How One Manufacturing Unit in Choutuppal Reduced Its Electricity Bill from ₹1.2 Lakhs to ₹45,000
A Choutuppal manufacturing unit cut its power bill from ₹1.2 lakh to ₹45,000 by identifying one hidden inefficiency. Learn how Bharat Smart Services made it.
Electricity is one of the largest operating costs for manufacturing industries. But high electricity bills are not always caused by high consumption. This case from a manufacturing unit in Choutuppal shows how identifying the real root cause of inefficiency can lead to dramatic savings — without changing production, staff, or working hours.
Where the Industry Was Struggling
The manufacturing unit in Choutuppal was paying around ₹1,20,000 per month for electricity. The team had already taken steps to improve power factor, but despite multiple attempts, they were only able to maintain it at around 0.7. The bill remained high, and the exact reason was unclear. That’s when they approached Bharat Smart Services.
What Our Team Observed On-Site
- Our technical team conducted a detailed energy assessment at the facility.
- Instead of looking only at overall consumption, we studied how electricity was flowing through different machines and systems.
- During this process, we discovered that one old motor was operating inefficiently and consuming significantly more power than required.
- This single piece of equipment was contributing disproportionately to both energy consumption and power quality issues.
The Focused Change That Made the Difference
- Based on our findings, we recommended one specific action:
- Replace the inefficient motor with an energy-efficient one.
- No other changes were made to the production process.
What Changed After the Fix
After the motor replacement:
- Monthly electricity bill reduced from ₹1,20,000 to ₹45,000
- Power factor improved from 0.7 to 0.98
- Energy performance became stable and predictable
This single intervention resulted in savings of over ₹75,000 per month.
What This Case Teaches Us
This case demonstrates that:
- High electricity bills are often caused by hidden inefficiencies, not visible overuse
- Improving power factor alone does not guarantee savings
- Identifying the root cause is more effective than adding more equipment
How Bharat Smart Services Supports Industries
We help industries:
- Understand how energy is actually used inside their facilities
- Identify inefficiencies before they become financial problems
- Take precise corrective action instead of costly trial-and-error
- Build long-term energy efficiency into operations
- A system where an industry owner can know the energy efficiency of the industry right from the
Energy optimisation is not about reducing output — it is about removing waste.
The Choutuppal case is a reminder that sometimes, one small correction can unlock very large savings.
We are here to help every industry find the root cause of high electricity bills and turn hidden losses into real savings.
Listen from our team member words here