MAHINDRA & MAHINDRA LTD. Integrated Annual Report 2023-24 58 In the automobile manufacturing sector, energy consumption primarily stems from motors and blowers, constituting almost 60% of a unit's energy usage. Among these, blowers, including Air Handling Units (AHUs) and Air Circulators, contribute over 40%. AHUs are indispensable for maintaining a healthy environment for operators, so they can neither be completely removed or even reduced in numbers. To tackle this, the AS team explored replacing conventional AHUs and Air Circulators with energyefficient alternatives. They identified two key interventions: Ÿ Replacement of Conventional AHUs with intelligent EC Blowers Ÿ Replacement of Conventional Air Circulators with BLDC and HVLS fans The implementation of intelligent EC Blowers at 7 plants of M&M resulted in energy savings of more than 50%. Similarly, BLDC Air Circulators, implemented at 9 plants, provided better airflow using less energy, resulting in more than 35% savings in energy cost. These interventions collectively led to significant benefits: Ÿ Energy savings equivalent to power 1,761 homes annually Ÿ Emission reduction of 5,502 tCO , akin to 2 planting 2.32 lakh trees Ÿ Energy cost savings of INR 6.2 crore Driving Efficiency through Intelligent Air Handling AS, Nashik In the automotive industry, the paint shop stands out as an energy guzzler and within this process, significant energy is consumed in heating pretreatment chemicals and baking Cathodic Electrodeposition (CED) paint coatings. Substantial CED material is utilised to protect car bodies from corrosion. AS, Nashik faced the challenge of seamlessly integrating new energy-efficient technology solutions in its 26-year-old pre-treatment and CED processes without compromising quality or productivity. Utilising the Project Evaluation Review Technique (PERT), the Unit meticulously analysed energy and material consumption trends. Collaborating with a leading surface treatment technology supplier, it identified two innovative products. Ÿ Gardoclean VP 42928 LB for degreasing Ÿ Cathoguard CG800 for CED coating. With Gardoclean VP 42928 LB, the degreasing stage operating temperature reduced to 40°C from existing 55-60°C. While with CED CG 800 – CED, material consumption could be reduced by 0.8kg per bodyshell. The project has led to significant annual saving of INR 35 lakh from reduced energy usage and INR 2.17 crore from material savings (fuel, water, and power). To cascade the deployment of green technology products, learnings from the AS, Nashik project are being shared with the Chakan plant for horizontal deployment. Revolutionising Material & Energy Efficiency AS, Nashik Featured below are some of the significant energy efficiency measures undertaken during the reporting period. The AS, Nashik Paint st shop is the 1 OEM in India to implement this technology at 40°C.
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