Cluster Profile

Rajkot forging industries

Gujarat
Rajkot
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Partnership: Scaling up Energy Efficient Technologies in Sm all Enterprises
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Suggested format for citation

TERI. 2016
Cluster Profile Report – Rajkot forging ind ustries
N ew Delhi: The Energy and Resources Institute 14pp.
[Project Report N o. 2014IE15]

D isclaimer
This d ocum ent is an output of an exercise und ertaken by TERI supported by
the Sw iss Agency for Developm ent and Cooperation (SDC) for benefit to
MSME units in the cluster. While every effort has been m ad e to avoid any
m istakes or omissions, TERI and SDC w ould not be in any w ay liable to any
person by reason of any m istake/ omission in the publication.

Published by
T E R I Press
The Energy and Resources Institute
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IH C Com plex, Lodhi Road
N ew Delhi-110 003
Ind ia

For more information

Project Monitoring Cell
TERI Tel. 2468 2100 or 2468 2111
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IH C Com plex, Lod hi Road Fax 2468 2144 or 2468 2145
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Contents
A CKN OWLEDGEMENTS
Overview of clu ster ...............................................................................................................................1
Prod u ct typ es and p rod u ction cap acities ...........................................................................................1
Annu al p rod u ction by forging ind u stries ..........................................................................................2
Raw m aterial u sage in clu ster ..............................................................................................................2
Energy scenario in the clu ster ..............................................................................................................3
Prod u ction p rocess ................................................................................................................................3
Technologies em p loyed ........................................................................................................................5
Energy consu m p tion .............................................................................................................................7
Energy saving op p ortu nities and p otential .......................................................................................9
Major stakehold ers ..............................................................................................................................11
Clu ster d evelop m ent activities ..........................................................................................................12
Acknow ledgements

TERI places on record its sincere thanks to the Sw iss Agency for Developm ent and
Cooperation (SDC) for supporting the long -term partnership project focusing on energy
intensive MSME clusters in Ind ia.

TERI team is indebted to Rajkot Engineering Association (REA), GIDC (Lod hika) Ind ustrial
Association (GLIA), AJI (GIDC) Ind ustries Association and Shapar -Veraval Ind ustrial
Association for provid ing support and inform ation related to forging units in Rajkot. TERI
also places on record the support provid ed by Mr N H Kantesaria (Chief Manager, GLIA),
Mr Bhavesh Patel (Presid ent, REA) and Mr Pinakin Mad eka (Director, Rolex Rolled Rings),
Mr Subod h Prasad Ray (Manager, Rolex Rolled Rings), Mr Paresh Ghod asara (Director,
Shrad ha Forge Pvt. Ltd ), Mr Pram od Bhanvadia (Managing Director, Microtech Rollers Pvt.
Ltd ) and Mr Mehul Makw ana (Director, Synergy Forge Pvt. Ltd ) for their support and
cooperation in organizing field visits and interactions w ith closed die forge and ring rolled
forging manufacturing unit entrepreneurs d uring the stud y. TERI extend s its sin cere thanks
to Mr Jignesh Patel (Secretary, IIF-Western region) and Mr Dilip Sarkar (Executive Secretary,
REA) for facilitating field visits.

Last but not least, our sincere thanks to MSME entrepreneurs and other key stakeholders in
the cluster for provid ing valuable data and inputs that helped in cluster analysis.
Rajkot forging industries
Overview of cluster
The Ind ian forging and heat treatm ent ind ustry is a m ajor contributor to the manufacturing
sector of the Ind ian econom y. Rajkot, located in Gujarat state houses a prom inent cluster of
about 140 forging units located in ind ustrial estates around the cit y. The forging units in
Rajkot cluster are principally know n for their ability to m ake superior precision com ponents
and cater to w ide range of secondary prod uction ind ustries includ ing autom obile,
m achinery and engineering, electrical equipm ent and others.

