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

Canonical: https://senseible.earth/answers/jet-dyeing-machine-efficient-pump-saving

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](https://senseible.earth/green-loan-check)
- [Surat process houses: buyer carbon data](https://senseible.earth/answers/surat-textile-processing-units-buyer-carbon-data)
- [Dyeing effluent heat recovery](https://senseible.earth/answers/dyeing-effluent-heat-recovery-fuel-saving)
- [Online flue gas analyser on a coal boiler](https://senseible.earth/answers/coal-boiler-online-flue-gas-analyser-saving)

Sources: [BEE, Detailed project report: energy efficient pump for jet machine (150 kg), Surat textile cluster (SAMEEEKSHA)](https://sameeeksha.org/pdf/dpr/surat_150kg.pdf), [CEA CO2 Baseline Database, version 22.0](https://cea.nic.in/cdm-co2-baseline-view?mappingId=234&lang=en)

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.