CASE STUDIES

Real installations, real savings — across pharma, auto, hospitality and process industries.

Hospitality

Taj Srinagar Transitions to High-Efficiency Heating & Cooling System

₹95+ lakh annual savings with ~1.6 year payback

8 heat pumps

  • Installed — 818 kW winter / 490 kW summer, 514 kW cooling capacity

~1.6 years

  • Payback, on ₹95+ lakh annual savings
  • Taj Srinagar — replaced diesel boilers, electric heaters & a 150 TR chiller
  • Now runs one integrated heat pump system on electricity instead of diesel (1.44 lakh L/yr)
  • Energy cost cut from INR 1.70 crore/yr to INR 0.75 crore/yr; heating & cooling combined, emissions cut sharply

Hospitality

Taj Vivanta Achieves Significant Reduction in Heating Cost

~60% reduction in energy consumption with stable year-round performance

INR 2.8 lakh

  • Saved in 3 months — ~480 units/day saved (winter), ~60% lower energy use

Stable performance

  • Across seasons — seamless integration, reduced reliance on electric heaters
  • Taj Vivanta, Katra — centralized hot water, ~100 kW load, ~50–60°C
  • Underperforming 2×50 kW heat pumps + electric heaters replaced with a Heatray Air Source Heat Pump
  • Capacity raised to 102 kW (winter) / 137 kW (summer); power input cut to ~34 kW
  • Energy use down to ~320 units/day (from 800); efficiency up to COP ~2.5

Residential Buildings

Louisandra by Suraj Estate Reduces Hot Water Energy Cost with Single Centralized System

24x7 Hot Water Supply for 68 Apartments

Through One Centralized System

10,200 Litres / Day Hot Water Demand | Reliable 24x7 Supply with Lower Electricity Consumption

₹15–20 lakh

  • Annual savings — cost reduction ~55–60%, payback ~1–1.5 years

~60% lower

  • Electricity use — ~12–15 lakh kg/yr CO₂ savings
  • Client: Suraj Estate – Louisandra, Dadar
  • Application: Centralized Domestic Hot Water System
  • Apartments: 68 Residences
  • Hot Water Demand: 10,200 Litres / Day
  • Objective: Reliable 24x7 hot water with lower electricity consumption
  • Solution: 2 × Air Source Heat Pumps | 85 kW Capacity per Heat Pump | 5 KL Insulated Storage Tank | PLC Based Automated Control System | Continuous Circulation Loop | Centralized Hot Water Distribution Network
  • Designed for Modern Residential Developments: One centralized hot water system replacing dozens of individual electric water heaters, delivering lower operating costs, simplified maintenance, and enhanced resident comfort.

Automotive

Eicher Achieves ~45% Reduction in Water Heating Cost

₹85+ lakh annual savings with <1 year payback

₹85+ lakh

  • Annual savings — daily savings INR 28,862, cost reduction ~45%, payback <1 year

CO₂ ~2.1 kg/SCM

  • Reduced fossil fuel dependence, ~7.0 lakh kg/yr CO₂ savings, cleaner operations
  • Eicher Motors — pre-treatment hot water, 500 kW thermal load, 50°C→55°C
  • PNG hot water generator replaced with Heatray Heat Pump; cost/day cut from INR 63,512 to INR 34,650
  • Efficiency up to COP ~3; PNG gas swapped for electricity, emissions down

Automobile

VE Commercial Vehicles - Air-to-Water Heat Pump

Robo Washing Application 65°C Process Heating

35 kW

  • Heat Pump Capacity

11.6 kW

  • Electrical input/unit

1.49 yrs

  • Payback -heating benefit
  • Client: VE Commercial Vehicles Limited,Pithampur
  • Application: Robo Washing
  • Washing Tanks: 2 - Clean & Super Clean
  • Tank Capacity: 1,600 L + 2.000 L
  • Required Temperature: 65°C
  • Operation Time: 24 hours/day
  • Annual operating days: 303 days/year
  • Existing Heating: Electrical heaters-8 kW x 6 per tank
  • Total Rated Heater Capacity: 96kW
  • Daily Electrical Consumption:1,025 kWh/day
  • Annual Electrical Consumption:3,10,000 kWh/year
  • Electricity Price:₹8/kWh
  • Heat Pump Offered:2 x 35 kW Air Source Heat Pumps
  • Control:SELEC PLC-based controller

Solution

  • 2 x 35 kW air-source heat pumps integrated with the existing heating system, with 24×7 operation capability and estimated 3x efficiency versus conventional electrical heating.

Automobile

SATYAM AUTO COMPONENTS LTD., Ludhiana - Water-to-Water Heat Pump

8O°C Hot Water Supply | Replace PNG with Electricity

76 kW (Total)

  • Heat Pump capacity

13.52 kW (Total)

  • Electrical input required

~1.0 year

  • Payback- heating benefit
  • Client:Satyam Auto Components Ltd., Ludhiana
  • Application: Process Heating Prewashing Tanks (Indirect Heating)
  • Daily PNG consumption:170 scm/day
  • Running hours: 24 Hrs/day
  • Target supply temperature: 80 °C
  • Cooling water (CT) in/out:27 °C/32 °C
  • Current fuel: PNG
  • PNG price: 62/scm
  • PNG calorific value: 9500 kcal/scm
  • Electricity tariff: 7.3/unit
  • Cooling tower: Available
  • Existing System:PNG based HWG (Hot Water Generator)
  • Hot water for:Prewashing Tanks - Degreasing/Phosphating/KOD
  • Existing return water temperature:60 °C
  • Heat pump system:2 x 38 kW Water Source Heat Pumps (Total 76 kW)
  • Electrical input required:13.52 kW (Total)
  • Hot water supply:60 °C to 80 °C
  • Heat source:Cooling Tower Return Water (32 °C to 27 °C)
  • Operating principle:Reverse Thermodynamic Carnot Cycle
  • Daily PNG cost:-₹10,540/day
  • Annual PNG cost:--38.98 lakh/year
  • Estimated savings:-32.63 lakh/year