H eat treatm ent is an allied process for treatm ent of forging and m achined com ponents.
Som e forging units have in -house heat treatm ent facilities, w hile others und ertake heat
treatm ent from external heat treatment units. The total prod uction from the Ind ian forging
ind ustry d uring 2015–16 w as about 2.45 m illion tonne. The m ajor raw m aterials used in the
Rajkot forging units includ e carbon steel and alloy steel. The prod ucts after forging are heat
treated and machined for use in various types of autom obile and engineering prod ucts.

The Rajkot forging cluster m ainly caters to the d em ands of large Original Equipm ent
Manufacturers (OEM) like Tata Motors, Mahindra & Mahind ra, L&T, Force Motors, Bajaj
Auto, General Motors, God rej and Ashok Leyland etc. Forging ind ustries in Rajkot provid es
em ploym ent to about 15000 people d irectly or ind irectly. The estim ated total turnover of
forging ind ustries in Rajkot is m ore than Rs 4000 crores. The d istribution of forging units
based on category and annual turnover is show n in the figure.

D istribution of forging D istribution of forging

industries based on category industries based on annual
turnover

Product types and production capacities

The prod ucts from the Rajkot forging cluster are used m ainly in d ifferent sectors
autom obiles, light and heavy m achine tools, com pressors, stationary d iesel engines, earth
m oving equipm ents, m aterial handling equipm ent, catering to both OEM and replacem ent
m arket, general engineering. Follow ings are som e of the prim ary prod ucts that are
m anufactured in Rajkot cluster:
 Closed d ie forging products

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 Cluster profile - Rajkot forging industries

 Ring rolling forging prod ucts

These prod ucts can be grouped into tw o kind s of

prod uct m anufacturers such as closed die forging
and ring rolling units. The prod ucts forged in
Rajkot are of various types. These includ e
propeller shaft, front axle, upper pin, crow n
w heels, gears, shafts, connecting rod s, forks,
cam shafts, bearing races and w heel hubs. These
prod ucts are custom m ad e and used m ainly in Primary products from Rajkot
the autom otive sector.

The prod uction by the forging units und er MSME

category is in the range of 25 to 3000 tonnes per
m onth. The p rod uct-w ise d istribution of forging
ind ustries in the cluster show s that close die
forged prod ucts account for about 62% of forged
prod ucts. The prod uction and installed capacity of
the similar ind ustries in the cluster varies from
unit to unit; the prod uction of a unit also varies
d uring the year. The prod uction is record ed
generally in term s of tonnes of forging
m anufactured of a particular type of prod uct.
Based on the interactions w ith stakehold ers in the
cluster, the total estim ated prod uction at cluster
level is 434,211 tonne per year as show n in the D istribution of forging
industries based products
table.

Annual production by forging

industries
Product category N umber of units Production (tonne/year)
Closed d ie forging 90 268,548
Ring rolling 50 165,663
Total 140 434,211
Source: Collective directory data of Rajkot Engineering A ssociation, GIDC Lodhika Industrial A ssociation, A JI (GIDC)
Industries A ssociation and Shapar-V eraval Industrial A ssociation

Raw material usage in cluster

The Rajkot forging cluster prod uces a variety of m aterials. The m ajor raw m a terials used in
the forging units includ e m ild steel, carbon steel, alloy steel, stainless steel, alum inium ,
super alloy and special steel. Different stainless steel grad es used by the units are
ASTM/ ASME SA 182 F, 304, 304L, 304H , 309H , 310H , 316, 316H , 316L, 316 LN , 317, 317L,
321, 321H , 347, 347H . Most of these raw materials are prod uced locally or obtain ed from
other d om estic m arkets. Long bars and billets are used as raw m aterials in forging
ind ustries. The main sources of raw m aterials of forging prod ucts are Jindal Steel Works Ltd
and Bhushan Steel Ltd .

