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ENERGY SAVING POTENTIAL IN WEAVING, KNITTING AND GARMENTING

ENERGY SAVING POTENTIAL IN WEAVING, KNITTING AND GARMENTING. A.SIVARAMAKRISHNAN, M.MUTHUVELAN G.ILANGO & M.ALAGARSAMY SITRA. Introduction. Textile industry – one of the major energy consumer Energy plays an important role in the economy of manufacturing process

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ENERGY SAVING POTENTIAL IN WEAVING, KNITTING AND GARMENTING

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  1. ENERGY SAVING POTENTIAL IN WEAVING, KNITTING AND GARMENTING A.SIVARAMAKRISHNAN, M.MUTHUVELAN G.ILANGO & M.ALAGARSAMY SITRA

  2. 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

  3. 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

  4. YARN WARPING SIZING WEAVING PRINTING & FINISHING DYEING PREPARATION TO DYEING FABRIC LAYING & CUTTING SEWING INSPECTION PACKING IRONING Production of Woven Garments

  5. YARN KNITTING DYEING / PRINTING FINISHING INSPECTION SEWING FABRIC LAYING & CUTTING IRONING FINISHING PACKING Production of KnittedGarments

  6. Power consumption in Woven Garment Production(30,000 Metres per day)

  7. Power Consumption in Knitted Garment Production1.0 lakh kg of fabrics/ month(i.e. 2,50,000 pieces)

  8. Power Consumption in Woven Garments

  9. Power Consumption in Knitted Garments

  10. Power Consumption in Fabric Forming (Woven)(30,000 metres / day)

  11. Power Consumption in Weaving

  12. Power Consumption in Chemical Processing

  13. Power Consumption in Chemical Processing

  14. Energy consumption in garment production (Woven/Knitted)Yarn stage to Garment (10,000 metres)

  15. 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

  16. Power Consumption in Knitted Garment Division (2,50,000 pieces/month)

  17. Woven Garmenting Section (50,000 pieces/month)

  18. 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 ID&FD fan motors and pumps

  19. 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

  20. 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

  21. 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

  22. 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

  23. 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

  24. 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.

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

  26. THANK YOU

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