Solution

  • 2 x 38 kW water source heat pumps integrated with the existing cooling tower and HWG system. Utilizes cooling tower return water (32 °C) at evaporator side to cool it to 27 °C, and heats process water from 60 °C to 80 °C at condenser side. System provides 24 x 7 hot water supply with 3x efficiency compared to electrical heating, ensuring significant fuel cost savings and lower carbon emission.

Pharmaceuticals

Glenmark Achieves 61% Reduction in Heating Cost

₹50+ lakh annual savings with <1 year payback

₹50+ lakh

  • Annual savings — daily savings ₹13,872, cost reduction ~61%, payback <1 year

CO₂ −2.68 kg/L

  • Eliminated diesel usage, lower carbon footprint, reduced fossil fuel dependence
  • Glenmark – Sikkim Plant — AHU heating, 10,000 L/day, 45°C→55°C
  • LDO boiler replaced with Heatray Heat Pump; cost/day cut from ₹22,750 to ₹8,900
  • Efficiency up to COP 3.5; diesel swapped for electricity, emissions down

Pharmaceuticals

Apothecon Achieves 56% Reduction in Heating Cost

₹55+ lakh annual savings with <1 year payback

₹55+ lakh

  • Annual savings — daily savings INR 18,408, cost reduction ~56%, payback <1 year

CO₂ 2.68 kg/L

  • Eliminated diesel/fuel dependency, lower carbon footprint, cleaner operations
  • Apothecon — AHU heating, 50,000 L/day, 54°C→59°C
  • Steam boiler replaced with Heatray Heat Pump; cost/day cut from INR 33,000 to INR 14,592
  • Efficiency up to COP 2.3; diesel/LDO/PNG swapped for electricity, emissions down

Industrial Manufacturing

Siemens Reduces Heating Cost by ~40%

₹10+ lakh annual savings with <2 year payback

₹11+ lakh

  • Annual savings — daily savings ₹1,350, cost reduction 30–40%, payback <2 years

CO₂ 0.82 kg/kWh

  • Lower energy consumption, higher efficiency (COP>3), cleaner heating
  • Siemens Ltd. – Kalwa Plant — kitchen process heating, 9,000 L/day, 30°C→70°C
  • Electric heating replaced with Heatray Heat Pump; cost/day cut from INR 2,025 to INR 675
  • Efficiency up to 300%+ (COP 3.5); emissions down

Chemicals

Rallis India Reduces Electric Heating Cost by ~60%

₹15–20 lakh annual savings with ~1–1.5 year payback

₹15–20 lakh

  • Annual savings — cost reduction ~55–60%, payback ~1–1.5 years

~60% lower

  • Electricity use — ~12–15 lakh kg/yr CO₂ savings
  • Rallis India Ltd. (Dahej Unit) — reactor jacket heating, 65–100 kW, up to 70°C
  • Electric coil heating replaced with Heatray Heat Pump; cost/day cut by ~60%
  • Efficiency up from ~100% resistance heating to COP ~2.5–2.7; lower, more efficient grid use

Chemicals

SHAHAJANAND CHEMICALS, Ankleshwar - Air-to-Water Heat Pump

80°C Hot Water Supply | Replace NG with Electricity -

30 kW (Total)

  • Hest Pump capacity

12 kW (Total)

  • Electrical input required

~1.17 year

  • Payback heating benefit
  • Client:Shahjanand Chemicals, Ankleshwar ,Gujarat
  • Application:Process Heating-Boiler Feed Pre-heating (Indirect Heating)
  • Daily NG consumption(existing):-64.4 SCM/day
  • Running hours: 24 Hrs/day (Heat Pump runs-20 Hrs/day)
  • Target supply temperature:80°C
  • Inlet water temperature:28 °C (Ambient soft water)
  • Current fuel: Natural Gas (NG)
  • NG price: ₹65/SCM
  • NG calorific value:9,500 kCal/SCM (theoretical),8,075 kCal/SCM (practical)
  • Electricity tariff: *7.5/unit
  • Existing system:Direct ambient water feed to NG-fired
  • Hot water for:Boiler Feed Pre-heating
  • Existing inlet water temperature:28 °C
  • Heat pump system:1 x 30 kW Air Source Heat Pump
  • Electrical input required:12 kW (Total)
  • Hot water supply:28 °C to 80 °C
  • Heat source:Ambient Air
  • Operating principle:Reverse Thermodynamic Carnot Cycle
  • Daily NG cost (existing):~₹4,186 / day
  • Annual NG cost (existing):~15.28 lakh / year
  • Estimated savings:~₹8.66 lakh / yearr

Solution

  • 1 x 30 kW air source heat pump integrated with the existing boiler feed line, replacing direct NG-based pre-heating.

Trusted across pharma, auto, hospitality and process industries to deliver consistent savings without disrupting operations.

GLENMARK

EICHER

TAJ

SIEMENS

RALLIS

APOTHECON