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 Cluster profile – Rajkot forging industries

Raw materials used in forging industries

Energy scenario in the cluster

Electricity and diesel are the m ajor sources of energy for the forging units. Electricity is
supplied by Paschim Gujarat VIJ Com pany Ltd (PGVCL) and d iesel is procured from local
m arket. Electricity is used for running all machinery and d iesel is used in DG -set in case of
em ergency d uring unsched uled pow er outage. The d etails of m ajor energy sources and
tariffs are show n in table.

Prices of major energy sources

Source Remarks Price
Electricity HT Rs 8.00 p er kWh (inclu sive of energy, d em and charges,
other p enalty/ rebate and electricity d u ty)
LT Rs 9.00 p er kWh (inclu sive of energy, d em and charges
and electricity d u ty)
Diesel From local m arket Rs 55 p er litre (p rice su bjected to m arket flu ctu ations)
FO From local m arket Rs 25 p er litre (p rice su bjected to m arket flu ctu ations)
NG GSPC Rs 34 p er scm (p rice su bjected to m arket flu ctu ations)
LDO From local m arket Rs 30 p er litre (p rice su bjected to m arket flu ctu ations)
Briqu ettes From local m arket Rs 5.5 p er kg (p rice su bjected to m arket flu ctu ations)

Production process
The forging ind ustries in Rajkot cluster
m ajorly prod uce closed d ie forging and
ring rolling prod ucts. The m ajor steps
involved in forging includ e cutting of
steel rod s in the form of billets, heating
of billets in the furnace and forging in
presses. The forged com ponents are
trim m ed and sent for heat treatm ent.
The generic prod uction steps of forging
prod ucts are show n in figure. The
generic process steps follow ed by the
unit are briefed below :

Raw material procurement and quality

inspection: The raw m aterial (steel bar)
is received from m ajor steel suppliers or
procured d irectly. The quality of raw

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 Cluster profile - Rajkot forging industries

m aterial steel is inspected w ith spectrom etric and m icroscope testing facilities either w ithin
the plant or from outsid e testing facilities for proper grad e and quality of steel.

Raw material cutting: Raw m aterial is cut in band saw m achine and shearing m achine in the
form of billets as per w eight required for forged job in d esired length.

Raw material heating and forging: The billets are heated in furnace oil (FO) of natural gas
(N G) fired furnaces or in ind uction billet heater upto about 1200–1270 oC as per forging
tem perature requirem ents of d ifferent grad es of steel. The heated billets are rem oved from
the furnace and placed in ham m er for forging. The heated billet is forged in to d esired shape
in one or num ber of strokes at the hamm er.

Trimming and coining: Trim m ing/ coining presses are used for rem ovin g extra m aterial on
the forged job. Trim ming is d one in one stroke in the trim m ing press.

Heat treatment: After trim m ing/ coining operation, d epend ing on the job requirem ent heat
treatm ent is d one on the forged job in hard ening furnace or tem pering furnace.

Inspection and despatch: Final inspection of jobs are d one for quality and dim ensional
accuracy and sent to the m achining shop or d espatch.

The prod uction process for each Forging com ponent in the cluster is m entioned below :

(i) Closed die forging process

The m etal is pressed betw een tw o dies (tooling) that contain a pre-cut profile based on
specifications of the prod uct. A tem perature of about 1,250 °C is m aintained for forging
operation. In closed d ie forging, m etals w eighing betw een a few kilogram s to about 25
tonnes are forged . The forgings are generally prod uced on hyd raulic presses, m echanical
presses, and ham mers. Using im pression d ie forging process, prod ucts w ith com plex shapes
and closer tolerances can be prod uced . Metals and alloys that can be forged through the
im pression-d ie process includ es carbon and alloy steels, tool steels, and stainless,
alum inium , and copper alloys, and certain titanium alloys.

