RCPL — Utilities Management

Recipe & Calculator

Batch Log

Monthly Summary

📋 Standard Batch Recipe — 200 Litres

#	Raw Material	Qty	% w/ Starch	Rate (₹/kg)	Cost (₹)
1	Tape Water	150 Ltr	300%	—	—
2	Maize Starch Powder	50 kg	100%	₹36.00	₹1,800
3	Caustic Soda Flakes	1.0 kg	2%	₹45.00	₹45
4	Borax Powder	1.25 kg	2.5%	₹240.00	₹300
Total Batch Cost \| Yield: 200 L \| Solids: ~25%					₹2,145

Preparation: 100L water + 45kg starch (5 min) → 25L water + 5kg starch + 1kg caustic soda (5 min) → add 25L water → add borax (5 min) → target viscosity 35±5 sec @ 27°C

⚗ Batch / Production Calculator

Enter either batches to prepare OR production tonnes — the other fields auto-calculate.

No. of Batches (200L each)

OR Production Target (Tonnes)

Starch Rate (₹/kg)

Caustic Soda Rate (₹/kg)

Borax Rate (₹/kg)

Dry Starch kg per Tonne of Board (Industry Standard) Industry range: 10–18 kg/tonne. Default 14 kg/tonne for 5-ply B flute.

📦 Requirement Calculation Result

Batches (200L)

—

Glue Yield

—

Litres

Water Required

—

Litres

Starch Required

—

Caustic Soda

—

Borax Powder

—

Total Glue Cost

—

Waste Allowance (5%)

—

Litres

📊 Monthly Glue Budget — 30 Tonnes/Day × 26 Days

Monthly Production

780

Tonnes / Month

Starch Required

10,920

kg / Month

Batches / Month

218

× 200L batches

Caustic Soda

218

kg / Month

Borax Powder

273

kg / Month

Est. Glue Cost

₹4.7L

Per Month

Based on 14 kg dry starch per tonne of board. Update the starch/tonne figure above to recalculate. Waste is included at 5% buffer.

📝 Record Batch Preparation

Date

Shift

No. of Batches Prepared

Actual Starch Used (kg)

Actual Caustic Used (kg)

Actual Borax Used (kg)

Viscosity Reading (sec @ 27°C)

Production Tonnes this Shift

Remarks

📋 Batch Log History

Date	Shift	Batches	Starch (kg)	Caustic (kg)	Borax (kg)	Viscosity	Prod T	Glue Cost	Remarks
No batch logs yet. Add a record above.

📅 Monthly Glue Consumption Summary

Select Month

Select a month and click Generate to view consumption summary.

Shift Calculator

Shift Log

Water Quality Log

Monthly Summary

🔥 Boiler Specifications — Cheema Boilers EnergyPac Plus

3,000

Steam Capacity

kg/hr (F&A 100°C)

14.0

Steam Pressure

kg/cm²

82%

Thermal Efficiency

On NCV basis

3,200

Wood NCV

kcal/kg

150–160

Flue Gas Temp

°C outlet

32.75

Boiler Elec. Load

kW (fans + pumps)

⚙ Shift Consumption Calculator

Operating Hours

Fuel Type

Wood Rate (₹/kg)

Average Load % (of 3 TPH)

Feed Water Temp (°C)

Blowdown % (of steam output)

📊 Shift Results

Steam Generated (kg)	—
Fuel Consumed (kg)	—
Fuel Cost (₹)	—
Feed Water Required (L)	—
Blowdown Water (L)	—
Total Water Used (L)	—
Steam Cost per kg (₹)	—
Boiler Electrical Load (kWh)	—
Total Operating Cost (₹)	—

📅 Monthly Boiler Cost Projection (26 Working Days × 12 hrs)

Monthly Steam

—

Tonnes / Month

Wood Required

—

Tonnes / Month

Wood Cost

—

₹ / Month

Water Used

—

kL / Month

Steam Cost/kg

—

₹ per kg steam

📝 Record Boiler Shift

Date

Shift

Fuel Type

Operating Hours

Steam Pressure (kg/cm²)

Steam Output (kg)

Fuel Consumed (kg)

Feed Water Input (L)

Flue Gas Temp (°C)

No. of Blowdowns

Fuel Rate Used (₹/kg)

Operator Name

Remarks / Issues

📋 Boiler Shift Log History

Date	Shift	Fuel	Hrs	Steam (kg)	Fuel (kg)	Fuel Cost	Water (L)	Pressure	Flue T°	Efficiency	Operator
No shift logs yet.

