Documente Academic
Documente Profesional
Documente Cultură
Submitted By:
Tushar Garg
M.Tech 2014-16
Energy Management
Textile Sector
No's of DCs
Sub Sector
With CPP
Without CPP
Total
Spinning
33
36
Processing
15
20
Composite
24
28
Fiber
Total
78
6
12
90
The 90 DCs are owned by 78 companies, comprising one cooperative and 77 private
sector companies.
No's
States
No of DCs
These DC are spread over 10 states.
of Textile
1
Andhra
Pradesh
Gujarat
11
Haryana
Himachal
Pradesh
Karnataka
Maharashtra 14
Madhya
Pradesh
Punjab
11
Rajasthan
31
10
Tamilnadu
Total
90
4% to GDP
World
Millions
India
Millions
% Share
In world
India
Rank
Spindles-Cotton
205
48
22
Spindles-Wool
15
Rotors
0.8
Shuttle Looms
4.5
2.3
51
1.6
.15
Handlooms
3.6
2.4
67
Total Looms
9.7
4.85
50
ENERGY COST
Energy Cost in the textile Industry accounts for 5 to 17 % of the total production cost.
Acc. to Asian Research programme in energy ,environment & climate survey, the energy
Consumption of the textile industry is
3 to 3.5 kWh/kg of yarn in a modernized spinning mill.
0.09 to 0.2 kWh/kg of fabric in knitting units
0.04 to 0.15 kWh/kg of fabric in dyeing.
In fabric dyeing units ,consumption of steam may vary from 4 kg to 9 kg of steam per kg of
fabric.
3.SPINNING
It is the Process of twisting the fiber. The amount of twist given the yarns
determines various characteristics. Light twisting yields soft-surfaced fabrics,
whereas hard-twisted yarns produce hard-surfaced fabrics, which provide
resistance to abrasion and are less inclined to retain dirt and wrinkles. Hard
twisted yarns are used in producing hosiery and crepes.
4.WEAVING
Two sets of yarns, called the warp and the woof (more commonly filling, or
weft) are used in weaving, which is carried out on a mechanism known as a loom. Warp
yarns run along the length of the loom; filling yarns run across it. Different patterns
and textures are achieved by varying the number of warp yarns and by altering the
sequence in which they are raised or lowered.
5.KNITTING
Knitting refers to interloping of one yarn system into vertical columns and horizontal
rows of loops called wales and courses, respectively. There are two main types of
knitting: weft knitting and warp knitting.
Knitting is a method by which yarn is manipulated to create
a textile or fabric.
Knitting creates multiple loops of yarn, called stitches, in a line or tube.
Knitting has multiple active stitches on the needle at one time. Knitted
fabric consists of a number of consecutive rows of interlocking loops. As each
row progresses, a newly created loop is pulled through one or more loops
from the prior row, placed on the gaining needle, and the loops from the
prior row are then pulled off the other needle.
Knitting may be done by hand or by using a machine.
Installed, kW
Total load, %
Blowroom
58.78
2.39
Carding
327.6
13.32
Drawframe
61
2.48
Ring frame
(Spining)
1,158.88
47.12
Humidification
plant
284.3
11.56
Compressor
93
3.78
Energy Consumption Share of Each Specialized Technical Field in the Textile Industry
Specialized Technical
Field
Fiber production
Spinning
Twisting
Textured- yarn
production
Weaving
Knitting
Dyeing
Clothing manufactur ing
Others
Total
Unit million
Fuel
Electricity Total
Share%
21,498
54,049
21.0
44,262
47,480
18.4
1,660
1,879
0.7
1,543
1,663
0.6
4,467
4,059
37,661
24,848
11,709
28,412
29,315
15,858
66,073
11.4
6.1
25.0
8,240
15,420
23,660
9.2
5,959
96,500
12,000
161,442
17,959
257,942
7.0
100.0
32,551
3,224
219
120
65%
15%
10%
10%
Total
100%
Sr.
No
Dyeing in jigger or
winches
3.5
Dyeing in H.T.H.P.
dyeing machine
There are six production processes involved in the manufacture of knitted garments:
Knitting: Knitting is the first step, in which, the fabric is made from yarn. The output is in
the form of a hose.
Scouring: The knitted fabrics are scoured in a bleaching or dyeing unit by boiling with
caustic soda in open tanks. The fabric is then washed in freshwater.
Bleaching: In the next slide Figure gives the process chart of the bleaching operation.
Bleaching is done manually, or mechanically in a winch.
Dyeing: In the next slide Figure gives the details of the dyeing process. Calendaring: After
bleaching/dyeing, the fabric is passed through steam heated rollers in the steam calendaring
machines.
Finishing: After calendaring, the fabric is ready to be made into garments in the finishing
units. These units use electrically operated stitching machines and electric irons. Some of the
processes like embroidery require sophisticated computer controlled machines.
6.Nearly half a million tones (437,760 tones) of firewood, chopped from the
nearby forests, are needed annually for the steam calendaring, bleaching and
dyeing operations
7.Almost fifty thousand tones (49,862 tones) of chemicals other than dyes are
consumed annually. The majority of the reacted chemicals are discharged
through the untreated wastewater.
8.Around fifteen hundred tones (1,470 tones) of dyes are used annually, of which
an estimated 292 tones find their way into the wastewater (i.e. almost 1 tone of
dyes per day).
9.An estimated 3,171 tones of paper waste, 9,430 tones of textiles waste (rags
and threads) and 59.25 tones of plastic wastes are contributed annually by the
industry to the municipal solid waste (MSW). In addition to these combustible
wastes, over 40,000 tones of ash is also disposed of. In total, the industry
contributes 56,492 tones annually to the MSW.
10.In addition, an estimated 91,250 tones of domestic solid waste are generated
annually. Both the industrial and municipal wastes lie littered, untreated all over
the town.
11.An estimated 2,430 tones of plastics and 25,532 tones of waste rags, and 20
tones of metals are collected annually, and taken out of the town for reuse or
recycling. No information is available on the fate of these resources
REFERENCES
1.http://www.textileschool.com/articles/109/blow-roofunctions#sthash.MFfx0rZS.dpuf
2.Info Source: PAT Book 2012 ,CII Super Directory 2012 Ministry of Textiles,CITI
3.Survey of energy conservation in India 2014
4. International Journal of Power System Operation and Energy Management ISSN
(PRINT): 2231 4407, Volume-2, Issue-1,2
5. J. Inst. Eng. India Ser. B (MarchMay 2013) 94(1):5360
DOI 10.1007/s40031-013-0040-5
6. Case Study Of The Textile Industry In Tirupur
7. M.Gohul, A.Mohamed Syed Ali, T.G.Raju, M.R.Saravanan, Dr.A.Pasupathy /
International Journal of Engineering Research and Applications (IJERA) ISSN: 22489622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.1421-1427