Closed die forging components

Production process in closed die forging Production process in closed die forging

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 Cluster profile – Rajkot forging industries

(ii) Ring rolling forging process

Long bars are used as a raw m aterial for ring rolling forging. Ind uction heating furnaces
using long bars are operated in line w ith ring rolling m achine or high speed hot form ing
m achine. H eated long bars are cut in required size an d pressed into pancake shape. Piercing
operation is d one and pre-sizing is carried out before ring rolling operation. Ring rolling is
d one in either typical ring rolling m achine or high speed hot form er m achine w here m ultiple
pieces can be processed sim ultaneously to enhance prod uction. After final sizing in press,
the com ponents are shifted to annealing furnaces (electrical/ FO/ gas fired ) for further heat
treatm ent. Shot blasting is d one to achieve d esired surface finish follow ed by rough and
final turning in lathe machines. Finally visual inspection is d one and com ponents are sen t
for final dispatch.

Production process in ring rolling forging Ring rolled components

Technologies employed
The use of outd ated technologies is a m ajor challenge in the cluster. Presently, m ost of the
units use belt d rop hamm ers for forging and few units use forging presses for precision.
Band saw used for cutting raw m aterial m ay be replaced by shearing m achines for
prod uctivity im provem ent. H eat treatm ent techniques includ e annealing, norm alizing, case
hard ening, precipitation strengthening, carburizing, nitriding, tem pering, quenching, and
ind uction hard ening. Mostly, heat treatm ent units use pit type furnaces and pusher type
furnaces. Som e of the prim ary process technologies are explained below .

(i) Oil fired and gas fired furnaces

Different d esigns of furnaces used includ e box and pusher types. Furnace oil, LDO, natural
gas, and LPG are com monly used as fuel in the furnaces. The forging furnaces are used for
heating of raw m aterial (billets of various grad es of steel) to 1150 –1200 oC. The capacities of
these furnaces are in the range of 50-400 kg per hr. Billets are heated either in batches or
continuously. H eat treatm ent furnaces are used for norm alizing, annealing, hard ening,
tem pering, and carburizing of forged and m achined com ponents as per requirem ents of the
specific jobs. The tem peratures in the furna ces vary w id ely d epend ing on the treatm ent and
ranges betw een 250-930 °C. The oil consum ption in the forging furnaces typically ranges
betw een 100–200 litre per tonne, and for heat treatm ent furnaces, the consum ption is about
60–80 litre per tonne. NG consum ption typically ranges betw een 100–150 scm per tonne and
for heat treatm ent furnaces, it is about 50–80 scm per tonne. Blow ers w ith electrical m otors
of 3 to 7.5 hp are used in furnaces for provid ing the com bustion air for fuel.

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 Cluster profile - Rajkot forging industries

Box type forging furnace

(ii) Electric furnaces
Electrical energy is also used for heating billets for forging and heat treatm ent. The
prod uction capacities of electrical ind uction furnaces typically range betw een 100–500 kg per
hr w ith a connected load of 100–1000 kW. The „specific energy consum ption‟ (SEC) of
electrical ind uction furnaces varies in the range of 450–500 kWh per tonne. The electrical
resistive heating furnaces are used for heat treatm ent operations w ith capacities ranging
from 200-600 kg per batch. The furnaces m ay be batch (p it type) or continuous (pusher type).
The rating of these furnaces varies from 15-120 kW. The furnaces have recirculating air fans
w ith electrical m otors betw een 3 to 7.5 hp.

Induction billet heater Bell type electrical heat

treatment furnace

(iii) Closed die hammers of belt drop type

These ham m ers are used for forging of hot billets into various shapes for shafts, flanges, gear
blanks, pipe fittings, rollers, hubs, and so on. The capacity of the forging ham m ers typically
range betw een 0.5 to 3 tonnes. Electric m otors of 30 to 100 hp are used for d riving the
ham m ers. Forging capacity, d epend ing on the num ber of ham m ers and their capacities,
varies from 300 to 3,500 tpa.

