ENERGY SAVING POTENTIAL

IN SPINNING, WEAVING,
KNITTING, PROCESSING 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
• SITRA- conducting energy audit for the past
three decades
• Recommended many energy conservation
measures to Textile industry
• Achieved good amount of energy saving
• Energy consumption in spinning, weaving,
knitting, processing & garmenting are
analysed 2
 Power Consumption In Textiles

NO DEPARTMENT WOVEN* KNITTED*

1 FIBRE TO YARN 10,000 8,000

2 YARN TO FABRIC 5,000 3,000

FACRIC TO
3 3,000 9,000
FINISHED FABRIC
4 GARMENTS 2,000 3,000

TOTAL 20,000 23,000

* 10,000 m / DAY – CASE STUDY UNITS 3

Production of Woven Garments

YARN WARPING SIZING WEAVING

PRINTING & FINISHING DYEING PREPARATION TO DYEING

FABRIC LAYING & CUTTING SEWING INSPECTION

PACKING IRONING

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Production of Knitted Garments

YARN KNITTING DYEING / PRINTING FINISHING

INSPECTION SEWING FABRIC LAYING & CUTTING

IRONING FINISHING PACKING

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

No. Section / Power % on Total

Process Consumption Consumption
(kW)

1 Fabric Forming 644 40.7

Chemical
2 438 28.6
Processing

3 Garmenting 500 31.6

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Power Consumption in Woven
Garments

Chemical
Processing Garmenting
28% 30%

Fabric
forming
42%

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

No. Section Power % on Total

Consumption Consumption
(kW)

1 Fabric Forming 144 23

Chemical
2 414 65
Processing

3 Garmenting 73 12

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Power Consumption in Knitted
Garments
Garmenting
12%

Knitting
23%

Dyeing
65%

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

S.No Process Woven Knitted

Garment Garment
1 Weaving 5000 --
2 Knitting -- 2200
3 Processing 3000 9000
4 Garmenting 2000 2800
Total 10000 14000
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 Power Consumption In Modern
Spinning Mills

H,C,L Pre Spg

22% 20%

Wdg
8%
Spg
50%

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45000 UNITS / DAY FOR 25000 SPINDLE MILL
Power Consumption in Fabric
Forming (Woven)
(30,000 metres / day)

Power
No Machine % Total
kW
1 Warping 34 5
2 Sizing 14 2
3 Pirn winding 21 3
4 Weaving 424 66
5 Humidification 70 11
6 Compressor 36 6
7 Lighting 30 5
8 Boiler 15 2
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Total 644 100
Power Consumption in Weaving
Prep. to
weaving
Ancillaries 12%
22%

weaving
66%

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Power Consumption in Chemical
Processing (Case Study - Woven)
Power in
No. Process % Total
kW
1 Preparatory 32 7.0
2 Dyeing 37 8.5
3 Printing 74 17.0
4 Finishing 190 43.0
5 Boiler 63 14.5
6 Thermic Fluid 21 5.0
Heater
7 Compressor & 21 5.0
Lighting
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Total 438 100.0
Power Consumption in Chemical
Processing (Case Study - Woven)
Prep. To
dyeing
Ancilla. 10%
20%

Printing
Dyeing &
20%
Finish.
50%

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Power Consumption in Chemical
Processing (Case Study - Knitted)
Power % on
No Process Consumption Total
(kW) Power
1 Knitting Machines 100 15.8
2 Dyeing, Finishing, 414 65.6
Boiler & ETP
3 Compressor and 44 7.0
Lighting
4 Garmenting 73 11.6

Total 631 100.0

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Power Consumption in Chemical
Processing (Case Study - Knitted)

Garmenting
12%
Knitting
16%

ETP, Boiler, Dyeing &

Lighting Finishing
42% 30%

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Power Consumption in Knitted Garment Division
(Case Study)
(2,50,000 pieces/month)

Power % on
S.No Process Consumption Total
(kW) Power
1 Garmenting 23 31.5
machine
2 Compressor 10 13.7
3 Lighting 19 26.0
4 Finishing 21 28.8
Total 73 100.0

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 Woven Garmenting Section
(Case Study)
(50,000 pieces/month)

Power % on
No. Process Consumption Total
(kW) Power
1 Laying, Cutting & 45 46.9
Sewing (150 m/cs)
2 Finishing 34 35.4
3 Lighting 17 17.7
Total 96 100.0

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 Specific Energy Consumption
• Units per kg of yarn produced (kWh / kg – 40s K
Converted)
• Units per kg or metre of fabric processed or
loom shift (kilowatt hour per kg or m or loom
shift)
• 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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 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
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 Energy Conservation Measures
SPINNING PROCESS

• Energy efficient belts for blowroom m/cs, AWES

motors, combers & simplex machines
• Maintaining optimum machine & process parameters
(lift & ring dia, tpi, machine uitlisation)
• Maintaining maximum utilisation and optimum waste
level in the production process
• Pneumafil and OHTCs will account for 25-30% of
machine power. Optimising suction pressure,
traverse moment will save to an extent of 25-40%.
• Optimising pneumafil waste in ringspinning will
reduce specific energy consumption. (1% reduction
in pneumafil waste will give 0.9% reduction in
ringframe UKG. 22
 Energy Conservation Measures
WEAVING PROCESS

• Loom shed accounts for about 50-60% of total weaving

consumption. Humidification, compressor and lighting
accounts for 30-40% depending on the types of loom.
• Loom shed utilization should be more than 90% and
10% drop in utilizations will increase specific energy
consumption by 3-4%.
• Maintenance of humidification plants (good air washer
efficiency) and SITRA-PCRA Climo Control system will
save 20-25% of humidification power.
• Optimising pressure and utilization in compressed air
system will give considerable amount of energy saving
(20-30%).
• Energy efficient Lighting system will give additional
energy saving.
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 Energy Conservation Measures
KNITTING PROCESS

• 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
FABRIC PROCESSING

• 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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 Conclusions

• 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
FOR YOUR
ATTENTION

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