Case Study Energy Saving in Textiles Study Energy Saving in Textiles by Converting Shuttle loom to...
Transcript of Case Study Energy Saving in Textiles Study Energy Saving in Textiles by Converting Shuttle loom to...
Case Study Energy Saving in Textiles
by Converting Shuttle loom to Rapier Loom
by
Ravinder & Narender Vannam BEE
2nd Workshop on Best practices in Energy Efficiency in Textile Sector
28 June, 2016- Ahmedabad
Awarded Gold Medal by DST-Dept. of Science &Technology –
Govt. of India and Lockheed Martin - USA
in India Innovation Programme.
Technology Description • We have designed & developed Updation Kit for converting Shuttle loom to Rapier
Loom.
Save electricity and reduce CO2 emission by 20%
Boost Productivity by
30%
Improves the Quality
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In-Situ upgradation to Rapier Loom.
Can upgrade the Loom without
shifting
No need to remove Looms in
workshed
Less wear & tear / breakages
No down time for setting.
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We have introduced Dwell mechanism.
Rapier stops at end of shed.
Types of Rapiers • Single Rigid Rapiers are not very popular.
• Double Flexible Rapiers are used in converting Shuttle loom to Rapier Looms.
• Differences of With Dwell & Without Dwell Rapiers are as follows:
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Description With Dwell Without Dwell
1 Crank End to end of Loom , distance 6 inch 12 inch
2 Rapier travel Rapier stops(dwell) at end
of shed
Rapier overtravels outside
shed
3 Speed of Loom, productivity Can be increased Can’t be increased
4 Wear of reciprocating parts Wear is less Wear is more
5 Breakdown Less More
6 Maintenance cost Less Very high
7 Distance between 2 looms No need to shift the existing
Looms
Needs more space. Hence
Looms need to be shifted.
8 Initial cost Marginally More Less
9 Life of Rapier kit 3 years 6 months
Types of Rapiers • Technical Recommendation:
• Hence looking at the advantages of Rapier with Dwell, it is recommended to use the same while upgrading Shuttle loom to Rapier loom.
• Rapier without Dwell is not recommended due to recurring maintenance problems.
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In-Situ upgradation scheme
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http://ministryoftextiles.gov.in/sites/default/files/news-mar/index.html#features/3
Developement • Special Cam Mechanism with Dwell
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Wooden Prototype Actual Cam machined on CNC
Video
Technology - benefits • Owner- save approx. 20% energy required in Power loom.
- Increase the productivity by 30%
- Improve Quality of the Fabric due to less stoppages.
• Operator-Reduce noise levels by 10%.
-Improve Ergonomics of machine . Less fatigue on operator.
- Improved safety: Existing Flying shuttle may leads to fatal accidents
- Women can also operate the upgraded Loom & hence empowers the women.
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Technology - benefits • Society-Save Natural Resources like, Wood being
used in Shuttle, Picking Arms.
• This will be cost effective to small players in :
Sircilla, Kadakandla, Warangal-Telangana,
Nagari, Hindupur-AP,
Bhiwandi, Solapur, etc. in Maharashtra, who can’t afford new machines.
• Our Technology will be ray of hope for poor weavers.
• Our solution is ¼ cost of China loom & 1/10 cost of European loom.
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Technology – benefits Energy & Environmental Savings per Powerloom/year
• Energy: 1MWH,
• Saving in Rs: 50,000,
Pollution avoided & hence combating climatic change:
CO2: - 3Ton-GreenHouse Gas-Global warming
SO2: - 16Kg- Acid rain polluting waterbodies
NOx : -8Kg- Carcenogenic Gas Note: 1unit=1KWH=1kg of CO2: =6gm of SO2: =3gm of NOx
1 unit saved = 3 units generated at Thermal power station Reference: pg183 LEED 2011 for India www.igbc.in
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Technology – benefits Operating cost Savings per Powerloom/year
• Electricity cost savings: Rs.50,000/-
• Material cost savings: Pirn winding m/c, operators productivity increase
• Simple payback period: 1.7 year - without subsidy
4-5 months with subsidy • ROI : 59% - without subsidy : 90% with subsidy
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Energy,Pollution & Population
Key levers in the Economy
CO2 = People x GDP x Energy x CO2
Emission person unit GDP Unit Energy
Population Std.of Energy intensity CO2intensity
living Eff.of economy energy source
Key Resources Our Team
Ravinder Vanam:
Qualifications : B.E.Mech. Walchand College of Engineering., MBA, Certified Energy Auditor-BEE,
Professional Experience:
• Worked for 3 decades in Industry
• Did Energy Audits in various Industries resulting in lots of Energy saving.
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Benefits
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Upgrading the powerlooms with our Technology provides considerable cost saving & Environmental benefits over any other alternatives.
Carbon Footprint of Cloth will be reduced drastically.
Trees are saved by avoiding use of Shuttle which is made of fine wood.
By reducing Energy requirement at DSM-Demand side management, Investment in new Power plants will be avoided, saving our precious Natural
resources like , Forests , Water etc.
NEW update
• the Innovation got included In-situ upgradation pilot scheme w.e.f.1.4.2016
• 50% Central Subsidy for upgradation.
• Further details are yet to come.
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Way forward
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• Got the Innovation included In-situ upgradation pilot scheme.
• Get support from State Govt.
• Funding by Banks.
• Get Green Climatic Funds for GAP funding.
BEE guidance material Paper 4 - Textiles
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Please add details of different types of weaving machines like :
1. Shuttle loom
2. Projectile Loom – ( Sulzer )
3. Rapier loom
4. Air Jet loom
5. Water jet loom etc.
And their Energy efficiency studies.
Thank you! Any Questions ????
Ravinder Vanam – 07036199102
Narender Vanam – 09224973138
www.srisaitextileconsultancy.webs.com
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