Closed die hammer forging Screw press

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 Cluster profile – Rajkot forging industries

(iv) Screw press

The capacity of screw presses is in the range of 100 to 1,500 tonnes. Electric m otors used for
d riving these presses range betw een 30 to 150 hp. Screw presses w ith electrical m otors of 5
to 30 hp are used for trim m ing and coining operations. These presses are operated w ith
pneum atic clutch and brake and screw is used for ad justing the height of stroke length. It is
used m ostly w ith shaft end heating jobs.

(v) Ring rolling machines

Ring rolling m achines are quipped to process one job at a tim e and are used by m ost of the
ring rolling units. These m achines can be effectively used for large d iam eter prod ucts.
Although use of ring rolling m achines w ould help in higher quality of prod ucts, the
processing rates are quite low .

Ring rolling operation

Energy consumption
Electricity, furnace oil and natural gas provid e the m ain source of energy for m ost of the
forging units in the Rajkot cluster. Alm ost all the units are d epend ent on grid electricity to
m eet their energy needs. The average connected load per unit is d epend ent on type of
prod ucts and installed capacity of the unit. A m ajority of the u nits have H T connection. The
other form s of energy use in the cluster includ e furnace oil and natural gas. FO is used for
heating for forging as w ell as heat treatm ent processes. N G is also used in som e heat
treatm ent furnaces. Most of the ring rolling units uses electrical resistance type furnaces for
heat treatm ent process. The pow er situation is quite good in Rajkot and hence the
d epend ence on DG set is very low .

(i) Unit level consumption

Energy intensity in large scale units is high as com pared to m icro, sm all and m edium scaled
units. The energy consum ption of forging units varies from 61 toe per year to 10,178 toe per
year. The annual energy consum ption of ring rolling units varies from 161 toe to 2,641 toe.
Also alm ost all of the forging units are using FO along w ith the electricity for heating
purpose w hile ring rolling units are m ostly using electrical ind uction furnaces for heating.

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 Cluster profile - Rajkot forging industries

Energy consumption of typical forging and ring rolling units

Category Thermal energy Electricity Total energy
(toe/year/unit) (kWh/year/unit) (toe/year/unit)
Forging
Micro 61 916 61
Sm all 262 16,489 264
Med iu m 542 24,108 544
Large 8782 16,240,200 10,178
Ring rolling
Micro 160 10,800 161
Sm all 69 29,679 71
Med iu m 372 480,483 413
Large 212 39,873,150 3,641
Source: Energy data collected from representative units in the
cluster

(ii) Cluster level consumption

The cluster level energy consum ption of Rajkot
forging cluster is estim ated to be 62,365 toe per year.
The share of d ifferent fuels show s that furnace oil,
electricity and natural gas account for a share of 40%,
36% and 22% respectively.

Share of energy consumption

Annual energy consumption of forging industries in
Rajkot cluster
Energy type Annual Equivalent Equivalent CO 2 Annual energy
emissions (tonne/yr) bill (million IN R)
consumption energy (toe)
Electricity 262.8 m illion kWh 22,597 257,498 1874
NG 16.1 m illion SCM 13,660 28,131 547
FO 25,163 kilo litre 24,836 72,568 629
LD O 360 kilo litre 331 986 10.8
Briquette 2476 tonne 941 0 14
Total 62,365 359,184 3074

Closed d ie forging units account for about 76% of energy consum ption in the cluster.The
break-up of estim ated energy consum ption of d ifferent types of forging units is show n in the
table.

Energy consumption of forging units in Rajkot cluster

Type of unit Energy consumption
(toe/year)
Closed d ie forging 47,342
Ring rolling 15,024
Total 62,365

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 Cluster profile – Rajkot forging industries

Energy saving opportunities and potential

Som e of the m ajor energy saving options in Rajkot forging units are summ arised below .