💧 Water Quality Requirements — IBR Standard (CBL Spec)

Water quality must be checked and logged regularly. Poor water quality causes scale buildup, reduces efficiency, and can void boiler warranty.

Parameter	Feed Water Limit	Boiler Water Limit
Total Hardness (as CaCO₃)	Max 5.0 mg/L	Not Detectable
pH Value	8.5 to 9.5	10.5 to 11.5
Dissolved Oxygen	Max 0.02 mg/L	—
TDS	Max 250–300 PPM	Max 3000 mg/L
Silica (as SiO₂)	Max 0.5 mg/L	Max 15 mg/L
Total Alkalinity (as CaCO₃)	—	Max 300 mg/L
Residual Sodium Sulphite	—	20–30 mg/L
Phosphates (if added)	—	15–30 mg/L

📝 Log Water Quality Test

Date

Test Type

pH Value

Hardness (mg/L)

TDS (PPM)

Silica (mg/L)

Alkalinity (mg/L)

Result

📋 Water Quality Log History

Date	Type	pH	Hardness	TDS	Silica	Alkalinity	Result
No water quality logs yet.

📅 Monthly Boiler Summary

Select Month

Select a month to view boiler performance summary.

Machine Load Register

Energy Calculator

Daily Energy Log

⚡ Installed Machine Load Register — WJ-120-2000-II + Boiler + Utilities

AVVNL Chaksu Industrial Rate: ₹7.80/kWh (HT Industrial LT-4, Rajasthan 2025–26). Update rate:

Total Installed Load

— kW

Avg Demand (75% factor)

— kW

Est. Monthly Units (26d×12h)

— kWh

Monthly Bill (Est.)

—

#	Equipment / Motor	Section	kW/Unit	Qty	Total kW	Op. Hrs/Day	Units/Day (kWh)	₹/Day
TOTAL					—		—	—

🏭 Production-Based Energy Estimate

Production Target (Tonnes/Day)

Working Days/Month

Operating Hours/Day

Demand Factor (%)

Electricity Rate ₹/kWh

📊 Energy Projection Results

Total Installed Load	—
Average Demand (kW)	—
Units per Day (kWh)	—
Units per Month (kWh)	—
Electricity Cost/Day	—
Electricity Cost/Month	—
Electricity Cost per Tonne	—
Annual Electricity Bill (est.)	—

🎯 Reference: 30 Tonnes/Day × 26 Days × 12 Hours — RCPL Standard Target

Monthly Production

780 T

Tonnes/Month

Total Machine Hours

312 hrs

26 days × 12 hrs

Corrugator Demand

— kW

Corrugator section only

Boiler Elec Demand

32.75 kW

Fans + Pumps + RALV

Monthly Units

—

kWh/Month

Monthly Bill (₹7.80/u)

—

Estimated

AVVNL Chaksu Rate Note: Above is approximate. Actual bill includes: Energy charge ~₹7.50–8.50/kWh + Fixed/Demand charge ~₹350–450/kVA/month + FPPCA surcharge + TOD charges. For HT consumers (above 75kW connected load), AVVNL HT-1 tariff applies — contact AVVNL Chaksu division for current notified tariff.

📝 Record Daily Energy Consumption

Date

Opening Meter Reading (kWh)

Closing Meter Reading (kWh)

Units Consumed (auto)

Rate Applied (₹/kWh)

Production Tonnes (that day)

Operating Hours

Electricity Cost (₹)

📋 Daily Energy Log History

Date	Opening	Closing	Units (kWh)	Rate	Cost (₹)	Prod T	₹/Tonne
No energy logs yet.