ENERGY SAVING POTENTIAL IN WEAVING, KNITTING AND GARMENTING

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ENERGY SAVING POTENTIAL IN WEAVING, KNITTING AND
GARMENTING

• A.SIVARAMAKRISHNAN, M.MUTHUVELAN
• G.ILANGO M.ALAGARSAMY
• SITRA

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Introduction

• Textile industry one of the major energy
  consumer
• Energy plays an important role in the economy of
  manufacturing process
• Power cost - 10 of total production cost of the
  fabric

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Introduction

• SITRA- conducting energy audit for the past three
  decades
• Recommended many energy conservation measures to
  Textile industry
• Achieved huge amount of energy saving
• Energy consumption in weaving, knitting
  garmenting are analysed in detail

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Production of Woven Garments
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Production of Knitted Garments
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Power consumption in Woven Garment
Production(30,000 Metres per day)
No. Section / Process Power Consumption (kW) on Total Consumption
1 Fabric Forming 644 40.7
2 Chemical Processing 438 28.6
3 Garmenting 500 31.6
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Power Consumption in Knitted Garment
Production1.0 lakh kg of fabrics/ month(i.e.
2,50,000 pieces)
No. Section Power Consumption (kW) on Total Consumption
1 Fabric Forming 144 23
2 Chemical Processing 414 65
3 Garmenting 73 12
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Power Consumption in Woven Garments

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Power Consumption in Knitted Garments
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Power Consumption in Fabric Forming
(Woven)(30,000 metres / day)
No Machine Power kW Total
1 2 3 4 5 6 7 8 Warping Sizing Pirn winding Weaving Humidification Compressor Lighting Boiler 34 14 21 424 70 36 30 15 5 2 3 66 11 6 5 2
Total Total 644 100
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Power Consumption in Weaving
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Power Consumption in Chemical Processing
No. Process Power in kW Total
1 2 3 4 5 6 7 Preparatory Dyeing Printing Finishing Boiler Thermic Fluid Heater Compressor Lighting 32 37 74 190 63 21 21 7.0 8.5 17.0 43.0 14.5 5.0 5.0
Total Total 438 100.0
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Power Consumption in Chemical Processing
No Process Power Consumption (kW) on Total Power
1 2 3 4 Knitting Machines Dyeing, Finishing, Boiler ETP Compressor and Lighting Garmenting 100 414 44 73 15.8 65.6 7.0 11.6
Total Total 631 100.0
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Energy consumption in garment production
(Woven/Knitted)Yarn stage to Garment (10,000
metres)
S.No Process Woven Garment Knitted Garment
1 2 3 4 Weaving Knitting Processing Garmenting 5000 -- 3000 2000 -- 2200 9000 2800
Total 10000 14000
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Specific Energy Consumption

• Units per kg or metre of fabric processed
  (kilowatt hour per kg or m)
• Steam consumed per kg or metre of fabric
  processed
• Water consumed per kg or metre of fabric
  processed
• Units per 10000 metres of fabric garmented

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Power Consumption in Knitted Garment Division
(2,50,000 pieces/month)
S.No Process Power Consumption (kW) on Total Power
1 2 3 4 Garmenting machine Compressor Lighting Finishing 23 10 19 21 31.5 13.7 26.0 28.8
Total 73 100.0
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Woven Garmenting Section (50,000 pieces/month)
S.No Process Power Consumption (kW) on Total Power
1 2 3 Laying, Cutting Sewing (150 m/cs) Finishing Lighting 45 34 17 46.9 35.4 17.7
Total Total 96 100.0
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Energy Conservation Measures

• ELECTRICAL SYSTEM
• Load optimization on transformers (50-60)
• Identifying under sized cables and strengthening
  with additional cables
• Adding and/or shifting of capacitors
• Operating motors at 85 load to have maximum
  efficiency.
• inverter drive system for IDFD fan motors and
  pumps

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Energy Conservation Measures

• PRODUCTIVE MACHINES
• Cogged V-belt / energy efficient belts / direct
  drive system
• Thermal insulation for yarn dyeing machines and
  evaporators to avoid radiation.
• Modifying the steam spray pipes in compacting
  machines

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Energy Conservation Measures

• MECHANICAL ENGINEERING
• Providing proper condensation return lines to get
  the heat recovery
• Thermal insulation for condensate steam pipeline
• Correcting the damaged gate valves and steam
  traps
• Providing heat recovery system for hot water let
  out from dyeing vessels.
• Flash steam recovery system is recommended for
  return condensation line

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Energy Conservation Measures

• BOILER
• Maintaining heat recovery system properly
• Reducing radiation heat loss in heat exchangers
• Maintaining proper condensation return line to
  save good amount of water and heat

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Energy Conservation Measures

• AIR COMPRESSOR SYSTEM
• Optimisation of air compressors speed and
  operating pressure
• Arresting air leakages
• Use of cleaning gun for machine cleaning
  Pressure in cleaning line should be 4-5 bar

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Energy Conservation Measures

• GARMENT SECTION
• Finishing and lighting system
• Use of servo stabilizer in the lighting circuit
• High efficient fluorescent tubes
• Reflectors and electronic ballasts
• Maintaining optimum height for fittings
• In some cases - improved work methods and
  practices

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Conclusion

• Significant amount of energy saving can be
  achieved in electrical and thermal energy
• Energy audits indicate - scope for saving up to
  5 of total electrical energy consumption.
• Providing thermal insulation for pipes and
  vessels, avoiding leakage of steams will save
  thermal energy up to 20
• Pay back period for the above conservation
  measures is less than two years.

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Acknowledgement

• The authors would like to thank
• Dr.Arindam Basu Director, SITRA
• Ms.Indra Doraiswamy Research Advisor, SITRA
• Staff of Engineering and Instrumentation Division

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THANK YOU