(i) Induction billet heater

Ind uction billet heater in forging is a revolutionary new age
technology having potential of 30-70% energy and m onetary
savings as com pared to oil fired heating for forging. Ind uction
technology is flexible in operation w ith red uction in scale
losses, w hich lead s to m aterial savings. It also avoid s other
hassles of storage of oil, piping arrangements etc. Due to very
low level of surface heat losses, it provid es better w orking
cond itions as com pared to fuel fired furnaces. The specific
energy consum ption (SEC) for FO fired furnace can be
brought d ow n from 0.15 toe/ tonne (150 litre/ tonne) to 0.04
toe/ tonne (450 kWh/ tonne) using ind uction billet heater. The
investm ent for ind uction billet heater ranges from Rs 15-50
Induction billet heater
lakh depend ing on size w ith sim ple payback period of 1 to 3
years.

(ii) Reheating furnaces

Box type furnaces are m ainly used in case of closed d ie forging. Cut billets are heated in
reheating furnaces and m anually transferred to ham m er for forging operation. These
furnaces are prone to high flue gas losses and surface heat losses. N orm ally fu rnace oil is
fuel used in box type forging furnaces w hile NG is used in heat treatment furnaces. Som e
units are operating electrical heat treatm ent furn aces.

Recuperator for w aste heat recovery from hot flue gasses of furnace
Many of the forging units use oil fired or gas fired forging and heat treatm ent furnaces. The
exit flue gas tem peratures of FO/ N G fired furnaces are in the range of 450-700 oC. These
furnaces have not been equipped w ith any heat recovery system . The w aste heat available
w ith high tem p erature flue gases can be recovered using a m etallic recuperator w hich can
preheat incoming com bustion air. The envisaged energy saving w ith WH R system is 8-15%.
N atural gas savings of 15-30 SCM per tonne can be achieved d epending on the flue gas
tem perature. The investm ent for recuperator varies from Rs 2-4 lakh w ith a sim ple payback
period of 8 m onths to 2 years.

Insulation for furnace

Forging and heat treatm ent furnaces used are m ostly built w ith a refractory brick lining
w hich are prone heat losses after a continuous usage over the period and results in fuel loss.
There is a huge potential in using ceram ic insulations in the box type furnaces, w hich
enables less fuel consum ption in cold start in the furnace along w ith less heat up tim e.
Energy savings of 4-6% can be achieved by improving insulation of the furnace. An N G
saving of 5 to 15 SCM per hour can be saved d epend ing on quantum of surface heat losses,
type of refractory used and size of the furnace. Relining or repairing of heat treatm ent
furnaces can be carried out w ith an investment of Rs 0.30-2 lakh d epend ing on size of the
furnace w ith sim ple payback period of 5 m onth s to 1.5 years.

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 Cluster profile - Rajkot forging industries

Thyristor control for electrical heat treatm ent furnaces

Electrical heat treatm ent furnaces used in the cluster are of resistance heating type. N orm ally
on-off control is used for controlling the heating cycle. In on -off control d ue to continuous
sw itching, life of heating coil red uces d ue to therm al shocks and frequent failure occurs.
Thyristor control can be used instead of on-off control, w hich can give around 7-15% energy
savings and can increase coil life d ue to sm ooth sw itching w ith the precise tem perature .
Investm ent for thyristor control varies from Rs. 0.20-1.5 lakh d epend ing on total electrical
rating of heating coils w ith a sim ple payback period of 3 m onths to 1 year.

(iii) High speed hot former machine for ring rolling

This new age technology has been ad opted by few ring rolling units in w hich m ultiple
num ber of ring rolling com ponents are forged at a t im e w ith high velocity and precision.
The conventional ring rolling m achines have an output of 10 pieces per m inute are form ed
w hereas high speed form er m achines have an output of 120-180 pieces per m inute w ith near
net job sizes. These are very sophisticated machines operated in line w ith ind uction long bar
heaters for fast prod uction. Th ese m achines increase prod uctivity w ith assured com ponent
quality along w ith significant energy saving potential.

