rate of return (IRR) 59.54% and 78.33%, net present value (NPV) Rs 8.47 and 13.12 lakh, one day of downtime each.

Why the 250 kg report saves 40% more

Nothing in the pump or the cost explains it. The pump is the same and costs about 9% more. The gap comes from the starting point: the 250 kg report assumes the old pump draws 7.00 kW at 46% efficiency, the 150 kg one 6.8 kW at 51%. Both reports print 750 kg of cloth a day per machine, whatever the machine size. A bigger machine needs a bigger pump only if its flow and head ask for it; neither report shows that.

The 7.00 kW baseline is above the audited pumps

• The 250 kg report's own Table 1.2 lists three audited pumps at 140, 148 and 142 kWh a day, which is 5.83, 6.17 and 5.92 kW, at 47.5%, 44.7% and 46.9%. Its text, section 1.4.1, gives the present draw as 5.83 kW.
• The saving uses 7.00 kW, higher than any of the three. Our reading: with 5.83 kW at 46%, the saving is 5.83 x 19 / 65 = 1.70 kW, or 14,315 kWh a machine and 71,574 for five, about 17% below the printed 86,100. The payback would be about 1.19 years, still under two.
• The 150 kg report's Table 1.2 lists audited pumps at 136 kWh a day at 42.5% and 124 at 53.7%; its saving uses 6.8 kW at 51%.

The carbon dioxide (CO2) lines

The reports print 52 and 73 tonnes a year and no factor. Divided by the kWh they are 0.84 and 0.85 kilograms of CO2 a kWh. At the Central Electricity Authority (CEA) factor for financial year (FY) 2025-26, 0.675, the same kWh give 41.7 and 58.1 tonnes. Both reports also say "The equipment reduces the coal consumption and also reduces SOx emissions". Our reading: that holds at the power station, which burns less coal when grid power falls, not at the unit.

Before you order

• Have the supplier measure flow, head and kW on your pump. Replace the worst first.
• New kW = present kW x present efficiency / 65.
• Keep before and after meter readings for a month; they are your evidence.

The 250 kg report, and the same on its audited kW

• Printed: 7.00 x 19 / 65 = 2.05 kW x 8,400 hours = 17,220 kWh a machine
• Five machines: 86,100 kWh x Rs 5.60 = Rs 4.82 lakh; Rs 4.78 lakh / Rs 4.82 lakh = 0.99 years
• On 5.83 kW: 1.70 kW x 8,400 = 14,315 kWh; five machines 71,574 kWh = Rs 4.01 lakh; payback 1.19 years
• CO2 on 71,574 kWh at 0.675: 48.3 tonnes (estimate)

Printed lines are the report's own at the report year's prices. The 5.83 kW case is our arithmetic from the report's text, not its claim. The 0.675 is the CEA version 22.0 factor for FY 2025-26.

What Senseible does here

Senseible reads fuel invoices and electricity bills into monthly records, so your jet machine power is on file by month. It cannot split one pump out of the bill; use a clamp reading from the supplier for that.

• Efficient pump on a 150 kg jet machine
• Variable frequency drive on a jet machine pump
• Old report CO2 versus today's grid factor
• Green loan readiness check

Sources: BEE, Detailed project report: energy efficient pump for jet machine (150 kg), Surat textile cluster (SAMEEEKSHA), BEE, Detailed project report: energy efficient pump for jet machine (250 kg), Surat textile cluster (SAMEEEKSHA), Central Electricity Authority (CEA), CO2 Baseline Database for the Indian Power Sector

Last reviewed 2026-11-05. Report figures are from BEE's Small and Medium Enterprises (SME) programme project reports, with electricity at Rs 5.60 a kWh. Check your tariff, your pump's measured kW and a current quote before you rely on the payback.