Automotive

How a Haryana Based Automotive Parts Manufacturer Cut Fuel Costs by 40%

Automotive Manufacturer

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Executive Summary

A major automotive parts manufacturer faced high steam costs and inefficiencies with a 1.5 TPH steam boiler consuming 665 KL of diesel annually. High fuel costs and also issues of fuel pilferage were a major concern for management. Energeia converted the boiler to run on natural gas, upgraded the control system, and added IoT monitoring, resulting in 40% fuel cost savings and reduced emissions.

Key Stats

₹0.17 Crore

Fuel Cost Savings

0 KL

Diesel Saved Annually

0 Tonnes

CO₂ Emission Reduction

Customer Overview

The factory is a major manufacturer of automotive parts, specializing in exhaust systems and related components for two-wheelers and four-wheelers. As a key supplier to renowned global brands such as Honda, Suzuki, Yamaha, Daikin, and Paramount, the company’s parent has 10+ facilities across the world.

The Challenges

The company was facing several challenges that were significantly impacting their operational costs:

  • High Boiler Operating Costs: The cost of running their steam boiler was exceedingly high.
  • Rising Diesel Prices: Increasing diesel prices further exacerbated the financial burden.
  • Lack of Energy Consumption Visibility: The company was unable to accurately measure the energy consumption of their boiler, making it difficult to identify opportunities for cost savings.

The company’s 1.5 TPH steam boiler, which was essential for running operations, originally consumed 95 liters of diesel per hour. Given that the plant operated for 7,000 hours annually, this translated to a consumption of 665 KL of diesel each year.

Automotive

Energeia’s Solution: Boiler Fuel Conversion Project

Energeia proposed a comprehensive solution to address the company’s challenges. The project involved several key components:

Boiler Fuel Conversion Implementation

  • End-to-End Project Management: Energeia managed the entire project, from initial planning to execution, ensuring seamless integration with the company’s existing systems.
  • Internal Pipeline Modification: The internal pipeline was modified to accommodate the new fuel type.
  • Boiler Conversion: The existing boiler was converted from diesel to natural gas, including the installation of a new burner.
  • Control System Upgrade: The boiler’s control system was upgraded to enhance efficiency and reliability.
  • IoT Monitoring System: Energeia implemented an IoT monitoring system to provide real-time data on energy consumption, enabling better management and optimization.

Results

After the conversion, the boiler now consumes around 105 SCM (Standard Cubic Meters) of PNG (Piped Natural Gas) per hour at full load, significantly reducing fuel costs and emissions.

The boiler conversion project delivered substantial financial and environmental benefits:

  • Fuel Cost Savings: The project resulted in a 40% reduction in fuel costs, amounting to ₹1.17 Crore annually.
  • Diesel Savings: The conversion saved 665 KL of diesel annually.
  • Environmental Impact: The reduction in diesel consumption led to a significant decrease in CO₂ emissions, equivalent to the environmental benefit of preserving approximately 62,144 trees.

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Anusua Das

HR Manager

Anusua is redefining HR with a passion for people and a purpose-driven approach.

She is an experienced HR leader with over 7 years of expertise across startups and MNCs, including roles at Cinépolis India, Talentoj, JindalX, and Rus Education. She excels in fostering collaborative work environments and is committed to shaping a values-driven culture. Known for her empathy and resilience, she has received accolades for her meaningful connections with employees and managers.

At Energeia, Anusua leads the HR function with a focus on inclusivity, co-creating policies with employees and driving a flexible, results-oriented work culture. Passionate about building meaningful workplaces, she ensures that new ideas are not just welcomed but actively implemented, making Energeia a space where people can thrive.

Rahul Chougule

Sr. Energy Analyst

Rahul turns raw data into impactful energy savings.

With an M.Tech in Heat Power Engineering and a B.E. in Mechanical Engineering, Rahul’s expertise lies in developing innovative, data-driven solutions to optimize energy performance across diverse sectors.

He is certified in Microsoft Power BI, Performance Measurement & Verification, and is a BEE Certified Energy Manager. At Johnson Controls, Rahul successfully led projects across Northeast America and the Middle East, delivering substantial energy savings through advanced M&V techniques. 

At Energeia, Rahul plays a critical role in the Shared Savings ESCOs, focusing on emissions reduction and sustainable energy solutions. He is passionate about using data analytics to drive meaningful change in energy performance, helping clients achieve cost savings and a reduced carbon footprint.

Srinivas Tejavath

Head, HVAC Division

Srinivas is the coolest HVAC expert and a prolific energy auditor.

A BEE-Certified Energy Manager, he’s conducted over 250 audits, bringing deep technical insight to Energeia’s E-Chill (HVAC) business vertical. Srinivas has held senior auditing and engineering roles at Johnson Controls, Electro-Mechanical & Refrigeration Group, Siri Exergy, Zenith Energy, Maytas Infra and Carbon Advisory Services, where he focused on finding inefficiencies in cooling systems.

With a B-Tech in Mechanical Engineering and an M-Tech in Energy Systems from Jawaharlal Nehru Technological University, Srinivas leverages his extensive theoretical and practical knowledge at Energeia to drive modern HVAC innovations and deliver impactful energy solutions for industries.

Rishabh Sharma

Founders’ Office

Rishabh is on a mission to reinvent energy systems for a sustainable future.

A Chemical Engineering graduate from the National Institute of Technology (NIT) Srinagar, Rishabh also holds a PGDM in Energy Management from NTPC School of Business. His unique blend of technical knowledge and strategic acumen fuels his passion for sustainability, and operational excellence.