Hi-speed hot former machine for ring rolling

(iv) Application of variable speed drives in press motors

Motor d riven system s often are oversized and inefficiently controlled . Variable Speed Drives
(VSDs) can provid e a more cost effective m ethod for red ucing flow or pressure by varying
the speed of the connected load to m atch the process requirem e nts. Energy savings in VSD
applications usually range from 8-20%. The investm ent required for VSD is around Rs. 0.20-
3 lakh d epend ing on electrical rating of the m otor w ith sim ple payback period of 8 m onths
to 2 years. One of the potential applications of VSDs in forging ind ustry is press m otors.
Mechanical and hyd raulic presses are generally used in forging ind ustries . Presses go und er
variable load d epend ing on job size and operation to be perform ed . Jerk load operations are
frequent in presses and this can be im proved by using VSDs. The VSD can red uce overall
pow er consum ption along w ith soft starting of the m otors w hich w ill im prove life of m otors.

(v) Compressed air

Energy savings of m ore than 40% can be realized through im proving the supply and
red ucing d em and in com pressed air system s. Opportunities can be found in the supply side
by installing new or optim izing existing equipm ent and red ucing the system pressure.
Dem and can be red uced through im proving end uses and repairing leaks. Blow -off nozzles
can be upgrad ed to high -efficiency engineered nozzles or replaced w ith a low -pressure
electric blow er. Som e of the potential areas of com pressor system w ith specific option are
m entioned below .

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 Cluster profile – Rajkot forging industries

Retrofitting air com pressor w ith variable frequency d rive

During norm al operation, screw air com pressor operated on unload ing position for m ore
than half the tim e. Installation of „variable frequency d rive‟ (VFD) to such com pressors w ill
m inimize the unload pow er consum ption resulting in energy savings of 20-35%. The
investm ent for VFD for air com pressor ranges from Rs 0.50-3 lakh d epend ing on size of the
com pressor w ith payback period of 6 m onths to 1.5 year s.

Arresting the com pressed air leakage

Com pressed air is an expensive utility in a plant. H ow ever, in m ost cas es, air leakages in
piping system are quite high (m ore than 20%) and go unnoticed . The compressed air leakage
can be red uced to about 5% w ith better operating practices. The plant can red uce significant
energy consum ption by controlling com pressed air leak ages w ith no or m inimum
investm ent.

Red uction in pressure setting of air com pressor

The pressure setting of air com pressors are often m uch higher than the actual air pressure
requirem ent at the point of use in the plant. The typical unload and load pressu re settings
are 8.5 and 7.5 bar respectively. Red ucing the com pressed air pressure as per end -use
requirem ents w ill result in high -energy savings. Red uction of generation pressure by one
bar can lead to energy saving of 6%.

(vi) Replacement of rew ound motors w ith energy efficient motors

“Rew ind ing” of m otors results in a d rop in efficiency of about 3-5%. It is a better to replace
all old m otors, w hich have und ergone rew inding tw o tim es or m ore. The old rew ound
m otors m ay be replaced w ith EE m otors (IE3 efficiency class). This w ould results into energy
savings of 3 to 7% w ith sim ple payback period of 1.5 to 3 years on the investm ents d one.

(vii) Lighting
Presently m ercury vapor lam ps (MVL) and halogen lam ps of 150W, 250W and 400 W are
generally used on shop floor. This lighting system has low lux levels w ith less life. Magnetic
ind uction lam ps of 100W, 150W and 200W can be installed in place of MVLs, w hich w ill give
better illum ination along w ith bright light w ith up to 1lakh burning hours life. T-12 tube
lights (of 52W includ ing choke) and halogen lamps (150W and 250W) are generally used by
Forging units in the cluster. These inefficient lightings can be replaced w ith energy efficient
LED lighting (LED tube lights of 10W and 20W) and flood lam ps and high bay lam ps (20W,
40W and 80 W) w hich w ould provid e better illum ination and energy savings. Since a large
num ber of lam ps are used in the units, the existing lighting m ay be replaced w ith EE
lighting in a phased m anner. The sim ple p ayback period for lighting is about 2 to 3.5 years.

