Case studies · Pharmaceuticals · Gujarat
KESECO ULTRA on a 1,000 kVA main incomer: 443 MWh a year saved, weather-normalised over 478 days
Pharmaceutical warehouse, Gujarat · KESECO ULTRA U-1000
- 11.0 % Weather-normalised saving (the planning figure)
- 443 MWh Saved per year (whole incomer)
- 478 days Metered (May 2025 – Aug 2026)
- 1,000 kVA Main incomer (mixed HVAC and motor load)
The challenge
ULTRA is not only for chillers. This pharmaceutical warehouse runs its whole load — HVAC, cold rooms, material handling and lighting — through one 1,000 kVA main incomer. Its consumption also swings with the weather and the load roughly doubled during the trial, so a simple before-and-after reading could not be trusted.
What AIRS did
- KESECO ULTRA U-1000 installed on the warehouse main incomer — passive, in-line, no moving parts and no power drawn of its own.
- AIRS installed and ran the metering itself: voltage, current, power factor, kW, kVA, kWh and kVAh logged continuously from seven months before installation.
- A four-month period with ULTRA out of circuit gave a control window in the same plant, the same year and the same loads.
- The saving was worked out three independent ways — raw before-and-after, matched fortnights and a weather-normalised model (IPMVP Option C) — and the lowest is the one quoted.
The result
- 11.0 % weather-normalised saving — about 443 MWh a year. This is the figure AIRS recommends for planning.
- Matched fortnights either side of reconnecting the unit showed 15.5 % (12,666 → 10,706 kWh a day).
- Every method of analysis cleared the 5 % minimum saving AIRS commits to.
- Run over the out-of-circuit weeks, the model returned 0.0 % — it measures the device, not the season.
- Power-factor gains at the site came mainly from capacitor work and are not counted in the saving.
Basis of calculation
Saving measured at the warehouse main incomer by AIRS-operated metering; weather correction by cooling degree-days, fitted only on months before ULTRA was installed. Days with less than 90 % logging are excluded from every period alike. ULTRA's effect depends on the load mix; AIRS sizes and projects each site individually.
At a glance
| Load | 1,000 kVA main incomer — HVAC, cold rooms, handling |
|---|---|
| Unit | KESECO ULTRA U-1000 |
| Metering | By AIRS, continuous, from before installation |
| Control period | 4 months with ULTRA out of circuit |
| Saving | 11.0 % · about 443 MWh a year |
| Commitment | 5 % minimum — exceeded |
| Method check | 0.0 % with the unit out of circuit |
About the equipment · Book an energy saving assessment
Client name withheld under the AIRS confidentiality policy. References are shared on request with the client's consent.
More results
- KESECO ULTRA on a 257 TR water-cooled chiller: 13.49 % better kW per TR, confirmed by the client — Chemicals, Gujarat: 13.49 % better kW per TR
- KESECO ULTRA on a 160 TR screw chiller: 17 % energy saved on process HVAC — Pharmaceuticals, Gujarat: 17 % energy saved
- KESECO ULTRA on a 350 TR water-cooled chiller: 15 % saved, 0.844 → 0.712 kW per TR — Pharmaceuticals, Gujarat: 15 % energy saved
- KESECO ULTRA on a 40 TR brine chiller: 10.31 % better kW per TR — Speciality chemicals, Central India: 10.31 % better kW per TR
- KESECO ULTRA on a mixed-load admin building: 5.98 % saved in an ON/OFF trial — Power equipment, Gujarat: 5.98 % energy saved