Implementation of 16 TPH Industrial Boiler by Maanya Boilers

What is an IBR Industrial Boiler?

An IBR boiler refers to any closed pressure vessel with a capacity exceeding 25 liters, where steam is generated for external use and is subject to regulation under the Indian Boiler Regulations (IBR) Act, 1950. These boilers must adhere to strict requirements covering design, materials, fabrication, testing, inspection, and certification. This regulation extends to devices like steam piping, feed piping, fittings, and other connected vessels.

Only boilers and components approved by designated IBR inspecting authorities (such as those recognized by the Central Boilers Board of India) can be used or imported into India.

Client Background (Implementation of 16 TPH Industrial Boiler by Maanya Boilers)

Morepan Laboratories Ltd., a leading pharmaceutical manufacturer based in Baddi, Himachal Pradesh, required a high-capacity, biomass-fuelled IBR-compliant boiler to meet its growing steam demand. The boiler needed to handle multiple agro-waste fuels, maintain high efficiency, and meet all statutory Indian Boiler Regulations (IBR) requirements.

Project Overview

Scope: Design, manufacture, supply, erection, and commissioning of one 16 TPH, 10.54 kg/cm² (g) steam pressure, water-tube, smoke-cum-water tube reciprocating grate boiler with superheater outlet steam temperature of 360°C.

Main Fuels Supported:

• 100% Paddy Straw

• 100% Mustard Straw

• 100% Peeling Waste

• Briquettes and wood waste (as secondary options)

Design Compliance: Boiler designed as per IBR 1950 with latest amendments.

Why MAANYA’s Reciprocating Grate Technology

• Three-zone grate control (drying, main combustion, unburnt fuel burnout)

• Continuous ash discharge for uninterrupted operation

• Adaptability to various fuel moisture and ash contents

• Low refractory cost due to water wall furnace design

• Proven European technology indigenously adapted for Indian fuels

Technical Highlights

Implementation Steps

• Design & IBR Approval – Drawings and calculations prepared per IBR and submitted to Chief Inspector of Boilers for clearance.

• Fabrication – Boiler drums, water walls, and economizers fabricated using IBR-grade materials; hydraulic grate assembled with alloy castings.

• Testing – Hydrostatic testing at 1.5× working pressure; NDT on welds via radiography and ultrasonic inspection.

• Erection & Commissioning – All mountings, ducting, chimney, feed tanks, and piping supplied and installed; VFDs for fans; automation integrated.

• IBR Site Certification – Steam trial witnessed by inspector; IBR certificates issued.

Results Achieved

• Increased Steam Capacity: From older 10 TPH unit to 16 TPH

• Fuel Flexibility: Can run entirely on agro-waste fuels, reducing dependency on coal

• Operational Safety: Zero accidents due to robust IBR compliance

• Emission Control: Achieved local pollution board standards with bag filter/wet scrubber

• Efficiency Gains: 76 ± 2% thermal efficiency with VFD-controlled fans

Conclusion

This project demonstrated Maanya Boilers Pvt. Ltd.’s ability to deliver turnkey, IBR-compliant steam solutions tailored for high-moisture biomass fuels. By combining advanced grate technology, precision engineering, and strict regulatory compliance, Maanya Boilers helped Morepan Laboratories achieve higher productivity, lower fuel costs, and assured legal operation.

The 16 TPH industrial boiler installation was specifically engineered to handle challenging fuel types like parali (rice straw) and other agro-waste materials. The design focused on optimizing combustion efficiency while minimizing particulate emissions, ensuring that the system operated well within IBR norms. This made the installation both sustainable and cost-effective for continuous industrial use.

To ensure reliability, Maanya Boilers incorporated an advanced fuel-feeding system, water-tube design, and automated pressure control mechanisms. These features helped maintain consistent steam pressure across long production cycles, improving process efficiency and equipment lifespan. Additionally, the automation system minimized manual intervention, allowing operators to monitor critical parameters safely and efficiently.

This 16 TPH industrial boiler project also highlights Maanya’s strength in offering customized end-to-end solutions—from design and fabrication to on-site commissioning and operator training. Each system is engineered to meet the client’s specific energy requirements, plant layout, and emission norms. The result is a boiler that delivers exceptional performance, even in demanding industrial conditions.

Through meticulous project planning, Maanya Boilers reduced downtime and installation delays, ensuring a seamless transition from the previous system to the new setup. The client reported a significant improvement in operational stability, along with a noticeable reduction in fuel consumption compared to earlier equipment. This outcome underscores the company’s reputation for combining quality with performance.

Beyond this installation, Maanya Boilers continues to innovate in industrial boiler technology with a focus on biomass energy, waste heat recovery, and pollution-control integration. Each new project contributes to India’s goal of cleaner industrial operations and reduced carbon footprint. The company’s design and manufacturing expertise make it a reliable partner for industries across sectors such as food processing, rice mills, pharmaceuticals, and textiles.

This 16 TPH industrial boiler installation delivered exceptional performance, reducing fuel costs and improving steam reliability for the client’s operations. It stands as a benchmark for how engineering precision and regulatory compliance can coexist with energy efficiency and sustainability.

Overall, this 16 TPH industrial boiler project reinforces Maanya Boilers’ commitment to innovation, safety, and long-term value. Our energy-efficient systems deliver consistent performance while ensuring full compliance with IBR standards and helping industries lower their operational costs. By adopting cleaner combustion technology and smarter automation, Maanya Boilers continues to play a key role in shaping a more sustainable industrial future.

To learn more about IBR certification and standards, visit the Indian Boiler Regulations portal.
Explore our Pollution Control Equipment and Our Services to see how Maanya Boilers can support your industrial heating requirements.