Major stakeholders
The prim ary stakehold ers in the cluster are the manufacturing units based in Rajkot and the
lead ing ind ustry association of the region –Rajkot Engineering Association (REA), GIDC
(Lod hika) Ind ustrial Association (GLIA), AJI (GIDC) Ind ustries Association and Shapar -
Veraval Ind ustrial Association. The other key stakehold ers includ e Central Manufacturing
Technology Institute (CMTI), N ational Sm all Ind ustries Corporation (N SIC), District
Ind ustries Centre (DIC), MSME-DI (Rajkot), SIDBI, Ind ian Institute of Found rym en, Rajkot
chapter m achinery supplier, etc.

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 Cluster profile - Rajkot forging industries

Out of these stakeholders, REA is the m ost proactive in the region. It has about 1000
m em bers d raw ing from all categories of ind ustries in Rajkot. The associatio n ad d resses the
issues related to the w elfare and grievance red ressed of their mem ber ind ustries. Presently
there are no ind ivid ual ind ustry associations for forging ind ustries.

Cluster development activities

There are no on-going activities in forging ind ustries in the cluster.

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About TERI
A d ynam ic and flexible not-for-profit organization w ith a global vision and a
local focus, TERI (The Energy and Resources Institute) is d eeply com m itted to
every aspect of sustainable d evelopm ent. From provid ing environm ent-friend ly
solutions to rural energy problem s to tackling issues of global clim ate change
across m any continents and ad vancing solutions to grow ing urban transport and
air pollution problem s, TERI‟s activities range from form ulating local and
national level strategies to suggesting global solutions to critical energy and
environm ental issues. The Ind ustrial Energy Efficiency Division of TERI w orks
closely w ith both large ind ustries and energy intensive Micro Sm all and Med ium
Enterprises (MSMEs) to im p rove their energy and environm ental perform ance.

About SD C
SDC (Sw iss Agency for Developm ent and Cooperation) has been w orking in
Ind ia since 1961. In 1991, SDC established a Global Environm ent Program m e to
support d eveloping countries in im plementing m ea sures aim ed at protecting the
global environm ent. In pursuance of this goal, SDC Ind ia, in collaboration w ith
Ind ian institutions such as TERI, cond ucted a stud y of the sm all-scale ind ustry
sector in Ind ia to id entify areas in w hich to introd uce technologies that w ould
yield greater energy savings and red uce greenhouse gas em issions. SDC strives
to find w ays by w hich the MSME sector can m eet the challenges of the new era
by m eans of im proved technology, increased prod uctivity and com petitiveness,
and m easures aim ed at im proving the socio-economic cond itions of the
w orkforce.

About SAMEEEKSHA
SAMEEEKSH A (Small and Medium Enterprises: Energy Efficiency Know led ge
Sharing) is a collaborative platform set up w ith the aim of pooling know led ge
and synergizing the efforts of various organizations and institutions - Indian and
international, public and private - that are w orking tow ard s the d evelopm ent of
the MSME sector in India through the prom otion and ad option of clean, energy -
efficient technologies and practices. The key partners are of SAMEEEKSH A
platform are (1) SDC (2) Bureau of Energy Efficiency (BEE) (3) Ministry of
MSME, Governm ent of Ind ia and (4) TERI.

As part of its activities, SAMEEEKSH A collates energy consum ption and related
inform ation from various energy intensive MSME sub-sectors in Ind ia. For
further d etails about SAMEEEKSH A, visit http:/ / w w w .sam eeeksha.org

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