With experience spanning ACME Group, HCL Foundation, GE, and Bharat Aluminum Company, Rishabh has excelled in managing strategic projects, leading ecological initiatives, driving lean deployments, and optimizing manufacturing processes. 

Rishabh’s career highlights include an invitation to Rashtrapati Bhawan for the National Innovation Clubs meeting at the 2017 Festival of Innovation, a bronze medal at the All India Student Design Awards, and a published business case study with Ivey Publishing, Canada.

At Energeia, he drives transformative change through cross-functional initiatives, pushing the boundaries of energy efficiency and sustainability worldwide.

Rimjhim Panwar

International Sales Manager

Rimjhim is a globally-seasoned manager who never forgets to dot her i’s and cross her t’s.

Adept at building lasting relationships across borders, she brings over a decade of expertise in the international energy sector. Her career spans key roles at Power Grid Corporation of India Limited (Powergrid), MEBSPL, and an almost seven-year tenure at Japan-based Mitsui & Co., Ltd. 

At Energeia, Rimjhim plays a pivotal role in driving international business strategy across Africa, the Middle East, and Southeast Asia. Her meticulous approach, humble leadership and strategic vision enable her to navigate diverse, global markets with precision and grace. 

With a strong focus on client satisfaction, Rimjhim is instrumental in expanding Energeia’s global footprint and advancing sustainable energy solutions across the Global South.

Riyaz Husain

Sr. Manager, Decarbonization

Riyaz is a growth-oriented leader whose curiosity is contagious.

He is a distinguished expert in decarbonization and sustainable technologies, holding a Mechanical Engineering degree and an M.Tech in Renewable Energy from TERI School of Advanced Studies. 

His credentials – including a BEE certification as an Energy Manager, a PMVA certification from EVO, and a COBENEFITS specialist designation from Renewables Academy AG in Berlin – reflect his deep expertise.

Riyaz’s active involvement in the International Environment Forum and the Hong Kong Chemical Biological & Environmental Engineering Society (HKCBEES) highlight his leadership in global sustainable development. He’s also the co-author of the book, Joy of Engineering and Management.

His unique ability to demystify complex concepts, combined with technical expertise and field experience, makes him a growth-hungry leader who’s constantly pushing the boundaries of what’s possible.

Sumit Gupta

Vice President, Sales

Sumit is a veteran industrial energy expert and passionate mentor.

With over 20+ years of experience in advancing industrial sustainability, he’s held key leadership roles at Thermax, Smart Joules, Alstom Power (now part of GE), IHEL (ISGEC Heavy Engineering) and Clyde Bergemann Power Group.

Trained in Mechanical Engineering, Sumit’s multidisciplinary experience spans New Business Development, Sales, Project Management and Operations. From designing boilers to scaling startups and even managing a paper mill as CEO, Sumit understands the energy optimization business in and out.

At Energeia, he oversees the sales and business strategy, leveraging his deep knowledge of customer needs to help organizations reduce their emissions and energy expenses. He’s a great mentor and thrives on helping his team realize their full potential.

Amlan Panda

Co-founder & CTO

Amlan knows energy technology like the back of his hand.

With a BTech in Electronics & Communication Engineering from the Delhi Technological University, Amlan’s expertise lies in bridging complex technological concepts with practical, on-ground applications.

At Energeia, he’s the bridge between big ideas and brass tacks. One day he’s mapping out the future, the next he’s in the trenches, training factory engineers on the latest energy efficient tech.

Amlan’s previous work with industry giants like Bharti Airtel and Vodafone India helped him hone his skills in supply chain management and process automation. As a Khemka Scholar and a member of tGELF Foundation’s Leaders Forum, he’s passionate about social entrepreneurship and deeply believes in India’s potential to be a global leader in new-age energy technology.

Sookrit Malik

Co-founder & CEO

Sookrit lives and breathes data-driven industrial energy innovation.

With an MA in International Energy and Resource Policy from The Fletcher School and a BA from Tufts University, Sookrit’s expertise lies in building modern, data-driven solutions for energy-intensive industries.
His award-winning research on industrial energy efficiency, born from his MA thesis, forms the foundation of Energeia’s mission. An India Renewable Energy Innovation Fellow at LISD and a member of the Aspen Institute Socrates Program, Sookrit envisions the fourth industrial revolution as a ‘resource revolution’ where we need to leverage new technologies to optimize the use of our limited natural resources.

His career spans roles at Fidelity Labs in Boston working on AI and blockchain, and EOS GmbH in Munich, focusing on additive manufacturing strategy.

Sookrit champions ethical and altruistic leadership beyond just business. After the 2015 Nepal Earthquake, he led a team building resilient school shelters, earning The Impact Award from tGELF Foundation. It was during this project that he serendipitously met his future Energeia co-founder, Amlan Panda.

Sankriti Malik

Head, Marketing & Growth

Sankriti is a dynamic growth catalyst, turning customer insights into impactful strategies.

She’s held multifaceted roles at high-growth startups like Kodo Tech, Athena Education, and Hora.AI, where she drove initiatives in product management, UX research, and branding. She’s also contributed to strategy roles at Indian Oil, Times Internet (BCCL) and The Copenhagen Post.

A Psi Chi Honors graduate from Wesleyan University in the US, Sankriti blends her expertise in UX design, data, and strategy to lead Energeia’s marketing efforts – always keeping the customer at the heart of her work. 
 
She’s passionate about gender equity in climate tech and actively contributes to networks like Leap.club and Ladies Who Lead. Her commitment to impactful digital design led her to join communities like GrowthX, IxDF, and Terra.do. In the past, she’s been a Fellow at the Patricelli Center for Social Entrepreneurship and co-founder of the Design Think Tank.